KMS 2/4

Hot Stamping Meter Marker

MHE

Medek & Schörner GmbH

11.01.2017
Rev: 1.00 eng

Instruction Manual
 About this Manual KMS 2/4

0-2 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 About this Manual

0 ABOUT THIS MANUAL

This instruction manual describes the hot stamping meter marker KMS 2/4, manufactured
by MEDEK & SCHÖRNER.

Original Instructions

The copyright on this manual remains with

MEDEK & SCHÖRNER GmbH

Dr. Karl Renner Strasse 9-11
2203 Grossebersdorf
AUSTRIA
Tel. +43 (0) 2245 4694 – 101
e-mail: [email protected]
Internet: http://www.medek.at

Complete or partial distribution for the purpose of competition and

information to competitors are not allowed!

Rev: 1.00 eng Instruction Manual – Original Instructions 0-3

 About this Manual KMS 2/4

0.1 TABLE OF CONTENTS

0 ABOUT THIS MANUAL .................................................................................... 0-3
0.1 TABLE OF CONTENTS ......................................................................................... 0-4
0.2 LIST OF FIGURES ................................................................................................ 0-7
0.3 LIST OF TABLES .................................................................................................. 0-9
0.4 REVISION LOG ................................................................................................... 0-9
0.5 COMPANY CONTACT ....................................................................................... 0-10
0.6 NOTATIONAL CONVENTIONS ........................................................................... 0-10
0.7 USING THIS MANUAL ...................................................................................... 0-12
1 PROPER USE................................................................................................. 1-13
2 PRECAUTIONS .............................................................................................. 2-14
3 TECHNICAL DESCRIPTION ............................................................................. 3-16
3.1 GENERAL ......................................................................................................... 3-16
3.2 TECHNICAL SPECIFICATIONS ............................................................................ 3-16
3.3 CONSTRUCTION .............................................................................................. 3-17
3.3.1 FRAME ............................................................................................................ 3-18
3.3.2 MARKING UNIT .............................................................................................. 3-18
3.3.2.1 MARKING WHEEL .................................................................................... 3-18
3.3.2.2 MARKING WHEEL PNEUMATIC LIFTING ................................................. 3-23
3.3.3 GUIDE ROLLER UNIT ....................................................................................... 3-25
3.3.4 CONTROL CONSOLE ....................................................................................... 3-26
3.3.4.1 MAIN CONTROLS..................................................................................... 3-27
3.3.4.2 TOUCH-SCREEN ....................................................................................... 3-29
3.3.4.2.1 START-SCREEN (1-0) ...................................................................... 3-30
3.3.4.2.2 MENU-SCREEN (1) ......................................................................... 3-31
3.3.4.2.3 INFO-SCREEN (0) ............................................................................ 3-32
3.3.4.2.4 SERVICE-SCREEN (0–0) .................................................................. 3-33
3.3.4.2.5 SETUP-SCREEN (SYS1) .................................................................... 3-33
3.3.4.2.6 SETUP QDM-SCREEN (SYS1-1) ....................................................... 3-34
3.3.4.2.7 SETUP PROFIBUS-SCREEN (SYS1-2) ............................................... 3-35
3.3.4.2.8 SETUP PROFIBUS ERROR-SCREEN (SYS1-2-1) ................................ 3-37
3.3.4.2.9 SETUP PROFIBUS OUT-SCREEN (SYS1-2-2) .................................... 3-37
3.3.4.2.10 SETUP PROFIBUS IN-SCREEN (SYS1-2-3)........................................ 3-38
3.3.4.2.11 SETUP MLM-SCREEN (SYS1-3) ....................................................... 3-38
3.3.4.2.12 SETUP OVERVIEW-SCREEN (SYS2) ................................................. 3-39
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KMS 2/4 About this Manual

3.3.4.2.13 HEATING-SCREEN (1-1) .................................................................. 3-39

3.3.4.2.14 HEATING HELP-SCREEN (1-1_?) ..................................................... 3-40
3.3.4.2.15 HEATING BASE ADJUSTMENT-SCREEN (1-1-2) .............................. 3-41
3.3.4.2.16 HEATING BASE ADJUSTMENT HELP-SCREEN (1-1-2_?) ................. 3-41
3.3.4.2.17 DRIVE-SCREEN (1-2) ....................................................................... 3-42
3.3.4.2.18 DRIVE-HELP-SCREEN (1-2_?) ......................................................... 3-43
3.3.4.2.19 OPTIONS-SCREEN (1-3) .................................................................. 3-44
3.3.4.2.20 OPTIONS MARKING WHEEL-SCREEN (1-3-1) ................................. 3-45
3.3.4.2.21 OPTIONS MARKING WHEEL HELP-SCREEN (1-3-1_?) .................... 3-46
3.3.4.2.22 OPTIONS COUNTER ZERO RESET-SCREEN (1-3-2) ......................... 3-46
3.3.4.2.23 OPTIONS COUNTER ZERO RESET HELP-SCREEN (1-3-2_?) ............ 3-48
3.3.4.2.24 OPTIONS CODE HEAD ACTUATING-SCREEN (1-3-3) ...................... 3-48
3.3.4.2.25 OPTIONS CODE HEAD ACTUATING HELP-SCREEN (1-3-3_?) ......... 3-49
3.3.4.2.26 OPTIONS SEVERAL COUNTERS-SCREEN (1-3-4) ............................. 3-50
3.3.4.2.27 EXTERNAL OPTIONS COUNTER-SCREEN (1-3-4-1) ......................... 3-50
3.3.4.2.28 EXTERNAL OPTIONS COUNTER HELP-SCREEN (1-3-4-1_?) ............ 3-51
3.3.4.2.29 MAINTENANCE COUNTER-SCREEN (1-3-4-2) ................................ 3-52
3.3.4.2.30 MAINTENANCE COUNTER HELP-SCREEN (1-3-4-2_?) ................... 3-53
3.3.4.2.31 OPERATION HOURS COUNTER-SCREEN (1-3-4-3) ......................... 3-53
3.3.4.2.32 TOTAL LENGTH COUNTER-SCREEN (1-3-4-4)................................. 3-54
3.3.4.2.33 ERROR INDICATION-SCREEN (1-4) ................................................. 3-55
3.3.4.2.34 ALARM HISTORY TIME-SCREEN (1-4-1) ......................................... 3-56
3.3.4.2.35 ALARM HISTORY NUMBER-SCREEN (1-4-2)................................... 3-56
3.3.4.2.36 PRESENT ALARMS-SCREEN (1-4-3) ................................................ 3-57
3.3.4.2.37 SUPERVISION DRIVE CONTROL-SCREEN (1-4-4) ............................ 3-57
3.3.4.2.38 SENSORS CONTROLS-SCREEN (1-4-5) ............................................ 3-58
3.4 OPTIONS ......................................................................................................... 3-59
3.4.1 MARKING WHEEL OPTIONS ........................................................................... 3-59
3.4.1.1 TORQUE ASSIST DRIVE + LENGTH COMPARISON
(OPTION QDM-MLM) .............................................................................. 3-59
3.4.1.2 SYNCHRONIZED DRIVE (OPTION SSYN) ................................................... 3-60
3.4.1.3 EXTERNALLY SYNCHRONIZED DRIVE (OPTION QSE) ............................... 3-61
3.4.1.4 EXTERNAL TACHO GENERATOR UNIT (OPTION UTG) ............................. 3-62
3.4.1.5 MARKING WHEEL PRE-SELECTION PNEUMATIC LIFTING
(OPTION PW)........................................................................................... 3-63
3.4.1.6 HEATING CONTROLLER SYSTEM (OPTION SC) ........................................ 3-63

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 About this Manual KMS 2/4

3.4.1.6.1 HEATING-SCREEN (1-1) .................................................................. 3-63

3.4.1.6.2 HELP-HEATING-SCREEN (1-1_?)..................................................... 3-64
3.4.2 COUNTER AND CODE HEAD OPTIONS ........................................................... 3-65
3.4.2.1 PNEUMATIC COUNTER RESET (OPTION PN) ........................................... 3-65
3.4.2.2 PNEUMATIC PRE-SELECTION COUNTER RESET (OPTION PN W) ............ 3-66
3.4.2.3 PNEUMATIC CODE HEAD ACTUATING (OPTION PC) ............................... 3-66
3.4.2.4 PNEUMATIC PRE-SELECTION CODE HEAD ACTUATING
(OPTION PC W)........................................................................................ 3-66
3.4.2.5 EXTERNAL DEVICE PRE-SELECTION (OPTION 2W) .................................. 3-66
3.4.3 MISCELLANEOUS OPTIONS ............................................................................ 3-67
3.4.3.1 ALARM HORN (OPTION HUP).................................................................. 3-67
3.4.3.2 HEIGHT INDICATION (OPTION HP) .......................................................... 3-67
3.4.4 ERROR INDICATIONS ...................................................................................... 3-68
4 RECEIPT, INSTALLATION AND CONNECTION ................................................. 4-69
4.1 UNPACKING .................................................................................................... 4-69
4.2 INSPECTION OF THE CONSIGNMENT ................................................................ 4-69
4.3 TRANSPORT .................................................................................................... 4-69
4.4 DIMENSION, SPACE REQUIREMENTS ............................................................... 4-69
4.5 INSTALLATION AND ALIGNMENT ..................................................................... 4-70
4.6 ELECTRICAL CONNECTION................................................................................ 4-70
4.7 COMPRESSED AIR CONNECTION ...................................................................... 4-71
5 SETTING UP.................................................................................................. 5-73
5.1 ADJUSTING THE GUIDE ROLLER UNIT ............................................................... 5-73
5.2 ADJUSTING THE MARKING WHEEL STAMPING PRESSURE ................................. 5-74
5.3 ADJUSTING OPTIONAL CONFIGURATIONS........................................................ 5-75
5.3.1 ADJUSTING PNEUMATIC FUNCTIONS – OPTION PN, PN W, PC, PC W,
PW, 2W .......................................................................................................... 5-75
5.3.2 ADJUSTING AUXILIARY DRIVE OPTION QDM-MLM ....................................... 5-76
5.3.3 ADJUSTING AUXILIARY DRIVE OPTION SSYN ................................................. 5-77
5.3.4 ADJUSTING AUXILIARY DRIVE OPTION QSE ................................................... 5-78
5.3.5 ADJUSTING EXTERNAL TACHO GENERATOR OPTION UTG ............................ 5-78
6 START-UP AND OPERATION ......................................................................... 6-81
6.1 STARTING THE MACHINE ................................................................................. 6-81
6.2 STOPPING/INTERRUPTING MARKING .............................................................. 6-81
6.3 CONTINUING MARKING................................................................................... 6-82
6.4 SWITCHING THE MACHINE OFF ........................................................................ 6-82

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KMS 2/4 About this Manual

6.5 EMERGENCY STOP ........................................................................................... 6-82

6.6 SERVICE MODE ................................................................................................ 6-83
7 MAINTENANCE ............................................................................................ 7-84
7.1 CLEANING MARKING WHEEL SLIP RINGS .......................................................... 7-85
7.2 CHECKING/CLEANING MARKING WHEEL CARBON BRUSHES ............................. 7-86
7.3 CLEANING TEXT SEGMENTS ............................................................................. 7-87
7.4 LUBRICATING .................................................................................................. 7-87
8 TROUBLESHOOTING ..................................................................................... 8-88
9 SPARE PARTS ............................................................................................... 9-90
10 APPENDIX ................................................................................................... 10-91
10.1 TECHNICAL SPECIFICATIONS .......................................................................... 10-91
10.2 DRAWINGS.................................................................................................... 10-91
10.3 MENU TREES ................................................................................................. 10-91
10.4 ELECTRIC ....................................................................................................... 10-91
10.5 USER FEEDBACK SHEET .................................................................................. 10-91
10.6 ADDITIONAL DOCUMENTATION .................................................................... 10-91

0.2 LIST OF FIGURES

Figure 1: Hot stamping meter marker KMS 2/4 – General view (standard configuration)................ 3-17
Figure 2: Marking wheel with/without cap ........................................................................................ 3-19
Figure 3: 4-digit counter – actuated mechanically (version 9808)..................................................... 3-19
Figure 4: Counter – reset manually .................................................................................................... 3-20
Figure 5: Text segments ..................................................................................................................... 3-20
Figure 6: Blind segment...................................................................................................................... 3-20
Figure 7: Heating cartridge ................................................................................................................. 3-21
Figure 8: Plug-in segments for letter pins .......................................................................................... 3-21
Figure 9: Letter pins ........................................................................................................................... 3-21
Figure 10: Counter – reset pneumatically (option PN, version 9808)................................................ 3-22
Figure 11: Code head – actuated with levers (version 6311 HH)....................................................... 3-22
Figure 12: Code head – actuated with steel pins (version 6311 HS).................................................. 3-23
Figure 13: Code head – actuated pneumatically (option PC, version 9808) ...................................... 3-23
Figure 14: Marking wheel pneumatic lifting ...................................................................................... 3-24
Figure 15: Guide roller unit ................................................................................................................ 3-25
Figure 16: Control console ................................................................................................................. 3-26
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 About this Manual KMS 2/4

Figure 17: Touch-screen – Start-Screen (1-0)..................................................................................... 3-30

Figure 18: Touch-screen – Menu-Screen (1) ...................................................................................... 3-31
Figure 19: Touch-screen – Info-Screen (0) ......................................................................................... 3-32
Figure 20: Touch-screen – Service-Screen (0–0) ................................................................................ 3-33
Figure 21: Touch-screen – Setup-Screen (sys1) ................................................................................. 3-33
Figure 22: Touch-screen – Setup QDM-Screen (sys1-1)..................................................................... 3-35
Figure 23: Touch-screen – Setup Profibus-Screen (sys1-2) ................................................................ 3-36
Figure 24: Touch-screen – Setup Profibus ERROR-Screen (sys1-2-1)................................................. 3-37
Figure 25: Touch-screen – Setup Profibus OUT-Screen (sys1-2-2) .................................................... 3-37
Figure 26: Touch-screen – Setup Profibus IN-Screen (sys1-2-3) ........................................................ 3-38
Figure 27: Touch-screen – Setup MLM-Screen (sys1-3) ..................................................................... 3-38
Figure 28: Touch-screen – Setup Overview-Screen (sys2) ................................................................. 3-39
Figure 29: Touch-screen – Heating-Screen (1-1) ................................................................................ 3-39
Figure 30: Touch-screen – Heating Help-Screen (1-1_?).................................................................... 3-40
Figure 31: Touch-screen – Heating Base Adjustment-Screen (1-1-2) ................................................ 3-41
Figure 32: Touch-screen – Heating Base Adjustment Help-Screen (1-1-2_?) .................................... 3-42
Figure 33: Touch-screen – Drive-Screen (1-2) .................................................................................... 3-42
Figure 34: Touch-screen – Drive-Help-Screen (1-2_?) ....................................................................... 3-44
Figure 35: Touch-screen – Options-Screen (1-3)................................................................................ 3-44
Figure 36: Touch-screen – Options Marking Wheel-Screen (1-3-1)................................................... 3-45
Figure 37: Touch-screen – Options Marking Wheel Help-Screen (1-3-1_?) ...................................... 3-46
Figure 38: Touch-screen – Options Counter Zero Reset-Screen (1-3-2) ............................................ 3-47
Figure 39: Touch-screen – Options Counter Zero Reset Help-Screen (1-3-2_?) ................................ 3-48
Figure 40: Touch-screen – Options Code Head Actuating-Screen (1-3-3) ......................................... 3-48
Figure 41: Touch-screen – Options Code Head Actuating Help-Screen (1-3-3_?) ............................. 3-49
Figure 42: Touch-screen – Options Several Counters-Screen (1-3-4) ................................................ 3-50
Figure 43: Touch-screen – External Options Counter-Screen (1-3-4-1) ............................................. 3-51
Figure 44: Touch-screen – External Options Counter Help-Screen (1-3-4-1_?) ................................. 3-51
Figure 45: Touch-screen – Maintenance Counter-Screen (1-3-4-2) .................................................. 3-52
Figure 46: Touch-screen – Maintenance Counter Help-Screen (1-3-4-2_?) ...................................... 3-53
Figure 47: Touch-screen – Operation Hours Counter-Screen (1-3-4-3) ............................................. 3-53
Figure 48: Touch-screen – Total Length Counter-Screen (1-3-4-4) .................................................... 3-54
Figure 49: Touch-screen – Error Indication-Screen (1-4) ................................................................... 3-55
Figure 50: Touch-screen – Alarm History Time-Screen (1-4-1) .......................................................... 3-56
Figure 51: Touch-screen – Alarm History Number-Screen (1-4-2) ..................................................... 3-56
Figure 52: Touch-screen – Present Alarms-Screen (1-4-3)................................................................. 3-57
Figure 53: Touch-screen – Supervision Drive Control-Screen (1-4-4) ................................................ 3-57
Figure 54: Touch-screen – Sensors Controls-Screen (1-4-5) .............................................................. 3-58

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KMS 2/4 About this Manual

Figure 55: Auxiliary torque assist drive (option QDM-MLM) ............................................................. 3-60
Figure 56: Auxiliary synchronized drive (option SSYN) ...................................................................... 3-60
Figure 57: Auxiliary externally synchronized drive (option QSE) ....................................................... 3-61
Figure 58: External tacho generator (option UTG)............................................................................. 3-62
Figure 59: Heating-Screen .................................................................................................................. 3-63
Figure 60: Help instructions for the Heating Screen ......................................................................... 3-64
Figure 61: Height indication (option HP) ............................................................................................ 3-67
Figure 62: Control console – yellow warning light ............................................................................. 3-68
Figure 63: Compressed air connection............................................................................................... 4-71
Figure 64: Adjusting the guide roller unit .......................................................................................... 5-73
Figure 65: Adjusting the stamping pressure – marking wheel standard configuration ..................... 5-74
Figure 66: Adjusting the external tacho generator option UTG......................................................... 5-79
Figure 67: Marking wheel slip rings ................................................................................................... 7-85
Figure 68: Marking wheel carbon brushes block ............................................................................... 7-86

0.3 LIST OF TABLES

Table 1: Notational conventions ........................................................................................................ 0-10
Table 2: Hot stamping meter marker KMS 2/4 – components (standard configuration) .................. 3-17
Table 3: Control console – main controls (standard configuration) .................................................. 3-28
Table 4: Control console – main controls (optional configuration) ................................................... 3-29
Table 5: Control console – touch-screen............................................................................................ 3-30
Table 6: Marking wheel options – overview ...................................................................................... 3-59
Table 7: Counter and code head options – overview ........................................................................ 3-65
Table 8: Miscellaneous options – overview ....................................................................................... 3-67
Table 9: Troubleshooting ................................................................................................................... 8-89

0.4 REVISION LOG

Revision Status Date Correction Author

1.00 Initial Version 11 January 2017 --- IBA

Rev: 1.00 eng Instruction Manual – Original Instructions 0-9

 About this Manual KMS 2/4

0.5 COMPANY CONTACT

MEDEK & SCHÖRNER GmbH

Dr. Karl Renner Strasse 9-11
2203 Grossebersdorf
AUSTRIA
Tel. +43 (0) 2245 4694 – 101
e-mail: [email protected]
Internet: http://www.medek.at

0.6 NOTATIONAL CONVENTIONS

The following table explains the notational conventions used in this manual.
Font / type / style Meaning

Italic Textual cross references are printed in italics.

Bold Important terms and passages in the text are indicated by bold
print.

Table 1: Notational conventions

In addition, the following warning symbols and signal terms are used:
ATTENTION: The WARNING symbol calls your attention to the possible severe personal
injury and health damage, which can occur in case of disregard of the safety instructions.
It also indicates that minor personal injury or substantial property damage can occur, if
proper precautions are not taken.

The NOTE symbol indicates special technical product information.

The TIP symbol indicates a hint, e.g. to refer to a section for further details.

The TOOL symbol indicates a certain action to be taken.

0-10 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 About this Manual

Rev: 1.00 eng Instruction Manual – Original Instructions 0-11

 About this Manual KMS 2/4

0.7 USING THIS MANUAL

First read the This manual starts with sections on the Proper Use of the equipment and
sections Precautions. These sections contain important information on personal and
Proper Use technical safety.
and
Precautions!

Read this The chapter Technical Description describes the functionality of the hot
manual carefully stamping meter marker and includes information on its Construction.
before set up The following sections guide you through Receipt, Installation and Connection
and initial and Setting Up.
operation of After that, you will find separate sections on Start-Up and Operation as well as
the equipment! Maintenance and Troubleshooting.
Finally, the sections Spare Parts and Appendix are included for your reference at
the end of the manual.

For reasons of clarity, this manual neither claims to cover all details of possible
equipment variations, nor in particular provides for every possible example of
installation, operation or maintenance.
Concerning the figures shown in this manual, differences to the actual
configuration of the machine can occur.
Hence, only those instructions are included in the manual that are required by
qualified personnel for the proper use in industrial areas.

0-12 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Proper Use

1 PROPER USE

Purpose of The hot stamping meter marker KMS 2/4 described in this manual is exclusively
the machine! designed for marking cables, tubes and similar products by embossing.
Other use is inadmissible, and consequently may only take place in special cases
after consultation with the manufacturer.
Follow the Proper use also includes the compliance with the installation, maintenance and
instructions! repair instructions provided by the manufacturer.

Trained The equipment is only allowed to be operated by qualified personnel who is

personnel familiar with its operation, maintenance, repair, and has been instructed about
only! potential hazards.

Comply Make sure that all industrial safety regulations and regulations for the
with legal prevention of industrial accidents in force in your country and applicable to the
requirements! operation of the machine are complied with at any time.

If the machine is used improperly or in another way than intended by the

manufacturer, the manufacturer will exclude any liability, and the responsibility
for all consequences will be born exclusively by the user.

EU-conformity If the equipment is delivered to an EU country, this manual also includes an EU-
declaration! declaration of conformity, which declares that the equipment complies with the
harmonised EU directives and harmonised standards.

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 Precautions KMS 2/4

2 PRECAUTIONS

Read the Read the entire instruction manual carefully before installation, initial operation,
manual! and maintenance of the machine.

Authorised The equipment is allowed to be operated by authorised personnel only.

personnel Take all necessary and suitable precautions to prevent unauthorised personnel
only! from operating the equipment.

EMERGENCY Whenever a situation arises which may mean a hazard to health, property or
STOP the environment, stop the equipment immediately by pressing the red
EMERGENCY STOP button on the control console.
ATTENTION: Do not touch any moving parts of the machine!
ATTENTION: Beware of the risk of injury when touching hot machine parts!
ATTENTION: Do not open the protective door during operation!
ATTENTION: Do not leave the machine unattended during operation!
ATTENTION: Do not wear loose-fitting clothes!
ATTENTION: At least once a month, press the EMERGENCY STOP button in
order to check for proper operation!

Maintenance, The machine may be maintained, readjusted or cleaned by authorised personnel

readjustment, only.
cleaning! Before maintaining, readjusting or cleaning, stop the machine, disconnect it
from the mains supply and let all parts cool down.

For the residual risk of the lateral danger of being drawn in in the direction of
Safety concept!
passage (lateral machine entry / exit of the cable), due to the moving material to
be stamped, no or only limited protective measures have been taken for reasons
of performance and handling-appropriate application, since these depend on the
integration into a total of the machines.
On the customer side, a connection protection must therefore be attached to
the entry and exit side of the marking good, which prevents access to the draw-
in point between the guide roller and the marking good. The relevant standards
and the applicable employee protection regulations must be observed. A
protective housing with a safety shutdown can also be installed by the customer.

Failure or If the equipment fails or suffers any damage, contact your local MEDEK &
damage! SCHÖRNER agent or MEDEK & SCHÖRNER directly.
Please always indicate the serial number according to the identification plate of
the machine or element referred to when contacting MEDEK & SCHÖRNER about
complaints or machine failure.

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KMS 2/4 Precautions

Spare parts! When ordering spare parts, please always indicate the description or
identification number as well as the drawing number and the serial number of
the equipment.

Rev: 1.00 eng Instruction Manual – Original Instructions 2-15

 Technical Description KMS 2/4

3 TECHNICAL DESCRIPTION
All meter/footage markers from MEDEK & SCHÖRNER are fully modular for maximum
flexibility. In addition, the excellent manufacturing quality ensures exceptional reliability
and a long service life of each machine.
This section of the manual includes the functional description of the hot stamping meter
marker KMS 2/4 giving information about the construction, components and available
options.
Since every machine is configured with different options, the section 10.1 Technical
Specifications in the appendix offers a separate list containing the standard equipment of
this machine as well as its integrated options.

3.1 GENERAL
The hot stamping meter marker KMS 2/4 is specifically designed for printing on cold plastic
tubing or plastic insulated cables.
The machine is equipped with a marking wheel with a circumference of 1 meter.
The marking wheel contains heated type segment supports and a heated base for a counter
(for consecutive numbering) or code head. These heated segments and the counter or code
head stamp specified text on the marking good sheath. In this way all kind of information
like company logo, length specifications in meter, dimensional data, manufacturing date,
etc. can be marked on the marking good.
Depending on the construction, the standard configuration permits marking speeds of up to
80 m/min; for higher speeds it is possible to use special text segments and counters with
sharp gravure (optional).
The default diameter of the marking good is 8-60 mm; the machine can be adapted to
customer’s requirements by MEDEK & SCHÖRNER.
The KMS 2/4, configured at the factory for left-to-right or right-to-left running, can be used
either after the cooling bath in the extrusion line or in a separate winding system.
Several options for the machine are available, either by ordering immediately or by
retrofitting later – for further information please contact MEDEK & SCHÖRNER.

3.2 TECHNICAL SPECIFICATIONS

For the technical data of this machine concerning serial number, year of manufacturing,
dimensions as well as marking details, refer to section 10.1 Technical Specifications in the
appendix.

Design and specifications are subject to change without notice.

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KMS 2/4 Technical Description

3.3 CONSTRUCTION
Figure 1 shows the hot stamping meter marker KMS 2/4:

12
3

10

11
4

9 6

7
8

Figure 1: Hot stamping meter marker KMS 2/4 – General view (standard configuration)

1 Castor mounted feet 2 Support column 3 Control console

Marking unit Marking unit

4 5 6 Marking wheel
base plate rack jack device

Guide roller unit Guide roller unit

7 8 9 Guide roller
base plate rack jack device
Stamping pressure Contact/lift pressure
10 11 12 MAINS SWITCH
fine adjustment screw regulators base plate

Table 2: Hot stamping meter marker KMS 2/4 – components (standard configuration)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-17

 Technical Description KMS 2/4

The whole equipment consists of as follows (refer to Figure 1):

• Castor mounted feet (1) and the support column (2) with two adjustment cranks (5+8);
• the marking unit featuring the marking unit base plate (4), the marking wheel (6)
mounted on a support arm as well as the fine adjustment screw (10) for adjusting the
stamping pressure of the marking wheel;
• the marking wheel’s contact/lift pressure regulators base plate (11);
• the guide roller unit base plate (7) with the guide roller (9);
• the control console (3) with buttons, indicator lamps, and the MAINS SWITCH (12).
All figures of this document show the meter marker KMS 2/4 for left-to-right running (i.e.
running direction “Right”). For right-to-left running (i.e. running direction “Left”), the
figures will necessarily vary in some cases.

The following subsections describe the equipment mentioned above in detail.

3.3.1 FRAME
As can be seen in Figure 1, the frame of the KMS 2/4 consists of the castor mounted feet (1)
and the support column (2) with two adjustment cranks for the approximate height
position of the marking unit base plate (5) and the guide roller unit base plate (8).

3.3.2 MARKING UNIT

3.3.2.1 MARKING WHEEL

In general, the marking wheel (6) is mounted on the support arm of the marking unit base
plate (4) (refer to Figure 1). The marking unit base plate can be adjusted in the height via
rack jack device (5) while the stamping pressure of the marking wheel on the marking good
has to be set via fine adjustment screw (10). This offers the possibility to increase or
decrease the marking pressure on the marking good depending on its diameter.
The marking wheel is equipped with heated type segment supports containing freely
definable text and a heated base for a built-in counter or code head. These heated text
segments and the counter or code head stamp the specified text on the marking good
sheath.
The circumference of the marking wheel is 1 meter.
Depending on the configuration, the built-in...
counter is actuated mechanically and can be reset to zero either manually or by an
electronically controlled pneumatic system;
code head can be actuated either manually or by an electronically controlled pneumatic
system.
For further information about the machine’s built-in counter or code head, please refer to
the enclosed documentation of the counter or code head.

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KMS 2/4 Technical Description

The standard configuration of the KMS 2/4 features a marking wheel with a built-in heated
counter (actuated mechanically and manually reset to zero).
Several options for the marking wheel are available.
Figure 2 shows the marking wheel with cap and without cap in standard configuration:

3
2

1
5

Figure 2: Marking wheel with/without cap

Wheel’s cap
1 2 Built-in counter 3 Manual reset lever
mounting screws
Handles for removing
4 5 Segment support 6 Heating cartridge
the wheel’s cap

In standard configuration, the marking wheel (refer to Figure 2) is equipped with:

• 4-digit counter (2):
The counter prints the length marks in meters or feet on the marking goods. The
actuating arm of the counter has a ball bearing at its end whose outer ring rides on a
curved rail or in the groove of a U-section ring (mounted on the marking unit support
arm). The eccentricity of the rail or ring causes the actuating arm to index the counter
mechanically with every full revolution of the marking wheel. After reaching “9999”, it
automatically restarts at “0000”.

Figure 3: 4-digit counter – actuated mechanically (version 9808)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-19

 Technical Description KMS 2/4

• Lever for manual reset (3):

The manual reset lever allows resetting the counter manually to “0000” individually (as
soon as the marking wheel has come to a standstill).

Figure 4: Counter – reset manually

• Segment support (5) for:

‒ Text segments:
These heated segments stamp the specified text on the surface of the marking
good. By means of different text segments, any specific text can be composed. The
text of the segments must be predefined by the customer when ordering the
KMS 2/4 to be engraved at factory.

Figure 5: Text segments

‒ Blind segments:
Whenever a text segment is removed from the marking wheel (e.g. because a
specific text will not be printed on specific marking good), a blind segment must be
mounted instead of the removed text segment in order to rebalance the marking
wheel correctly. The whole segment support must be equipped completely with
text segments or blind segments at any time.

Figure 6: Blind segment

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KMS 2/4 Technical Description

• Heating cartridges (6):

The text segments mounted on the segment support as well as the counter (and code
head, if available) are electrically heated by heating cartridges. They are powered via
collector rings on the rear side of the marking wheel and carbon brushes in the marking
wheel support plate. The heating system is designed and adjusted at factory for each
individual configuration to match the specified extrusion line speed.

Figure 7: Heating cartridge

For further information about the heating system for other type segments or counters in
the marking wheel as well as available options for the marking wheel, please contact
MEDEK & SCHÖRNER.

In non-standard configurations, a marking wheel can be equipped with:

• Plug-in segments for letter pins:
For printing frequently changing combinations of letters, numbers, and symbols,
MEDEK & SCHÖRNER offers plug-in segments for letter pins. The plug-in segments are
to be mounted on the segment support instead of or in combination with the engraved
text segments, and to be filled with interchangeable letter pins. This system provides
optimum flexibility.

Figure 8: Plug-in segments for letter pins

• Letter pins:
Interchangeable letter pins to be installed into and removed from the plug-in segments
to compose individual text.

Figure 9: Letter pins

Rev: 1.00 eng Instruction Manual – Original Instructions 3-21

 Technical Description KMS 2/4

• 5 or 6-digit counter
• Pneumatic counter reset:
This method allows resetting the counter pneumatically controlled to “0000(0)(0)”
individually even while the marking wheel is rotating – for a detailed description refer
to section 3.4.2.1 Pneumatic Counter Reset (Option PN).

Figure 10: Counter – reset pneumatically (option PN, version 9808)

• Code head:
Up to 8 digits, a code head is designed for stamping the marking good with individual
customer-specific combinations of characters. On contrary to a counter, a code head
must be actuated either manually or via a pneumatic controlled system. It is not
possible to “reset” a code head.
Actuating can be done...
‒ Manually with levers (version HH):
The code head can be actuated with levers only when the marking wheel has come
to a standstill.

Figure 11: Code head – actuated with levers (version 6311 HH)

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KMS 2/4 Technical Description

‒ Manually with steel pins (version HS):

The code head can be actuated with steel pins only when the marking wheel has
come to a standstill.

Figure 12: Code head – actuated with steel pins (version 6311 HS)

‒ Pneumatically controlled:
On contrary to the manual variants described above, the code head can be
actuated pneumatically even while the marking wheel is rotating – for a detailed
description refer to section 3.4.2.3 Pneumatic Code Head Actuating (Option PC).

Figure 13: Code head – actuated pneumatically (option PC, version 9808)

3.3.2.2 MARKING WHEEL PNEUMATIC LIFTING

The pneumatic lifting of the marking wheel raises or lowers the marking wheel
pneumatically controlled. The operator activates the lifting of the marking wheel manually
via control console and touch-screen.
The pneumatic lifting of the marking wheel features a pneumatic cylinder (2) and a 4/2 way
valve (refer to Figure 14) for lowering and raising the marking wheel. As already mentioned
in section 3.3.2.1 Marking Wheel, the fine adjustment knob (1) offers the possibility to
adapt the machine to the diameter of the marking good (i.e. the marking depth).

Rev: 1.00 eng Instruction Manual – Original Instructions 3-23

 Technical Description KMS 2/4

Furthermore, the lifting and lowering pressure of the marking wheel can be adjusted
separately (refer to Figure 14).
The lifting pressure is adjustable via LIFT PRESSURE regulator (3); it is factory set for safe
and quick lifting speed and should not be changed.
The contact pressure is adjustable via CONTACT PRESSURE regulator (4) and controls the
printing pressure of the air-loaded marking wheel support arm. This is very helpful in cases
where the marking good is very wavy and rigid or the cable diameter is not stable.
On the control console, the pneumatic lifting of the marking wheel is controlled by the
MARKING WHEEL pushbuttons (refer to Figure 14 and to section 3.3.4.1 Main Controls) and
via touch-screen – refer to section 3.3.4.2.20 Options Marking Wheel-Screen (1-3-1).

Figure 14: Marking wheel pneumatic lifting

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KMS 2/4 Technical Description

In normal operation with activated security function, it is not possible to lower the marking
wheel when the protective door is open.
When opening the protective door during production (i.e. marking wheel is stamping the
marking good), the system raises the marking wheel automatically into its standby position
and lets the green POWER (I) pushbutton on the control console start blinking (refer to
section 3.3.4.1 Main Controls). Having closed the protective door, the operator must
confirm it by pressing the green POWER (I) pushbutton. Afterwards the marking wheel can
be lowered again.

3.3.3 GUIDE ROLLER UNIT

Figure 15 shows the guide roller unit, consisting of one fixed guide roller (9), the guide
roller unit base plate (7), and the rack jack device (8) for the adjustment of the approximate
height position of the guide roller unit base plate:

Figure 15: Guide roller unit

The guide roller unit is positioned below the marking unit. The guide roller provides optimal
positioning of the marking good to the marking wheel.
The vertical alignment of the guide roller unit to the marking good must be done with the
rack jack device.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-25

 Technical Description KMS 2/4

3.3.4 CONTROL CONSOLE

The control console is mounted on the machine’s base plate and contains all electric
components. For maintenance reasons, the operator can open its door at the rear side.
Figure 16 shows the control console in standard configuration (without any option). At the
front side, the control console features main controls (1) and a touch-screen (2) as follows
(refer to Figure 16):

Figure 16: Control console

The following subsections describe the main controls and the touch-screen mentioned
above in detail.

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KMS 2/4 Technical Description

3.3.4.1 MAIN CONTROLS

Active controls are illuminated.

The control console in its standard configuration provides the following main controls (see
Table 3):
MAINS SWITCH The MAINS SWITCH establishes or cuts off the entire power supply of
the machine.

MAINS SUPPLY The white indicator lamp MAINS SUPPLY glows when the power to
the entire machine is on.

EMERGENCY The red, locking EMERGENCY STOP button cuts the power supply for
STOP all safety relevant functions of the machine.
Afterwards, the button must be turned clockwise to unlock it – refer
also to section 6.5 Emergency Stop.

POWER The green POWER (I) pushbutton switches the machine on.
The pushbutton blinks after having pressed the EMERGENCY STOP
button. It stops blinking and glows constantly as soon as the
EMERGENCY STOP button is unlocked.
Fast blinking of the pushbutton means that the system operates in
service mode with deactivated security function (refer also to section
6.6 Service Mode).
The red POWER (0) pushbutton switches the machine off.

HEATING 1 The green HEATING 1 (I) pushbutton starts the heating of the marking
wheel.
The pushbutton blinks as long as the system is in the heat-up phase
for the marking wheel. It stops blinking and glows constantly as soon
as the required temperature is reached.
The red HEATING 1 (0) pushbutton stops the heating of the marking
wheel.

MARKING The green MARKING WHEEL () pushbutton lowers the marking
WHEEL wheel pneumatically into operating position, i.e. the marking wheel
starts stamping the marking good.
The red MARKING WHEEL () pushbutton raises the marking wheel
pneumatically into standby position, i.e. the marking wheel stops
stamping the marking good.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-27

 Technical Description KMS 2/4

SERVICE The SERVICE OFF/ON key switch activates or deactivates the security
OFF / ON function.
When in position ON, the system temporarily operates with
deactivated security function (for the detailed procedure, refer to
section 6.6 Service Mode). In this case, the system does not raise the
marking wheel automatically into its standby position when opening
the protective door.
As soon as the protective door is closed, the system returns to normal
operation mode with activated security function.
When in position OFF, the system operates with activated security
function, i.e. the marking wheel is raised automatically into its
standby position when opening the protective door.

ALARM QUIT The blue ALARM QUIT pushbutton acknowledges an error indication
for the machine.
The pushbutton blinks after an error has occurred. Pressing the
button acknowledges the error. As long as the error is not solved, the
pushbutton and also the yellow warning light mounted on the top of
the control console glow constantly. The optional alarm horn (if
installed) stops.

Table 3: Control console – main controls (standard configuration)

Depending on several options, the control console may provide the following main controls
in addition (see Table 4).
HEATING 2 Not available for KMS 2/4.

TAPE Not available for KMS 2/4.

GUIDANCE Not available for KMS 2/4.

COUNTER The blue COUNTER RESET pushbutton resets the built-in counter of
RESET the marking wheel pneumatically to zero.
The pushbutton is available with option PN, PN W, and PN 2W only.

CODE The blue CODE CHANGE pushbutton actuates the built-in code head
CHANGE of the marking wheel pneumatically.
The pushbutton is available with option PC, PC W, and PC 2W only.

DRIVE The green DRIVE (I) pushbutton starts the machine’s drive system of
the marking wheel.
The red DRIVE (0) pushbutton stops the drive system.
The pushbuttons are available with option QDM-MLM, QSE, and SSYN
only.

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KMS 2/4 Technical Description

TORQUE The TORQUE - / + switch selects the motor mode:

-/+ “-“ sets the dynamic braking mode to slow the marking wheel
ADJUST down, i.e. to increase the distance of the length marks on the
marking good;
“+“ sets the accelerating mode to speed the marking wheel up,
i.e. to decrease the distance of the length marks on the
marking good.
The 10-speed potentiometer ADJUST sets the amount of acceleration
torque or dynamic braking of the motor. The total range of the
potentiometer is ten revolutions.
Both the switch and the potentiometer are available with
option QDM-MLM only.

SPEED The 10-speed potentiometer SPEED ADJUST sets the speed of the
ADJUST drive motor by +/- 4% compared to the external reference value. The
displayed value should be close to 1.000 m. The total range of the
potentiometer is ten revolutions.
The potentiometer is available with option QSE only.

Table 4: Control console – main controls (optional configuration)

3.3.4.2 TOUCH-SCREEN
Being integrated in the control console, the touch-screen offers a simple and easy user
interface for operating the KMS 2/4.
The screenshots depicted in this document refer to a machine configured with all available
options. For other configurations, the screenshots will necessarily vary in some cases.

In general, the menu bar at the bottom of the screen featuring the buttons...

...is available in each menu level and leads directly to the corresponding screen. Table 5 lists
the general elements displayed on the touch-screen:
Button Opens the Menu-Screen (1) – refer to section 3.3.4.2.2
Menu-Screen (1)

Button Opens the Heating-Screen (1-1) – refer to section 3.3.4.2.13

Heating-Screen (1-1)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-29

 Technical Description KMS 2/4

Button Opens the Drive-Screen (1-2) – refer to section 3.3.4.2.17

Drive-Screen (1-2)
Only relevant in combination with an optional auxiliary drive.

Button Opens the Options-Screen (1-3) – refer to section 3.3.4.2.19

Options-Screen (1-3)

Button Leads backwards to the previous screen

(not in all screens available)

Button Opens the corresponding help screen for the active screen
(not in all screens available)

Button Opens the Error Indication-Screen (1-4) – refer to section 3.3.4.2.33

Error Indication-Screen (1-4)

Table 5: Control console – touch-screen

For more details about the hierarchy level of all screens as well as help screens and error
screens, refer to section 10.3 Menu Trees in the appendix.

3.3.4.2.1 START-SCREEN (1-0)

After switching the machine on, the Start-Screen (1-0) appears displaying the logo of
MEDEK & SCHÖRNER.

Figure 17: Touch-screen – Start-Screen (1-0)

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KMS 2/4 Technical Description

Few seconds later, the system leads you automatically to the Menu-Screen (1).

3.3.4.2.2 MENU-SCREEN (1)

Having pressed the button in the menu bar, the Menu-Screen (1) appears. It
displays information about the current heating power for the marking wheel as well as the
pre-selection counters (optional).

Figure 18: Touch-screen – Menu-Screen (1)

Button Opens the Info-Screen (0) – refer to section 3.3.4.2.3 Info-Screen (0)

Display Displays the current heating power in per cent for the marking wheel
HEATING POWER: The field in front of the value glows green as long as the heating
WHEEL 1 element is actively powered.

Display Only relevant in combination with an optional pre-selection counter

PRESELECTION
COUNTER:
ACTUAL

Display Only relevant in combination with an optional pre-selection counter

PRESELECTION
COUNTER:
TRIGGER

Display Only relevant in combination with an optional auxiliary drive

.m

Rev: 1.00 eng Instruction Manual – Original Instructions 3-31

 Technical Description KMS 2/4

3.3.4.2.3 INFO-SCREEN (0)

Having pressed the button in the Menu-Screen (1), the Info-Screen (0) appears. It
displays general information about the machine.

Figure 19: Touch-screen – Info-Screen (0)

Button Opens the Setup-Screen (sys1) – refer to section 3.3.4.2.5

Setup-Screen (sys1)

Display Displays the type of the machine

KMS-2/4

Display Displays the serial number of the machine

MC NO.: /

Display Displays the software version of the machine

SOFT.VERS.: .

Display Displays the current date

TT.MM.JJ

Display Displays the time

HH.mm

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KMS 2/4 Technical Description

3.3.4.2.4 SERVICE-SCREEN (0–0)

Having long pressed the green POWER (I) pushbutton on the control console for more than
three seconds, the Service-Screen (0–0) appears. It enables the operator to enter the
service mode in order to deactivate temporarily the system’s security function, e.g. for
service reasons.

Figure 20: Touch-screen – Service-Screen (0–0)

Button Confirms entering the service mode and therefore the deactivation of
the security function – refer also to section 6.6 Service Mode

3.3.4.2.5 SETUP-SCREEN (SYS1)

Having long pressed (more than 2 seconds) the button in the Info-Screen (0), the
Setup-Screen (sys1) appears. It offers several possibilities to set up the machine, e.g.
language, process direction, date/time, etc.

Figure 21: Touch-screen – Setup-Screen (sys1)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-33

 Technical Description KMS 2/4

Button Sets the menu language

LANGUAGE Pressing on a flag symbol sets the corresponding language to be
displayed in all screens.

Button Opens the Setup QDM-Screen (sys1-1) – refer to section 3.3.4.2.6

Setup QDM-Screen (sys1-1)
Only relevant in combination with an optional auxiliary drive system.

Button Defines the marking wheel as meter or feet marking wheel

MARKING Pressing the button toggles between meter and feet. After replacing
WHEEL the machine’s meter marking wheel with a feet marking wheel (or
vice versa), the operator must inform the system about the new
marking wheel by pressing this button.

Button Defines the machine’s process direction

PROCESS Pressing the button toggles between < (right-to-left running)
DIRECTION and > (left-to-right running). After changing the machine’s process
direction (i.e. to convert the machine mechanically from right-to-left
running to left-to-right running or vice versa), the operator must
inform the system about the new process direction by pressing this
button.

Button Opens the Setup Profibus-Screen (sys1-2) – refer to section 3.3.4.2.7

Setup Profibus-Screen (sys1-2)
Only relevant in combination with an optional profibus.

Button Opens the Setup MLM-Screen (sys1-3) – refer to section 3.3.4.2.11

Setup MLM-Screen (sys1-3)

Button Opens the dialogue for setting time and date

Button Opens the Setup Overview-Screen (sys2) – refer to section 3.3.4.2.12

Setup Overview-Screen (sys2)

3.3.4.2.6 SETUP QDM-SCREEN (SYS1-1)

Having pressed the button in the Setup-Screen (sys1), the
Setup QDM-Screen (sys1-1) appears. It defines the maximum speed for option QDM-MLM.

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KMS 2/4 Technical Description

Figure 22: Touch-screen – Setup QDM-Screen (sys1-1)

Display + Displays and sets the maximum speed for the auxiliary torque assist
button drive (option QDM-MLM) in meters per minute

The buttons + or – increment or decrement the value. The

button applies the input. Whenever required, the factory-set values
defined by MEDEK & SCHÖRNER can be restored by pressing the
button.

Button Applies the input for the maximum speed

Button Restores the factory-set values for the maximum speed

3.3.4.2.7 SETUP PROFIBUS-SCREEN (SYS1-2)

Having pressed the button in the Setup-Screen (sys1), the
Setup Profibus-Screen (sys1-2) appears. It defines the slave address for the profibus and
leads to the corresponding sub-screens.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-35

 Technical Description KMS 2/4

Figure 23: Touch-screen – Setup Profibus-Screen (sys1-2)

Display + Displays and sets the slave address

button
The operator must define the address of the slave that wants to
access the machine’s profibus interface.
The buttons + or – increment or decrement the value.
Whenever changing this address, the machine must be rebooted!

Button Opens the Setup Profibus ERROR-Screen (sys1-2-1) – refer to section

3.3.4.2.8 Setup Profibus ERROR-Screen (sys1-2-1)

Button Opens the Setup Profibus OUT-Screen (sys1-2-2) – refer to section

3.3.4.2.9 Setup Profibus OUT-Screen (sys1-2-2)

Button Opens the Setup Profibus IN-Screen (sys1-2-3) – refer to section

3.3.4.2.10 Setup Profibus IN-Screen (sys1-2-3)

Changing the slave address requires a reboot of the machine!

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KMS 2/4 Technical Description

3.3.4.2.8 SETUP PROFIBUS ERROR-SCREEN (SYS1-2-1)

Having pressed the button in the Setup Profibus-Screen (sys1-2), the
Setup Profibus ERROR-Screen (sys1-2-1) appears. It displays the meaning of
WORD 1 - ERROR.

Figure 24: Touch-screen – Setup Profibus ERROR-Screen (sys1-2-1)

3.3.4.2.9 SETUP PROFIBUS OUT-SCREEN (SYS1-2-2)

Having pressed the button in the Setup Profibus-Screen (sys1-2), the
Setup Profibus OUT-Screen (sys1-2-2) appears. It displays the meaning of WORD 2 - OUT.

Figure 25: Touch-screen – Setup Profibus OUT-Screen (sys1-2-2)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-37

 Technical Description KMS 2/4

3.3.4.2.10 SETUP PROFIBUS IN-SCREEN (SYS1-2-3)

Having pressed the button in the Setup Profibus-Screen (sys1-2), the
Setup Profibus IN-Screen (sys1-2-3) appears. It displays the meaning of WORD 3 - IN.

Figure 26: Touch-screen – Setup Profibus IN-Screen (sys1-2-3)

3.3.4.2.11 SETUP MLM-SCREEN (SYS1-3)

Having pressed the button in the Setup-Screen (sys1), the
Setup MLM-Screen (sys1-3) appears. It defines the settings for the auxiliary torque assist
drive in combination with length comparison (option QDM-MLM).

Figure 27: Touch-screen – Setup MLM-Screen (sys1-3)

Display + Displays and sets the amount of pulses and length in millimeters for
button QDM-MLM
PULSE / mm In order to adjust the length comparison, the operator must define
the amount of pulses per which length coming.
The buttons + or – increment or decrement the value. The
button applies the input.

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KMS 2/4 Technical Description

Button Saves and applies the settings.

3.3.4.2.12 SETUP OVERVIEW-SCREEN (SYS2)

Having pressed the button in the Setup-Screen (sys1), the
Setup Overview-Screen (sys2) appears. It offers information about the machine’s
configuration with all active delivered options.

Figure 28: Touch-screen – Setup Overview-Screen (sys2)

3.3.4.2.13 HEATING-SCREEN (1-1)

Having pressed the button in the menu bar, the Heating-Screen (1-1) appears. It
displays the current settings of the marking wheel heating.

Figure 29: Touch-screen – Heating-Screen (1-1)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-39

 Technical Description KMS 2/4

Button Starts the marking wheel heating

Button Stops the marking wheel heating

Button Opens the Heating Base Adjustment-Screen (1-1-2) – refer to section

3.3.4.2.15 Heating Base Adjustment-Screen (1-1-2)

Display + Displays and sets the heating power for the marking wheel in per cent
button
The buttons + or – increment or decrement the value.

Display Displays the heating for the marking wheel in per cent relatively to
the maximum continuous heating power (100%)
The field in front of the value glows green as long as the heating
element is actively powered.

Display Indicates the heating up mode for the marking wheel

The display flashes as long as the end temperature is not reached.

Button Stops the heating up mode

The system returns to the normal heating mode automatically.

3.3.4.2.14 HEATING HELP-SCREEN (1-1_?)

Having pressed the button in the Heating-Screen (1-1), the Heating Help-Screen (1-1_?)
appears. It offers additional support to the heating topic.

Figure 30: Touch-screen – Heating Help-Screen (1-1_?)

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KMS 2/4 Technical Description

3.3.4.2.15 HEATING BASE ADJUSTMENT-SCREEN (1-1-2)

Having pressed the button in the Heating-Screen (1-1), the
Heating Base Adjustment-Screen (1-1-2) appears. It offers the possibility to set the
parameters for the cooling time and heat up time of the marking wheel.

Figure 31: Touch-screen – Heating Base Adjustment-Screen (1-1-2)

Display + Displays and sets the cooling time for the marking wheel in minutes
button
The buttons + or – increment or decrement the value.
COOLING
TIME (CT)

Display + Displays and sets the heat-up time for the marking wheel in minutes
button
The buttons + or – increment or decrement the value.
HEAT-UP
TIME (HT)

3.3.4.2.16 HEATING BASE ADJUSTMENT HELP-SCREEN (1-1-2_?)

Having pressed the button in the Heating Base Adjustment-Screen (1-1-2), the
Heating Base Adjustment Help-Screen (1-1-2_?) appears. It offers additional support to the
heating base adjustment topic.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-41

 Technical Description KMS 2/4

Figure 32: Touch-screen – Heating Base Adjustment Help-Screen (1-1-2_?)

3.3.4.2.17 DRIVE-SCREEN (1-2)

This screen is available with options QDM-MLM, QSE, SSYN only – refer to section 3.4.1
Marking Wheel Options and its corresponding subsections for the auxiliary drives.

Having pressed the button in the menu bar, the Drive-Screen (1-2) appears. It
defines the settings of the (optional) marking wheel auxiliary drive.

Figure 33: Touch-screen – Drive-Screen (1-2)

Button Activates the auxiliary drive for the marking wheel

After powering the machine up, the drive motor controller is in the
start-up mode (approx. 10 seconds). During this mode, it is not
possible to activate the auxiliary drive.

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KMS 2/4 Technical Description

Button Deactivates the auxiliary drive for the marking wheel

Button Activates or deactivates the electromagnetic brake for the marking

wheel drive
The pressed button activates the brake, i.e. the marking wheel is
blocked;
the released button deactivates the brake, i.e. the marking wheel can
be turned.

Display + Displays and sets the ratio for the marking wheel synchronization
button
The buttons + or – increment or decrement the value.
RATIO 1:
Pressing the button confirms the input and applies
the new settings immediately.
After powering the machine up, the drive motor controller starts with
a ration of 1:1. About 15 seconds later, the system sends the actual
adjusted ratio to the controller automatically.

3.3.4.2.18 DRIVE-HELP-SCREEN (1-2_?)

Having pressed the button in the Drive-Screen (1-2), the Drive-Help-Screen (1-2_?)
appears. It offers additional support to the auxiliary drive topic.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-43

 Technical Description KMS 2/4

Figure 34: Touch-screen – Drive-Help-Screen (1-2_?)

The upper screen is available with option SSYN only, while the lower screen is available
with option QDM-MLM only – refer to section 3.4.1 Marking Wheel Options and its
corresponding subsections for the auxiliary drives.

3.3.4.2.19 OPTIONS-SCREEN (1-3)

Having pressed the button in the menu bar, the Options-Screen (1-3) appears. It
leads to the corresponding sub-screens for setting several options for the marking wheel,
the pneumatic reset of the counter, the pneumatic actuating of the code head, and several
counters.

Figure 35: Touch-screen – Options-Screen (1-3)

Button Opens the Options Marking Wheel-Screen (1-3-1) – refer to section

3.3.4.2.20 Options Marking Wheel-Screen (1-3-1)

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KMS 2/4 Technical Description

Button Opens the Options Counter Zero Reset-Screen (1-3-2)– refer to

section 3.3.4.2.22 Options Counter Zero Reset-Screen (1-3-2)
Only relevant in combination with the optional pneumatic reset of the
built-in counter (Option PN)

Button Opens the Options Code Head Actuating-Screen (1-3-3)– refer to

section 3.3.4.2.24 Options Code Head Actuating-Screen (1-3-3)
Only relevant in combination with the optional pneumatic actuating
of the built-in code head (Option PC)

Button Opens the Options Several Counters-Screen (1-3-4) – refer to section

3.3.4.2.26 Options Several Counters-Screen (1-3-4)

3.3.4.2.20 OPTIONS MARKING WHEEL-SCREEN (1-3-1)

Having pressed the button in the Options-Screen (1-3), the
Options Marking Wheel-Screen (1-3-1) appears. It defines the settings for the pneumatic
lifting of the marking wheel.

Figure 36: Touch-screen – Options Marking Wheel-Screen (1-3-1)

Button Puts the marking wheel into operating position

Button Puts the marking wheel into standby position

Rev: 1.00 eng Instruction Manual – Original Instructions 3-45

 Technical Description KMS 2/4

Display + Defines the value for the pre-selection counter

button
The pre-selection counter of option PW makes the marking wheel
stamp the marking good in other intervals than the usual 1 meter or 2
feet; e.g. the value of “5” means that the marking wheel stamp the
marking good only every 5th meter/feet.
The buttons + or – increment or decrement the value.

Pressing the button activates or deactivates the pre-

selection counter using the defined value.
Display and buttons are available with option PW only.

3.3.4.2.21 OPTIONS MARKING WHEEL HELP-SCREEN (1-3-1_?)

Having pressed the button in the Options Marking Wheel-Screen (1-3-1), the
Options Marking Wheel Help-Screen (1-3-1_?) appears. It offers additional support to the
pneumatic marking wheel lifting topic.

Figure 37: Touch-screen – Options Marking Wheel Help-Screen (1-3-1_?)

3.3.4.2.22 OPTIONS COUNTER ZERO RESET-SCREEN (1-3-2)

This screen is available with options PN only – refer to section 3.4.2 Counter and Code Head
Options and its corresponding subsections.

Having pressed the button in the Options-Screen (1-3), the

Options Counter Zero Reset-Screen (1-3-2) appears. It defines the settings for the (optional)
pneumatic resetting of the built-in counter.

3-46 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

Figure 38: Touch-screen – Options Counter Zero Reset-Screen (1-3-2)

Display + Defines the mode for resetting the counter to zero

button
MAN....... manual mode
AUTO...... automatic mode
Pressing the button toggles between the two modes.

Button Resets the counter to zero

Pressing the button in the manual mode (MAN) resets the counter
immediately to zero, independent of its position relative to the
marking good.
Pressing the button in the automatic mode (AUTO) resets the counter
to zero while it is not in contact with the marking good. This prevents
damage to the product or the counter.

Display + Defines the value for the pre-selection counter

button
Having reached the defined value of the pre-selection counter, the
system resets the built-in counter of the marking wheel automatically
to zero.
The buttons + or – increment or decrement the value.

Pressing the button activates or deactivates the

pre-selection counter using the defined value.
The values apply either with the next automatic reset, or immediately
by pressing the button .
Display and buttons are available with option PN W only.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-47

 Technical Description KMS 2/4

3.3.4.2.23 OPTIONS COUNTER ZERO RESET HELP-SCREEN (1-3-2_?)

Having pressed the button in the Options Counter Zero Reset-Screen (1-3-2), the
Options Counter Zero Reset Help-Screen (1-3-2_?) appears. It offers additional support to
the pneumatic reset of the built-in counter.

Figure 39: Touch-screen – Options Counter Zero Reset Help-Screen (1-3-2_?)

3.3.4.2.24 OPTIONS CODE HEAD ACTUATING-SCREEN (1-3-3)

This screen is available with options PC and PC W only – refer to section 3.4.2 Counter and
Code Head Options and its corresponding subsections.

Having pressed the button in the Options-Screen (1-3), the

Options Code Head Actuating-Screen (1-3-3) appears. It defines the settings for the
(optional) pneumatic actuating of the built-in code head.

Figure 40: Touch-screen – Options Code Head Actuating-Screen (1-3-3)

3-48 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

Display + Defines the mode for actuating the code head

button
MAN....... manual mode
AUTO...... automatic mode
Pressing the button toggles between the two modes.

Button Actuates the code head

Pressing the button in the manual mode (MAN) actuates the code
head immediately, independent of its position relative to the marking
good.
Pressing the button in the automatic mode (AUTO) actuates the code
head while it is not in contact with the marking good. This prevents
damage to the product or the code head.

Display + Defines the value for the pre-selection counter

button
Having reached the defined value of the pre-selection counter, the
system actuates the built-in code head automatically.
The buttons + or – increment or decrement the value.

Pressing the button activates or deactivates the

pre-selection counter using the defined value.
The values apply either with the next automatic actuating, or
immediately by pressing the button .
Display and buttons are available with option PC W only.

3.3.4.2.25 OPTIONS CODE HEAD ACTUATING HELP-SCREEN (1-3-3_?)

Having pressed the button in the Options Code Head Actuating-Screen (1-3-3), the
Options Code Head Actuating Help-Screen (1-3-3_?) appears. It offers additional support to
the pneumatic actuating of the built-in code head.

Figure 41: Touch-screen – Options Code Head Actuating Help-Screen (1-3-3_?)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-49

 Technical Description KMS 2/4

3.3.4.2.26 OPTIONS SEVERAL COUNTERS-SCREEN (1-3-4)

Having pressed the button in the Options-Screen (1-3), the
Options Several Counters-Screen (1-3-4) appears. It leads to the corresponding sub-screens
for displaying and setting the counter for external options, maintenance counter, operating
hours counter, and total length counter.

Figure 42: Touch-screen – Options Several Counters-Screen (1-3-4)

Button Opens the External Options Counter-Screen (1-3-4-1) – refer to

section 3.3.4.2.27 External Options Counter-Screen (1-3-4-1)

Button Opens the Maintenance Counter-Screen (1-3-4-2) – refer to section

3.3.4.2.29 Maintenance Counter-Screen (1-3-4-2)

Button Opens the Operation Hours Counter-Screen (1-3-4-3) – refer to

section 3.3.4.2.31 Operation Hours Counter-Screen (1-3-4-3)

Button Opens the Total Length Counter-Screen (1-3-4-4) – refer to section

3.3.4.2.32 Total Length Counter-Screen (1-3-4-4)

3.3.4.2.27 EXTERNAL OPTIONS COUNTER-SCREEN (1-3-4-1)

This screen is available with option 2W only – refer to section 3.4.2 Counter and Code Head
Options and its corresponding subsection.

Having pressed the button in the

Options Several Counters-Screen (1-3-4), the External Options Counter-Screen (1-3-4-1)
appears. It defines the settings for the counter for external options.

3-50 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

Figure 43: Touch-screen – External Options Counter-Screen (1-3-4-1)

Display + Defines the value for the counter

button
Having reached the defined value of the counter, the system triggers
DISTANCE the external option, e.g. an external device for cutting the marking
good. The value corresponds to the distance (in meters or feet)
between the KMS 2/4 and the external device.
The buttons + or – increment or decrement the value.

Button Defines the unit of length

Pressing the button defines the distance value either in meters or
feet.

3.3.4.2.28 EXTERNAL OPTIONS COUNTER HELP-SCREEN (1-3-4-1_?)

Having pressed the button in the External Options Counter-Screen (1-3-4-1), the
External Options Counter Help-Screen (1-3-4-1_?) appears. It offers additional support to
the counter for external options.

Figure 44: Touch-screen – External Options Counter Help-Screen (1-3-4-1_?)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-51

 Technical Description KMS 2/4

3.3.4.2.29 MAINTENANCE COUNTER-SCREEN (1-3-4-2)

Having pressed the button in the
Options Several Counters-Screen (1-3-4), the Maintenance Counter-Screen (1-3-4-2)
appears. It offers information about the current marking length since the last maintenance
of the machine as well as the possibility to define the marking length when the next
maintenance has to be done (i.e. defining the maintenance interval). It is possible to reset
the maintenance counter and to activate or deactivate the maintenance interval
supervision.

Figure 45: Touch-screen – Maintenance Counter-Screen (1-3-4-2)

Display Displays the current marking length

The displayed value represents the number of indexes of the built-in
counter in the marking wheel since the last reset of the maintenance
counter.

Display + Displays the marking length for the next maintenance

button
In case the current marking length reaches the predefined value of
the marking length for the next maintenance AND the supervision is
enabled (see description below), the system triggers an alarm in order
to inform the operator that maintenance is required.
Pressing on this field, the value can be edited.

Button Resets the maintenance counter to zero

Button Activates or deactivates the maintenance interval supervision

The pressed button activates the supervision. Only with activated
supervision the system triggers an alarm in order to inform the
operator that maintenance is required (see description above).

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KMS 2/4 Technical Description

3.3.4.2.30 MAINTENANCE COUNTER HELP-SCREEN (1-3-4-2_?)

Having pressed the button in the Options Several Counters-Screen (1-3-4), the
Maintenance Counter Help-Screen (1-3-4-2_?) appears. It offers additional support to the
maintenance counter.

Figure 46: Touch-screen – Maintenance Counter Help-Screen (1-3-4-2_?)

3.3.4.2.31 OPERATION HOURS COUNTER-SCREEN (1-3-4-3)

Having pressed the button in the
Options Several Counters-Screen (1-3-4), the Operation Hours Counter-Screen (1-3-4-3)
appears. It offers information about operating time of the machine as well as several
components.

Figure 47: Touch-screen – Operation Hours Counter-Screen (1-3-4-3)

Display Displays the amount of operating time (in hours) for the entire
machine
TOTAL

Rev: 1.00 eng Instruction Manual – Original Instructions 3-53

 Technical Description KMS 2/4

Display Displays the amount of operating time (in hours) for the machine’s
drive system
DRIVE
Only relevant in combination with an optional auxiliary drive

Display Not available for KMS 2/4

JTFM

Display Displays the amount of operating time (in hours) for the marking
wheel heating
HEATING WHEEL

Button Resets the counter for the marking wheel heating operating time to
zero

3.3.4.2.32 TOTAL LENGTH COUNTER-SCREEN (1-3-4-4)

Having pressed the button in the
Options Several Counters-Screen (1-3-4), the Total Length Counter-Screen (1-3-4-4)
appears. It offers information about the total marking length of the machine.

Figure 48: Touch-screen – Total Length Counter-Screen (1-3-4-4)

Display Displays the amount of the total marking length (in meters or feet)
done by the machine
ACTUAL COUNT

Button Resets the counter for the total marking length to zero

Button Only relevant in combination with the optional pneumatic reset of the
built-in counter
AUTO RESET AT
COUNTER RESET

3-54 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.3.4.2.33 ERROR INDICATION-SCREEN (1-4)

Having pressed the button in the Menu-Screen (1) or Info-Screen (0), the
Error Indication-Screen (1-4) appears. It leads to the corresponding sub-screens for alarm
topics (alarm history and present alarms), as well as for drive and sensors topics.

Figure 49: Touch-screen – Error Indication-Screen (1-4)

Button Opens the Alarm History Time-Screen (1-4-1) – refer to section

3.3.4.2.34 Alarm History Time-Screen (1-4-1)

Button Opens the Alarm History Number-Screen (1-4-2) – refer to section

3.3.4.2.35 Alarm History Number-Screen (1-4-2)

Button Opens the Present Alarms-Screen (1-4-3) – refer to section 3.3.4.2.36

Present Alarms-Screen (1-4-3)

Button Opens the Supervision Drive Control-Screen (1-4-4) – refer to section

3.3.4.2.37 Supervision Drive Control-Screen (1-4-4)
Only relevant in combination with an optional auxiliary drive

Button Opens the Sensors Controls-Screen (1-4-5) – refer to section

3.3.4.2.38 Sensors Controls-Screen (1-4-5)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-55

 Technical Description KMS 2/4

3.3.4.2.34 ALARM HISTORY TIME-SCREEN (1-4-1)

Having pressed the button in the Error Indication-Screen (1-4), the
Alarm History Time-Screen (1-4-1) appears. It lists all alarms raised by the system, sorted by
time stamp.

Figure 50: Touch-screen – Alarm History Time-Screen (1-4-1)

The buttons and let the operator navigate through the list.

3.3.4.2.35 ALARM HISTORY NUMBER-SCREEN (1-4-2)

Having pressed the button in the Error Indication-Screen (1-4), the
Alarm History Number-Screen (1-4-2) appears. It lists all alarms raised by the system, sorted
by number.

Figure 51: Touch-screen – Alarm History Number-Screen (1-4-2)

The buttons and let the operator navigate through the list.

3-56 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.3.4.2.36 PRESENT ALARMS-SCREEN (1-4-3)

Having pressed the button in the Error Indication-Screen (1-4), the
Present Alarms-Screen (1-4-3) appears. It lists all alarms that are still present, i.e. still need
to be solved.

Figure 52: Touch-screen – Present Alarms-Screen (1-4-3)

3.3.4.2.37 SUPERVISION DRIVE CONTROL-SCREEN (1-4-4)

This screen is available with options QDM-MLM, QSE, SSYN only – refer to section 3.4.1
Marking Wheel Options and its corresponding subsections for the auxiliary drives.

Having pressed the button in the Error Indication-Screen (1-4), the

Supervision Drive Control-Screen (1-4-4) appears. It lists several details about the motor
controller for the (optional) auxiliary drive system.

Figure 53: Touch-screen – Supervision Drive Control-Screen (1-4-4)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-57

 Technical Description KMS 2/4

3.3.4.2.38 SENSORS CONTROLS-SCREEN (1-4-5)

Having pressed the button in the Error Indication-Screen (1-4), the
Sensors Controls-Screen (1-4-5) appears. It displays the status of several sensors.

Figure 54: Touch-screen – Sensors Controls-Screen (1-4-5)

Display Not relevant for KMS 2/4

COLOR TAPE 1 -
END

Display Not relevant for KMS 2/4

COLOR TAPE 2 -
END

Display Not relevant for KMS 2/4

TAPE BREAKAGE
INDICATOR

Display Displays the current status of the proximity switch sensor for the
pneumatic functions of the marking wheel
PN-PROXIMITY
SWITCH Only relevant in combination with options PN, PC, and PW.

Display Displays the current status of the terminal battery

TERMINAL - green.......sensor OK
BATTERY red ..........sensor NOT OK

Button Not relevant for KMS 2/4

3-58 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.4 OPTIONS
This chapter describes all available options for the KMS 2/4.

3.4.1 MARKING WHEEL OPTIONS

Options for the marking wheel are as follows:

Option Description

QDM-MLM Auxiliary torque assist drive – refer to section 3.4.1.1 Torque Assist Drive +
Length Comparison (Option QDM-MLM)

SSYN Auxiliary synchronized drive – refer to section 3.4.1.2 Synchronized Drive

(Option SSYN)

QSE Auxiliary externally synchronized drive – refer to section 3.4.1.3 Externally

Synchronized Drive (Option QSE)

UTG External tacho generator unit for synchronization – refer to section 3.4.1.4
External Tacho Generator Unit (Option UTG)

PW Marking wheel pneumatic pre-selection lifting – refer to section 3.4.1.5

Marking Wheel Pre-Selection Pneumatic Lifting (Option PW)

Table 6: Marking wheel options – overview

3.4.1.1 TORQUE ASSIST DRIVE + LENGTH COMPARISON (OPTION QDM-MLM)

The optional auxiliary torque assist drive (option QDM-MLM) compensates for inaccurate
length marks on the marking goods due to slippage, flexure, shrinkage or similar effects of
the marking goods. By accelerating or decelerating the marking wheel, the QDM-MLM drive
reduces the internal friction of the marking device so that the marking goods have to carry
only an extremely smooth-running marking wheel. In addition, it compares the marked
length with readings of an external length measuring device. This ensures high measuring
precision.
Option QDM-MLM features an electric motor with gearbox (1), driving the marking wheel
directly (refer to Figure 55).
On the control console, option QDM-MLM is controlled by the DRIVE pushbuttons, the
TORQUE switch and the ADJUST 10-speed potentiometer (refer to Figure 55 and section
3.3.4.1 Main Controls). Via switch, the motor is set to accelerate the marking wheel or to
act as dynamic brake reducing the marking wheel speed. Turning the potentiometer sets
the amount of acceleration or braking.
The actual marking length (in meters) is displayed on the touch-screen. This enables the
operator to minimize the measuring errors by manual fine-tuning even during high speed
marking. The displayed value should be close to 1.000 m.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-59

 Technical Description KMS 2/4

Figure 55: Auxiliary torque assist drive (option QDM-MLM)

3.4.1.2 SYNCHRONIZED DRIVE (OPTION SSYN)

The optional synchronized drive (option SSYN) also compensates for inaccurate length
marks on the marking good due to slippage, flexure, shrinkage or similar effects of the
marking good. In SSYN configuration, the machine’s special electronic unit receives high
frequency measuring signals (4096 pulses per half a meter) from an external incremental
transmitter driven by the marking good. This unit allows the operator to fine-tune the
synchronization ratio between the external sensing wheel and the machine’s marking
wheel in 0.01% steps in order to compensate for any transmitter errors or subsequent
changes in product length. In this way highest accuracy of measurement can be reached.
Option SSYN features an electric motor with gearbox (1), driving the marking wheel directly
(refer to Figure 56; depicted without protective cover).
On the control console, option SSYN is controlled by the DRIVE pushbuttons (refer to
Figure 56 and section 3.3.4.1 Main Controls), while the ratio between external sensing
wheel and marking wheel is set via touch-screen – refer to section 3.3.4.2.17
Drive-Screen (1-2).

Figure 56: Auxiliary synchronized drive (option SSYN)

3-60 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

It is recommended to use the external universal tacho generator (option UTG) as external
transmitter, but also any modern laser length measuring equipment may be used.
For more details about the external universal tacho generator UTG, refer to section 3.4.1.4
External Tacho Generator Unit (Option UTG).

3.4.1.3 EXTERNALLY SYNCHRONIZED DRIVE (OPTION QSE)

The optional externally synchronized drive (option QSE) also compensates for inaccurate
length marks on the marking goods due to slippage, flexure, shrinkage or similar effects of
the marking goods.
The KMS 2/4 configured with option QSE receives an external encoder signal as reference
value for the extrusion line speed. The machine’s electronic unit then converts this external
reference value (frequency) into a DC control voltage. The actual marking length (in meters)
is then displayed on the touch-screen to enable the operator to fine-tune the drive motor
synchronously to the line speed, even during high speed marking.
Option QSE features an electric motor with gearbox (1), driving the marking wheel directly
(refer to Figure 57).
On the control console, option QSE is controlled by the DRIVE pushbuttons and the
SPEED ADJUST 10-speed potentiometer (refer to Figure 57 and section 3.3.4.1 Main
Controls). Turning the potentiometer, the system changes the drive motor speed by +/-
4% compared to the external reference value. The displayed value should be close to
1.000 m.

Figure 57: Auxiliary externally synchronized drive (option QSE)

Rev: 1.00 eng Instruction Manual – Original Instructions 3-61

 Technical Description KMS 2/4

3.4.1.4 EXTERNAL TACHO GENERATOR UNIT (OPTION UTG)

Figure 58 shows the optional external tacho generator unit (option UTG):

5
2

Figure 58: External tacho generator (option UTG)

The external tacho generator unit (refer to Figure 58) is mounted on a robust pillar,
adjustable in the height and can be fixed with a locking lever on the support column (1). A
guide roller (2) that is adjustable vertically and laterally provides optimal positioning of the
marking good to the sensing wheel (3) above. The sensing wheel is driven by the marking
good and thereby drives the tacho generator (4) to provide an output signal proportional to
the line speed. This signal is then converted into a frequency related three-phase voltage
for the motor of the auxiliary drive of the KMS 2/4.
The external tacho generator UTG must be connected with the delivered cable set (5) to the
control console of the KMS 2/4.
For more details, please contact MEDEK & SCHÖRNER.

3-62 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.4.1.5 MARKING WHEEL PRE-SELECTION PNEUMATIC LIFTING (OPTION PW)

The optional pre-selection pneumatic lifting of the marking wheel (option PW) raises or
lowers the marking wheel pneumatically controlled, depending on a pre-selection counter.
Via this counter, the operator forces the marking wheel to stamp the marking good in other
intervals than usual (1 meter or 2 feet). As long as the counter does not reach the
pre-selected value defined by the operator, the system raises the marking wheel in order
not to stamp the marking good.
Example: The operator sets the pre-selection counter to a value of "5", so that the marking
wheel stamps the marking good only every 5th revolution of the marking wheel (i.e. every
5th meter).
Option PW features the same functionality of the pneumatic lifting of the marking wheel in
combination with the touch-screen for the definition of the pre-selection counter – refer to
section 3.3.4.2.20 Options Marking Wheel-Screen (1-3-1).

3.4.1.6 HEATING CONTROLLER SYSTEM (OPTION SC)

3.4.1.6.1 HEATING-SCREEN (1-1)

Different to the standard heating system the dynamic heat controller system SC controls
the heating power of the meter marker in accordance to the production speed (SC= speed
controlled).
The actual production speed is given from a sensor to the control unit.

Figure 59: Heating-Screen

With the heating-screen, the marking wheel heating can be set.

The buttons I and 0 activate or deactivate the marking wheel heating.
With the keys + and – the heat for the segments and the length counter on the marking
wheel can be selected. The heat is indicated in percentage of the highest continuous
heating power (=100%).
The power data contains of a basic value (BASE %) plus a value which increases
proportional to the production speed (SPEED %).
The area 100% flashes during the heating-up time after activating the heating system. By
that way the marking wheel will be heated up to operation temperature very fast.
Rev: 1.00 eng Instruction Manual – Original Instructions 3-63
 Technical Description KMS 2/4

By pressing the button 100% STOP, the heating-up mode is stopped immediately and the
system switches automatically to the normal heating mode with the set parameters.
By pressing the button ?, screen 1-1_? appears – see section Heating Help-Screen (1-1_?).
By pressing the button WHEEL-SET screen 1-1-2 appears – see section 3.3.4.2.15
Heating Base Adjustment-Screen (1-1-2).

3.4.1.6.2 HELP-HEATING-SCREEN (1-1_?)

Figure 60: Help instructions for the Heating Screen

SPEED% value refers to 100 m/min line speed!

Example:
25% BASE heat and 20% SPEED heat will result in:
45% heat power at 100m/min
35% heat power at 50m/min
30% heat power at 25m/min
Adjust the BASE% at zero speed (2-5 m/min), so that the marks are OK.
Wait for a few minutes to stabilize the segment temperature.

At production speed adjust the SPEED% in the same way.

Note the adjustments for different products and production speeds to reconstruct your
results of marking.

3-64 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.4.2 COUNTER AND CODE HEAD OPTIONS

Options in respect of counter and coding head are as follows:

Option Description

PN Counter pneumatic reset – refer to section 3.4.2.1 Pneumatic Counter Reset

(Option PN)

PN W Counter pneumatic reset with pre-selection value – refer to section 3.4.2.2

Pneumatic Pre-Selection Counter Reset (Option PN W)

PC Code head pneumatic actuating – refer to section 3.4.2.3 Pneumatic Code

Head Actuating (Option PC)

PC W Code head pneumatic actuating with pre-selection value – refer to section

3.4.2.4 Pneumatic Pre-Selection Code Head Actuating (Option PC W)

2W 2nd pre-selection value for external device – refer to section 3.4.2.5 External
Device Pre-Selection (Option 2W)

Table 7: Counter and code head options – overview

3.4.2.1 PNEUMATIC COUNTER RESET (OPTION PN)

The optional pneumatic counter reset (option PN) sets the built-in counter of the marking
wheel from the current value to zero. The operator initiates the reset either manually by
pushing a button on the control console or the touch-screen, or automatically in
combination with a pre-selection counter (option PN W or PN 2W).
Option PN features a pneumatic cylinder mounted on the marking wheel and a control
valve.
On the control console, option PN is controlled via the blue COUNTER RESET pushbutton to
reset the counter manually (refer to section 3.3.4.1 Main Controls), and via touch-screen –
refer to section 3.3.4.2.22 Options Counter Zero Reset-Screen (1-3-2).
For further information, please refer to the enclosed documentation of the counter or code
head.

Option PN is specifically designed for ascending counters. For more details about using
option PN for descending counters, please contact MEDEK & SCHÖRNER.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-65

 Technical Description KMS 2/4

3.4.2.2 PNEUMATIC PRE-SELECTION COUNTER RESET (OPTION PN W)

The optional pneumatic pre-selection counter reset (option PN W) features the setting of
the built-in counter of the marking wheel from the current value to zero automatically,
depending on the value of an operator definable pre-selection counter. By the time the
operator defined marking length is reached (i.e. the value of the pre-selection counter), the
system sets the counter automatically to zero.
On the control console, option PN W is controlled via touch-screen – refer to section
3.3.4.2.22 Options Counter Zero Reset-Screen (1-3-2).

3.4.2.3 PNEUMATIC CODE HEAD ACTUATING (OPTION PC)

The optional pneumatic code head actuating (option PC) indexes the built-in code head of
the marking wheel by one digit. The operator initiates the actuating either manually by
pushing a button on the control console or the touch-screen, or automatically in
combination with a pre-selection counter (option PC W or PC 2W).
Option PC features a pneumatic cylinder mounted on the marking wheel and a control
valve.
On the control console, option PC is controlled via the blue CODE CHANGE pushbutton to
actuate the code head manually (refer to section 3.3.4.1 Main Controls), and via touch-
screen – refer to section 3.3.4.2.24 Options Code Head Actuating-Screen (1-3-3).
For further information, please refer to the enclosed documentation of the counter or code
head.

3.4.2.4 PNEUMATIC PRE-SELECTION CODE HEAD ACTUATING (OPTION PC W)

The optional pneumatic pre-selection code head actuating (option PC W) features the
indexing of the built-in code head of the marking wheel by one digit automatically,
depending on the value of an operator definable pre-selection counter. By the time the
operator defined marking length is reached (i.e. the value of the pre-selection counter), the
system actuates the code head automatically.
On the control console, option PC W is controlled via touch-screen – refer to section
3.3.4.2.24 Options Code Head Actuating-Screen (1-3-3).

3.4.2.5 EXTERNAL DEVICE PRE-SELECTION (OPTION 2W)

Option 2W is available only in combination with option PN W or PC W.

The optional external device pre-selection (option 2W) features a second pre-selection
counter to be used for controlling an external device, e.g. a cut-off device for the marking
goods. By the time the operator defined marking length is reached (i.e. the value of this
second pre-selection counter), the system triggers the external device automatically.
On the control console, option 2W is controlled via touch-screen – refer to section
3.3.4.2.27 External Options Counter-Screen (1-3-4-1).

3-66 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Technical Description

3.4.3 MISCELLANEOUS OPTIONS

Options for miscellaneous topics are as follows:

Option Description

HUP Additional alarm horn warning indicator – refer to section 3.4.3.1 Alarm Horn
(Option HUP)

HP Height position indication – refer to section 3.4.3.2 Height Indication

(Option HP)

Table 8: Miscellaneous options – overview

3.4.3.1 ALARM HORN (OPTION HUP)

In case of failures, the optional alarm horn (option HUP) features an acoustic warning
signal. This alarms the operator additionally to the yellow warning light – refer to section
3.4.4 Error Indications.
Option HUP is mounted on top of the yellow warning light.

3.4.3.2 HEIGHT INDICATION (OPTION HP)

The optional height indication (option HP) enables the operator to retrieve a once found
optimal position of the marking unit or guide roller unit in a convenient way. It is mounted
on the shaft of the rack jack device of the marking unit or guide roller unit. When changing
the height position with the crank of the rack jack device, option HP displays the height.
Option HP features a shaft for the crank in order to adjust the marking unit or guide roller
unit in the height as well as a display of the current height (refer to Figure 61).

Figure 61: Height indication (option HP)

After having aligned the machine exactly to the height of the extrusion line, it is
recommended to define this height as zero baseline “0000” and to note the +/- difference
(i.e. above or below the height of the extrusion line) to the optimal positions of the
corresponding marking unit. Keep these notes always near the machine.

Rev: 1.00 eng Instruction Manual – Original Instructions 3-67

 Technical Description KMS 2/4

3.4.4 ERROR INDICATIONS

In order to indicate errors or warnings, the machine features a yellow warning light
mounted on top of the control console.

Figure 62: Control console – yellow warning light

In case of an error, the yellow warning light starts blinking. The error must be
acknowledged by pressing the blue ALARM QUIT pushbutton on the control console. As
long as the error is not solved by the operator, the yellow warning light continues blinking.
The yellow warning light is available only in combination with features that trigger an
alarm. If the machine is not configured in this way, the machine does not feature the yellow
warning light, i.e. in standard configuration of the KMS 2/4 there is no warning light.
Optionally, the yellow warning light can be combined with an acoustic alarm made by an
alarm horn – refer to section 3.4.3.1 Alarm Horn (Option HUP).

3-68 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Receipt, Installation and Connection

4 RECEIPT, INSTALLATION AND CONNECTION

The KMS 2/4 is delivered in a wooden crate (the machine as well as options and accessories
according to the packing list).

4.1 UNPACKING
Please refer to the information note “UNPACKING” attached on the outside of the wooden
crate.

4.2 INSPECTION OF THE CONSIGNMENT

Inspect the equipment for possible transport damage and for completeness of delivery.
In case of missing parts or of other shortcomings, contact MEDEK & SCHÖRNER
immediately, either directly or your local representative.
Please always indicate the machine serial number(s) when reporting complaints (see EU-
conformity declaration and identification plate).

4.3 TRANSPORT

ATTENTION: For lifting and transporting the unit, ensure to comply with all relevant
standards, specifications, accident prevention regulations and operating conditions!
Use the lifting eye to be mounted on the support column only for transporting the
machine. Please consider that the lifting eye’s lifting capacity is designed for the weight
of the machine!
Transport the machine always in upright position! If you handle the machine in a wrong
way, it can topple!

Due to its mounted pulleys, the machine can be easily transported to the installation site.

4.4 DIMENSION, SPACE REQUIREMENTS

Space requirements and dimensions are quoted in the section 10.1 Technical Specifications
in the appendix.

Rev: 1.00 eng Instruction Manual – Original Instructions 4-69

 Receipt, Installation and Connection KMS 2/4

4.5 INSTALLATION AND ALIGNMENT

ATTENTION: The machine may be installed and aligned by authorised personnel only!

To install and align the machine, do as follows:

1. Place the KMS 2/4 after the cooling bath of the extrusion line in order to let the
marking good cool down and dry completely before starting the stamping process.
2. Place the KMS 2/4 on a solid, level and free of vibration foundation to ensure that the
machine does not topple.
3. It is recommended to align the machine by placing test marking goods on the guide
roller. Position the marking wheel exactly above the center line of the marking good.
Align the guide roller corresponding to the marking wheel as well as to the marking
good. For a rough lateral alignment, move the machine.
4. Having found the correct position, insert the delivered adjusting spindles into the
threaded holes of the pedestal. Turn the adjusting spindles downwards with an Allen
key.
5. Place the delivered fixing clamps for the adjusting spindles under the spindles in such
way that the pointed end of the spindle is inserted into the provided countersink of the
fixing clamp.
6. Afterwards, turn the spindles downwards until the castors lift off the ground.
7. Check the correct alignment of the machine with a water level.
8. If the machine is aligned in a correct way, it is recommended to fix the fixing clamps of
the adjusting spindles on the ground as well as the fastening angles that are mounted
on the pedestal’s sides and can be adjusted in the height.
The correct alignment of the machine will be finished during the stamping process.

4.6 ELECTRICAL CONNECTION

ATTENTION: The machine may be connected to the mains supply by authorised personnel
only!
Make sure that your mains supply complies with the rating of your machine’s type plate!

The KMS 2/4 is equipped with a fixed power cable on the control console to be connected
to your mains supply.

4-70 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Receipt, Installation and Connection

Mains supply and mains frequency are quoted in the section 10.1 Technical Specifications in
the appendix.

4.7 COMPRESSED AIR CONNECTION

ATTENTION: The machine may be connected to the compressed air supply by authorised
personnel only!

At the rear side, the KMS 2/4 is equipped with a connector for the local compressed air
supply. Figure 63 shows the connection with fine pressure regulator and manometer.

3
1

Figure 63: Compressed air connection

For establishing the connection to the local compressed air supply, do as follows (refer to
Figure 63):

1. Fix a hose with 8 mm inner diameter of your local compressed air supply to the
machine’s single standard plug-in air input (1) located at the rear side of the machine.
This supports all pneumatic users with compressed air.
2. Pull and turn the rotary knob of the fine pressure regulator (2) to increase or decrease
the system’s pressure. While observing the manometer (3), set the pressure to the
factory recommended value of 5.5 bars.
3. Having set the correct pressure, release the knob to lock the valve.

Rev: 1.00 eng Instruction Manual – Original Instructions 4-71

 Receipt, Installation and Connection KMS 2/4

The system’s pressure must not fall below 5.0 bars!

4-72 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Setting Up

5 SETTING UP
Before starting the machine and taking into operation, it is necessary to set up the KMS 2/4.
The following subsections guide you through the set up.

5.1 ADJUSTING THE GUIDE ROLLER UNIT

For adjusting the machine’s guide roller unit, do as follows:

1. Place the marking good on the guide roller unit.

2. Put the crank on the shaft (1) of the rack jack device of the guide roller unit (refer to
Figure 64). Loosen the locking mechanism (2) of the rack jack device. Turn the crank in
order to raise the guide roller unit to the height of the extrusion line. It is good practice
to adjust the guide roller unit a bit higher to slightly overstretch the marking good in
order to let it run exactly in the middle of the groove of the guide roller. Having found
the optimal height, tighten the locking lever.

Figure 64: Adjusting the guide roller unit

3. Be sure that with this adjusted position of the guide roller unit, the marking wheel is in
firm contact with the marking good without squeezing it.
Please consider that adjusting the guide roller unit in the height is not the correct way to
adjust the stamping pressure on the marking good. This must be done via
CONTACT PRESSURE regulator (refer to pos. 4 in Figure 14).

For adjusting the marking unit in the height as well as the stamping pressure, refer to
section 5.2 Adjusting the Marking Wheel Stamping Pressure.

Rev: 1.00 eng Instruction Manual – Original Instructions 5-73

 Setting Up KMS 2/4

5.2 ADJUSTING THE MARKING WHEEL STAMPING PRESSURE

For adjusting the machine’s stamping pressure of the marking wheel (including the
pneumatic lifting) onto the marking good, do as follows:

1. On the control console, press the red MARKING WHEEL () pushbutton to raise the
marking wheel into its standby position.
2. Place the marking good on the guide roller unit.
3. Raise the guide roller into its working position as described in section 5.1 Adjusting the
Guide Roller Unit, step 2.
4. On the control console, press the green MARKING WHEEL () pushbutton to lower the
marking wheel into its working position.
5. On the marking unit base plate, turn the fine adjustment screw (1) to align the marking
unit support arm into horizontal position or even slightly angular (refer to Figure 65).

Figure 65: Adjusting the stamping pressure – marking wheel standard configuration
5-74 Instruction Manual – Original Instructions Rev: 1.00 eng
KMS 2/4 Setting Up

6. Adjust the whole marking unit base plate in the height with the rack jack device (2) so
that the marking wheel is in firm contact with the marking good. Be sure that the
marking wheel does not squeeze the marking good. Fix the position with the locking
mechanism (3).
7. Turn the CONTACT PRESSURE regulator (4) to adjust the stamping pressure of the
marking wheel on the marking good. The higher the value of the compressed air
pressure, the higher the stamping pressure of the marking wheel.

5.3 ADJUSTING OPTIONAL CONFIGURATIONS

5.3.1 ADJUSTING PNEUMATIC FUNCTIONS – OPTION PN, PN W, PC,

PC W, PW, 2W

For a machine configured with...

– pneumatic reset of the built-in counter of the marking wheel (option PN), possibly
in combination with a pre-selection counter (option PN W),
– configured with pneumatic actuating of the built-in code head (option PC), possibly
in combination with a pre-selection counter (option PC W),
– a pre-selection counter for the pneumatic lifting of the marking wheel (option PW),
– a pre-selection counter for external options (option 2W),
...do as follows:
1. Option PN:
If available and desired, check the pneumatic reset function of the counter:
a) Remove the marking good from the guide roller.
b) On the touch-screen, set the manual mode (MAN) for resetting the counter to zero
as described in section 3.3.4.2.22 Options Counter Zero Reset-Screen (1-3-2).
c) Turn the marking wheel by hand.
d) Press either the RESET button of the Options Counter Zero Reset-Screen (1-3-2) on
the touch-screen or the blue COUNTER RESET pushbutton on the control console.
2. Option PN W:
If available, set the value for the optional pre-selection counter as described in section
3.3.4.2.22 Options Counter Zero Reset-Screen (1-3-2).
3. Option PC:
If available and desired, check the pneumatic actuating function of the code head:
a) Remove the marking good from the guide roller.
b) On the touch-screen, set the manual mode (MAN) for actuating the code head as
described in section 3.3.4.2.24 Options Code Head Actuating-Screen (1-3-3).
c) Turn the marking wheel by hand.
d) Press either the INDEX button of the Options Code Head Actuating-Screen (1-3-3)
on the touch-screen or the blue CODE CHANGE pushbutton on the control console.
Please consider that after having actuated the code head for testing purposes, you maybe
have to turn the numbers of the code head back manually.

Rev: 1.00 eng Instruction Manual – Original Instructions 5-75

 Setting Up KMS 2/4

4. Option PC W:
If available, set the value for the optional pre-selection counter as described in section
3.3.4.2.24 Options Code Head Actuating-Screen (1-3-3).
5. Option PW:
If available, set the value for the optional pre-selection counter as described in section
3.3.4.2.20 Options Marking Wheel-Screen (1-3-1).
6. Option 2W:
If available, set the value for the optional pre-selection counter for external options as
described in section 3.3.4.2.27 External Options Counter-Screen (1-3-4-1).

5.3.2 ADJUSTING AUXILIARY DRIVE OPTION QDM-MLM

For a machine configured with the auxiliary torque assist drive with length comparison
(option QDM-MLM), do as follows:

1. On the control console, set the MAIN SWITCH to ON.

2. Press the green POWER (I) pushbutton to switch the machine on.
3. Press the green HEATING 1 (I) pushbutton to start the heating of the marking wheel.
Wait until the required temperature is reached.
4. Place the marking good on the guide roller.
5. Put the guide roller unit and the marking unit in the height into working position as
described in section 5.1 Adjusting the Guide Roller Unit and section 5.2 Adjusting the
Marking Wheel Stamping Pressure.
Be sure that the guide roller and the marking wheel adjusted in these positions are in firm
contact with the marking good without squeezing or deforming it. Otherwise, the
measuring accuracy may be reduced.
6. On the control console, press the red DRIVE (0) pushbutton to switch the drive
definitively off.
7. With running extrusion line, perform a length marking of the marking good (without the
auxiliary drive) and measure the distance between the single length marks.
In case the length marks are...
‒ too far apart, the drive must accelerate the marking wheel in order to decrease the
distance between the length marks.
On the control console, set the TORQUE - / + switch to "+".
‒ too close together, the drive must decelerate the marking wheel in order to
increase the distance between the length marks.
On the control console, set the TORQUE - / + switch to "-".
8. On the control console, press the green DRIVE (I) pushbutton to switch the drive on.
9. On the control console, set the value of the 10-speed potentiometer ADJUST to "1.0".
10. Perform another length marking of the marking good (now with the auxiliary drive
accelerating or decelerating the marking wheel) and measure the distance between the

5-76 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Setting Up

single length marks again.

In case the length marks are still...
‒ too far apart, you must increase the acceleration of the marking wheel.
On the control console, set the value of the potentiometer ADJUST higher.
‒ too close together, you must decrease the deceleration of the marking wheel.
On the control console, set the value of the potentiometer ADJUST lower.
With option QDM-MLM, the actual marking length (in meters) is displayed on the touch-
screen in the last line of the Menu-Screen (1) as well as the Drive-Screen (1-2).
This is very helpful in case of higher marking speeds.
11. Repeat step 10 until the length marking of the marking good is within the specified
tolerance limits.
Once having found the optimum settings, it is good practice to note the values for each
type and diameter of the used material and marking speed.

5.3.3 ADJUSTING AUXILIARY DRIVE OPTION SSYN

For a machine configured with the auxiliary synchronized drive (option SSYN), do as follows:

1. Proceed as described for option QDM-MLM in section 5.3.2

Adjusting Auxiliary Drive Option QDM-MLM, step 1-5.
2. The necessary signals for the motor controller of the SSYN drive must come from an
external device. If the machine is equipped with the external tacho generator
(option UTG), proceed as described in section 5.3.5
Adjusting External Tacho Generator Option UTG, step 1-4.
3. Put the guide roller unit and the marking unit in the height into working position as
described in section 5.1 Adjusting the Guide Roller Unit and section 5.2 Adjusting the
Marking Wheel Stamping Pressure.
Be sure that the guide roller and the marking wheel adjusted in these positions are in firm
contact with the marking good without squeezing or deforming it. Otherwise, the
measuring accuracy may be reduced.
4. On the control console, press the green DRIVE (I) pushbutton to switch the drive on.
5. On the touch-screen, set the ratio between external sensing wheel and marking wheel
to 1.0000 (that corresponds to a ratio of 1:1) as described in section 3.3.4.2.17
Drive-Screen (1-2). Press the ENTER button.
6. Start the extrusion line and increase the speed gradually.
7. Perform length marking on the marking good and measure the distance between the
single length marks.
8. If necessary, correct the ratio to the required value and press the ENTER button to
apply the new settings. The speed of the marking wheel will change immediately.

Rev: 1.00 eng Instruction Manual – Original Instructions 5-77

 Setting Up KMS 2/4

Example: The actual distance between two meter marks is 1003 mm. This corresponds
to a deviation of 0.3%. Therefore, set the ratio value to "10030".

5.3.4 ADJUSTING AUXILIARY DRIVE OPTION QSE

For a machine configured with the auxiliary externally synchronized drive (option QSE), do
as follows:

1. Proceed as described for option QDM-MLM in section 5.3.2

Adjusting Auxiliary Drive Option QDM-MLM, step 1-5.
2. On the control console, press the green DRIVE (I) pushbutton to switch the drive on.
3. On the control console, set the value of the 10-speed potentiometer SPEED ADJUST to
"5.0".
4. With running extrusion line, perform a length marking of the marking good (with the
auxiliary drive accelerating or decelerating the marking wheel) and measure the
distance between the single length marks.
In case the length marks are...
‒ too far apart, you must increase the acceleration of the marking wheel.
On the control console, set the value of the potentiometer SPEED ADJUST higher.
‒ too close together, you must decrease the deceleration of the marking wheel.
On the control console, set the value of the potentiometer SPEED ADJUST lower.
Example: The actual distance between two meter marks is 1004 mm. This corresponds
to a deviation of 0.4%. Therefore, set the value of SPEED ADJUST to "5.50" in order to
increase the drive motor speed by 0.4%.
The actual marking length (in meters) is displayed on the touch-screen in the last line of the
Menu-Screen (1) as well as the Drive-Screen (1-2).
This is very helpful in case of higher marking speeds.
5. Repeat step 4 until the length marking of the marking good is within the specified
tolerance limits.
Once having found the optimum settings, it is good practice to note the values for each
type and diameter of the used material and marking speed.

Changing the extrusion line speed more than 10 % requires readjusting the drive settings!

5.3.5 ADJUSTING EXTERNAL TACHO GENERATOR OPTION UTG

For the adjustment of the external tacho generator (option UTG), do as follows:

5-78 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Setting Up

1. At the rear side, turn the crank (1) of the rack jack device to adjust the base plate with
the guide roller (2) of the UTG to the height of the extrusion line (refer to Figure 66). Fix
the adjusted height with the locking lever (3).

5 1

Figure 66: Adjusting the external tacho generator option UTG

2. Fine-tune the position of the guide roller to the marking good in order to let the
marking good run straight over the guide roller.
To adjust the guide roller...
‒ vertically: release the clamping lever (4), move the guide roller up or down into the
preferred position, and fix the lever;
‒ laterally: turn the handwheel (5) clockwise or anti-clockwise to move the guide
roller into the preferred position.
3. Unhook the swivel arm with the sensing wheel (6) from its standby position and lower it
onto the marking good in working position.
4. If necessary, fine-tune the contact pressure of the sensing wheel by turning the ratchet
disc (7) with the adjustment spring of the swivel arm.
Be sure that the sensing wheel adjusted in this position, is in firm contact with the marking
good without squeezing or deforming it. Otherwise, the measuring accuracy may be
reduced.

Rev: 1.00 eng Instruction Manual – Original Instructions 5-79

 Setting Up KMS 2/4

5-80 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Start-Up and Operation

6 START-UP AND OPERATION

ATTENTION: The machine may be started and operated by authorised personnel only!
Before starting, make sure that the machine is placed, aligned, connected, installed, and
set up in a correct way as described in the previous chapters.

6.1 STARTING THE MACHINE

For the starting sequence for the KMS 2/4, do as follows:

1. Check the adjusted compressed air pressure. If necessary, readjust it to the

recommended value of 5.5 bars.
2. On the control console, set the MAINS SWITCH to ON. The white MAINS SUPPLY lamp
must glow. If it does not glow, turn the EMERGENCY STOP button on the control
console clockwise to unlock it.
3. Press the green POWER (I) pushbutton to switch the machine on. The pushbutton must
glow. On the touch-screen, the Start-Screen (1-0) appears.

4. Press the green HEATING 1 (I) pushbutton on the control console or the button
in the Heating-Screen (1-1) to start the heating of the marking wheel. Wait until the
required temperature is reached.
5. Place the marking good on the guide roller unit.
6. Raise the guide roller unit into working position as described in section 5.1 Adjusting
the Guide Roller Unit.
7. On the control console, press the green MARKING WHEEL () pushbutton to lower the
marking wheel into its working position and adjust the stamping pressure of the
marking wheel onto the marking good as described in section 5.2 Adjusting the Marking
Wheel Stamping Pressure.
8. Start the extrusion line, increasing its speed gradually.

6.2 STOPPING/INTERRUPTING MARKING

For stopping the production line, do as follows:

1. Press the red HEATING 1 (0) pushbutton on the control console or the button in
the Heating-Screen (1-1) to stop the heating of the marking wheel.

Rev: 1.00 eng Instruction Manual – Original Instructions 6-81

 Start-Up and Operation KMS 2/4

6.3 CONTINUING MARKING

For continuing the marking process after having stopped, do as follows:

1. Press the green HEATING 1 (I) pushbutton on the control console or the button
in the Heating-Screen (1-1) to start the heating of the marking wheel. Wait until the
final temperature is reached.
2. Start the extrusion line, increasing its speed gradually.

6.4 SWITCHING THE MACHINE OFF

For switching the KMS 2/4 for a longer period off, do as follows:

1. Raise the marking wheel into standby position.

2. Remove the marking good from the machine.

3. Press the red HEATING 1 (0) pushbutton on the control console or the button in
the Heating-Screen (1-1) to stop the heating of the marking wheel.
4. Press the red POWER (0) pushbutton on the control console to switch the machine off.

6.5 EMERGENCY STOP

ATTENTION: Whenever a situation arises which may mean a hazard to health, property or
the environment, stop the equipment immediately by pressing the red EMERGENCY STOP
button on the control console.

In case of emergency, do as follows:

1. In hazardous situations, press the red, locking EMERGENCY STOP button on the control
console IMMEDIATELY to cut the power supply for all safety relevant functions of the
machine. The green POWER (I) pushbutton on the control console starts blinking.
2. To go on afterwards, turn the EMERGENCY STOP button clockwise to unlock it.
3. Acknowledge the end of the hazardous situation by pressing the green POWER (I)
pushbutton on the control console. The pushbutton must glow constantly.

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KMS 2/4 Start-Up and Operation

6.6 SERVICE MODE

ATTENTION: The service mode may be used by authorised personnel only!

To activate the service mode and therefore deactivate the security function temporarily for
service reasons, do as follows:

1. On the control console, turn the SERVICE OFF/ON key switch in position ON.
2. Long press the green POWER (I) pushbutton (more than three seconds). The
Service-Screen (0–0) appears on the touch-screen – refer to section 3.3.4.2.4
Service-Screen (0–0).
3. On the touch-screen, press the SERVICE button of the Service-Screen (0–0) in order to
confirm the deactivation of the security function. The green POWER (I) pushbutton on
the control console starts fast blinking.
In service mode, the system does not raise the marking wheel automatically into its
standby position when opening the protective door.

4. To end the service mode afterwards, turn the SERVICE OFF/ON key switch in
position OFF.
As soon as the protective door is closed, the system automatically returns to normal
operation mode with activated security function.

Rev: 1.00 eng Instruction Manual – Original Instructions 6-83

 Maintenance KMS 2/4

7 MAINTENANCE

ATTENTION: The machine may be maintained and cleaned by authorised personnel only!

The KMS 2/4 requires maintenance work only on a small scale. This includes:
• Cleaning the slip rings on the marking wheel;
• Checking and cleaning the carbon brushes of the marking wheel;
• Cleaning the text segments of the marking wheel;
• Lubricating the in-built counter or code head.

Before maintaining or cleaning the machine, do as follows:

1. Set the MAINS SWITCH on the control console to position OFF (0) to switch the
machine completely off.
2. Disconnect the machine from the mains supply.
3. Wait until all moving parts of the machine have come to a standstill and have cooled
down.

ATTENTION: At least once a month, press the EMERGENCY STOP button in order to check
for proper operation!

Regarding maintenance intervals, please consider that they depend entirely on the type of
material to be marked as well on marking speeds, stamping temperatures, etc. and may
vary strongly.
Therefore, the following sections can give only recommendations.

7-84 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Maintenance

7.1 CLEANING MARKING WHEEL SLIP RINGS

ATTENTION: Be sure that the machine is disconnected from the mains supply and the
marking wheel has already cooled down!

For cleaning the slip rings of the marking wheel, do as follows (refer to Figure 67):

Figure 67: Marking wheel slip rings

1. Loosen the marking wheel’s central nut (1) with the delivered box spanner (2) and pull
the marking wheel off.
2. Using compressed air, remove any dust from the slip rings (3), the axle of the marking
wheel, and the bearings.
3. Remove remaining dust on the slip rings with sand paper.
4. Reinstall the marking wheel by tightening the central nut.
During the installation of the marking wheel, be sure to lift up the actuating arm of the
built-in counter to reach a correct insertion in the U-section ring or a correct placement of
the actuating arm on the indexing curve.

Rev: 1.00 eng Instruction Manual – Original Instructions 7-85

 Maintenance KMS 2/4

Typically, check the slip rings every four weeks.

However, the actual interval for checking and cleaning depends on the degree of
contamination.

7.2 CHECKING/CLEANING MARKING WHEEL CARBON BRUSHES

ATTENTION: Be sure that the machine is disconnected from the mains supply and the
marking wheel has already cooled down!

For checking and cleaning the carbon brushes of the marking wheel, do as follows (refer to
Figure 68):

Figure 68: Marking wheel carbon brushes block

1. Remove the marking wheel as described in section 7.1 Cleaning Marking Wheel Slip
Rings, step 1.
2. Check the carbon brushes (1) for wear and pressure against the slip rings (refer to
Figure 68). If the brushes are shorter than 5 mm (about 25% of their original length),
replace them with new ones.
3. Remove the knurled brush holder cap (2) and pull the brush holder with the carbon
brush out of the brush block (3). Repeat this step for all carbon brushes.
4. If the pressure against the slip rings is not correct, clean the carbon brushes and the
brush block.
5. Insert the brush holders with the carbon brushes into the brush block and fix the
knurled cap.
6. Reinstall the marking wheel as described in section 7.1 Cleaning Marking Wheel Slip
Rings, step 4.
7-86 Instruction Manual – Original Instructions Rev: 1.00 eng
KMS 2/4 Maintenance

During the installation of the marking wheel, be sure to lift up the actuating arm of the
built-in counter to reach a correct insertion in the U-section ring or a correct placement of
the actuating arm on the indexing curve.

Typically, check the carbon brushes together with the slip rings every four weeks.
However, the actual interval for checking and cleaning depends on the degree of
contamination.

7.3 CLEANING TEXT SEGMENTS

ATTENTION: Be sure that the machine is disconnected from the mains supply and the
marking wheel has already cooled down!

Clean the text segments of the marking wheel from any pigment and dust with a brass wire
brush.

For detailed instructions about cleaning the marking wheel’s built-in counter or code head,
please refer to the enclosed documentation of the counter or code head.

Typically, check and clean the text segments every week.

However, the actual interval for checking and cleaning depends on the degree of
contamination.

7.4 LUBRICATING

Lubricate the built-in counter or code head of the marking wheel as described in the
enclosed documentation of the counter or code head.

Rev: 1.00 eng Instruction Manual – Original Instructions 7-87

 Troubleshooting KMS 2/4

8 TROUBLESHOOTING
This section may give some advice in case of errors or failures on the equipment. Table 9
provides detailed information on trouble shooting.

Error Cause Remedy

Irregular, excessive Friction between marking wheel Raise the guide roller unit with
distances between and marking good too low the crank of the rack jack device.
marks

Inconsistent and Temperature for corresponding Increase the temperature of the

weak marking line speed too low heated marking wheel as
described in section 3.3.4.2.13
Heating-Screen (1-1).

Stamping pressure too low Increase the stamping pressure

of the marking wheel onto the
marking good via
CONTACT PRESSURE regulator as
described in section 5.2
Adjusting the Marking Wheel
Stamping Pressure.

Marking smudgy Temperature for corresponding Reduce the temperature of the

with diffuse line speed too high heated marking wheel as
contours described in section 3.3.4.2.13
Heating-Screen (1-1).

Stamping pressure too high Reduce the stamping pressure of

the marking wheel onto the
marking good via
CONTACT PRESSURE regulator as
described in section 5.2
Adjusting the Marking Wheel
Stamping Pressure.
Marking barely Speed too high, gravure of the Reduce the speed, select a
legible text segments badly adapted to sharper gravure.
the type of marking good

Marking is Character size of text segments Select a gravure that is better

incomplete or too big for marking good adapted to the marking good.
disappears along diameter
upper or lower
edge Off-centerd adjusted guide roller Center the guide roller laterally
as described in section 5.1
Adjusting the Guide Roller Unit.

8-88 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Troubleshooting

Error Cause Remedy

Marking wheel Option UTG: Lower the UTG’s swivel arm with
does not rotate No contact of external tacho the sensing wheel onto the
although green generator’s sensing wheel onto marking good in order to get
DRIVE (I) marking good firmly contact.
pushbutton is
pressed
Oscillating Marking wheel not balanced in a Equip free text segments
movement of the correct way positions of the marking wheel
marking wheel with blind segments and balance
the marking wheel again.

Option QDM-MLM, Contact MEDEK & SCHÖRNER.

option SSYN,
option QSE:
Incorrect parameters for the
motor controller

After a reset of the Counter contaminated Clean the counter according to

counter the its enclosed manual and try again
number discs are to reset the counter to zero.
not positioned
exactly to zero Option PN: Readjust the pneumatic reset to
Pneumatic cylinder of the zero according to the counter’s
pneumatic reset to zero in the enclosed manual.
marking wheel not adjusted in a
correct way

Repetition of Control ring or indexing curve of Realign the control ring or

length marks or the counter misaligned indexing curve of the counter –
code marks please refer to the enclosed
documentation of the counter or
code head.

Counter or code head fails to Clean the counter or code head

actuate thoroughly – please refer to the
enclosed documentation of the
counter or code head.

Pneumatic counter Option PN, Check the connection to your

reset or code head option PC: local compressed air supply or
actuating does not Compressed air supply increase pressure (5.0 bars
work disconnected or pressure too low minimum).

Option PN, Check the electrical installation.

option PC:
power supply failed or controls
defective

Table 9: Troubleshooting

Rev: 1.00 eng Instruction Manual – Original Instructions 8-89

 Spare Parts KMS 2/4

9 SPARE PARTS
When ordering spare parts, please always indicate the description or identification number
as well as the drawing number and the serial number of the equipment.

9-90 Instruction Manual – Original Instructions Rev: 1.00 eng

KMS 2/4 Appendix

10 APPENDIX

10.1 TECHNICAL SPECIFICATIONS

10.2 DRAWINGS

10.3 MENU TREES

10.4 ELECTRIC

10.5 USER FEEDBACK SHEET

10.6 ADDITIONAL DOCUMENTATION

Rev: 1.00 eng Instruction Manual – Original Instructions 10-91