Unislit II 630

Winding machine
Commission: 111101
Year of construction: 2022

Translation of the original operating instructions

2022/02/22
Version 1

www.kampf.de Slitter.Winder.Kampf.
 Important
Read carefully before use
Keep for later reference

Kampf Schneid- und Wickeltechnik 111101_en-US_2022-02-22_v1 Copyright KAMPF 2022

GmbH & Co. KG
Mühlener Straße 36-42
51674 Wiehl
GERMANY

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Table of contens
1 Important information in advance........................................................................................................... 13
1.1 Purpose of this user manual .......................................................................................................... 13
1.2 How to use this document ............................................................................................................. 14
1.2.1 Read chronologically....................................................................................................... 14
1.2.2 Document formats........................................................................................................... 14
1.2.2.1 Printed document ......................................................................................... 14
1.2.2.2 Digital version ............................................................................................... 15
1.2.3 Scope of the document ................................................................................................... 15
1.2.4 Cross-references............................................................................................................. 16
1.2.5 Symbols/formatting ......................................................................................................... 17
1.2.6 Page layout ..................................................................................................................... 19
1.3 Application as specified ................................................................................................................. 20
1.4 Foreseeable misuse ...................................................................................................................... 20
1.5 Product identification ..................................................................................................................... 21
1.6 Liability and warranty ..................................................................................................................... 22
1.7 Reorder of the operating instructions............................................................................................. 23
1.8 Copyright........................................................................................................................................ 23
1.9 Provisos ......................................................................................................................................... 23
1.10 Copyright protection....................................................................................................................... 23

2 General safety instructions ..................................................................................................................... 24

2.1 Symbols used ................................................................................................................................ 25
2.1.1 Warnings – layout and meaning...................................................................................... 25
2.1.2 Symbols/formats in this user manual .............................................................................. 26
2.1.3 Symbols on the product .................................................................................................. 28
2.1.3.1 Warnings ...................................................................................................... 28
2.1.3.2 Prohibition signs ........................................................................................... 29
2.1.3.3 Warning signs............................................................................................... 29
2.1.3.4 Mandatory signs ........................................................................................... 31
2.1.3.5 Information signs .......................................................................................... 31
2.1.3.6 Exit signs ...................................................................................................... 31
2.1.4 Symbols on the packaging .............................................................................................. 33
2.2 Intended audience ......................................................................................................................... 34
2.2.1 Owner.............................................................................................................................. 34
2.2.2 Necessity of operator training ......................................................................................... 34
2.2.3 Specialized personnel ..................................................................................................... 34
2.2.4 Operating personnel / instructed operating personnel .................................................... 34
2.2.5 Specially qualified operating personnel........................................................................... 34
2.2.6 Qualified electrician......................................................................................................... 35
2.2.7 Personnel qualification according to activities on the machine ....................................... 36
2.3 Notes on hazards........................................................................................................................... 38
2.3.1 Hazards from electricity................................................................................................... 38
2.3.2 Hazards from gas, dust, steam, smoke........................................................................... 39
2.3.3 Hazards from hydraulics, pneumatics ............................................................................. 40
2.3.4 Hazards from noise ......................................................................................................... 40
2.3.5 Hazards from fluids, oils, greases and other chemical substances ................................ 41
2.3.6 Hazards from inertial masses.......................................................................................... 41
2.3.7 Dangers from batteries.................................................................................................... 42
2.3.8 Hazards from Laser......................................................................................................... 44
2.3.9 Hazards due to excessive core overhang ....................................................................... 44
2.3.10 Hazards due to incorrect winding cores .......................................................................... 45
2.4 Information for the owner ............................................................................................................... 46
2.4.1 Operating procedures ..................................................................................................... 46

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2.4.2 Safety through regular servicing ..................................................................................... 46

2.4.3 Operator's responsibilities ............................................................................................... 48
2.4.4 Prevention of unauthorized access ................................................................................. 48
2.4.5 Adequate lighting ............................................................................................................ 49
2.4.6 Owner's responsibility to warn of hazard from rotating rollers......................................... 49
2.5 Machine-specific information ......................................................................................................... 50
2.5.1 Emergency stop .............................................................................................................. 50
2.5.2 Work areas...................................................................................................................... 52
2.5.2.1 Overview of the working areas ..................................................................... 52
2.5.2.2 Safety mark .................................................................................................. 52
2.6 Personal protective equipment ...................................................................................................... 53
2.7 Notes on setting up the machine ................................................................................................... 53
2.8 Notes on working on the machine ................................................................................................. 54
2.9 Residual risks................................................................................................................................. 56

3 Technical data........................................................................................................................................... 58
3.1 General .......................................................................................................................................... 58
3.2 Driven side and operating side ...................................................................................................... 58
3.3 Unwinder........................................................................................................................................ 58
3.4 Web control.................................................................................................................................... 59
3.5 Base machine ................................................................................................................................ 59
3.6 Winder............................................................................................................................................ 61
3.7 Power requirements....................................................................................................................... 62
3.8 Data for the installation site ........................................................................................................... 62

4 Transport-storage-installation ................................................................................................................ 63
4.1 Transport........................................................................................................................................ 63
4.1.1 Scope of supply............................................................................................................... 63
4.1.2 Transport instructions...................................................................................................... 64
4.2 Storage .......................................................................................................................................... 65
4.3 Rolls ............................................................................................................................................... 66
4.3.1 Loading instructions with wooden boxes......................................................................... 66
4.3.1.1 Transport of rolls in wooden boxes............................................................... 66
4.3.1.2 Lifting instructions for rolls in wooden boxes ................................................ 67
4.3.1.2.1 Wooden crates when loading with a crane ................................ 67
4.3.1.2.2 Wooden crates when loading with a forklift................................ 68
4.3.2 Transporting rolls ............................................................................................................ 69
4.3.3 Lifting instruction for rolls ................................................................................................ 70
4.3.4 Storing rolls ..................................................................................................................... 71
4.3.5 Rubberized rolls .............................................................................................................. 72
4.3.5.1 Transport of rubberized rolls......................................................................... 72
4.3.5.2 Storage of rubberized rolls ........................................................................... 73
4.3.6 AD-Rolls .......................................................................................................................... 74
4.3.6.1 Storage of AD-Rolls...................................................................................... 74
4.3.6.2 Transport of AD rolls..................................................................................... 75
4.3.6.3 Centering rings ............................................................................................. 75
4.4 Installation...................................................................................................................................... 76
4.4.1 Installation tools .............................................................................................................. 76
4.4.2 Installation material ......................................................................................................... 76
4.4.3 Installation instructions.................................................................................................... 76
4.4.4 Benchmark ...................................................................................................................... 77
4.4.5 Rough alignment of the individual machine units............................................................ 77
4.4.6 Adjustment of the individual machine units ..................................................................... 78
4.4.7 Fastening the machine to the ground.............................................................................. 80
4.4.8 Installation/pipework........................................................................................................ 80

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4.5 Disassembly of the machine .......................................................................................................... 81

5 Product description.................................................................................................................................. 82
5.1 Definitions ...................................................................................................................................... 82
5.2 Mode of Operation ......................................................................................................................... 82
5.3 Machine overview .......................................................................................................................... 83
5.4 Material web path .......................................................................................................................... 83
5.5 Unwinder........................................................................................................................................ 84
5.5.1 Parent roll lift-in unit ........................................................................................................ 84
5.5.2 Locking unit of the lifting-in unit....................................................................................... 85
5.5.3 Parent roll clamping device ............................................................................................. 86
5.5.4 Chucking head ................................................................................................................ 87
5.5.5 Dynamic brake ................................................................................................................ 88
5.5.6 Emergency brake ............................................................................................................ 89
5.5.7 Idler roll, adjustable at one end ....................................................................................... 90
5.6 Base machine ................................................................................................................................ 91
5.6.1 Web control ..................................................................................................................... 91
5.6.2 Light box.......................................................................................................................... 92
5.6.3 Idler roll ........................................................................................................................... 92
5.6.4 Dancer roll....................................................................................................................... 93
5.6.5 Spreader roller ................................................................................................................ 94
5.6.6 Transport roll ................................................................................................................... 95
5.6.7 Material threading device ................................................................................................ 95
5.6.8 Main drive........................................................................................................................ 96
5.6.9 Spring-loaded multi-disc brake........................................................................................ 97
5.6.10 Linearly adjustable idler roll............................................................................................. 98
5.6.11 Eccentrically adjustable idler roll ..................................................................................... 99
5.6.12 Ionizing device ................................................................................................................100
5.7 Longitudinal slitting unit ................................................................................................................. 101
5.7.1 Blade cut in air ................................................................................................................101
5.7.2 Top knife unit...................................................................................................................101
5.7.2.1 Knife carriage for top knife............................................................................101
5.7.2.2 Knife holder for razor blade ..........................................................................101
5.8 Rewinder........................................................................................................................................ 103
5.8.1 Winding crossbar ............................................................................................................104
5.8.2 Winding arm ....................................................................................................................105
5.8.3 Locking unit .....................................................................................................................107
5.8.4 Winding head ..................................................................................................................108
5.8.5 Contact roller unit ............................................................................................................109
5.9 Edge trim suction unit .................................................................................................................... 110

6 Processing and automation technology ................................................................................................111

6.1 General information about operating the individual pages ............................................................ 111
6.1.1 Storage location for screenshots.....................................................................................114
6.2 Navigation ...................................................................................................................................... 115
6.3 General .......................................................................................................................................... 117
6.3.1 Machine (main menu) .....................................................................................................117
6.3.1.1 Machine ........................................................................................................118
6.3.1.2 Rewinder ......................................................................................................119
6.3.1.3 Unwinder ......................................................................................................120
6.3.1.4 Winding side .................................................................................................122
6.3.1.5 Oscillation .....................................................................................................123
6.3.1.6 Operating mode............................................................................................124
6.3.1.7 Machine status .............................................................................................124
6.3.1.8 Edge trim suction unit ...................................................................................125
6.3.2 Manual control.................................................................................................................126
6.3.2.1 Edge trimming suction ..................................................................................126

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6.3.2.2 Change contact roll.......................................................................................126

6.3.2.3 Ionization ......................................................................................................127
6.3.2.4 Braking the transport rolls.............................................................................127
6.3.2.5 Machine lighting............................................................................................127
6.3.2.6 Winding side Direction of rotation.................................................................127
6.3.3 User administration .........................................................................................................128
6.3.3.1 Overview of users.........................................................................................129
6.3.3.2 Overview of user rights.................................................................................129
6.3.3.3 User login/logout...........................................................................................130
6.3.3.4 Change user .................................................................................................130
6.3.3.5 Rights ...........................................................................................................133
6.4 Recipes .......................................................................................................................................... 135
6.4.1 Recipe list........................................................................................................................135
6.4.1.1 Overview of recipes ......................................................................................136
6.4.1.2 Material recipes ............................................................................................137
6.4.1.3 Slitting recipes ..............................................................................................139
6.4.1.4 Save/load recipes .........................................................................................141
6.4.1.5 Running data ................................................................................................143
6.4.2 Recipe view.....................................................................................................................144
6.4.2.1 Recipe list .....................................................................................................146
6.4.2.2 Machine ........................................................................................................148
6.5 Slitting pattern ................................................................................................................................ 149
6.5.1 Enter slitting pattern ........................................................................................................149
6.5.1.1 Slitting pattern...............................................................................................150
6.5.1.2 Knife type......................................................................................................154
6.5.1.3 Winding head type........................................................................................154
6.5.1.4 Knife .............................................................................................................154
6.5.1.5 Winding side .................................................................................................156
6.5.2 Actual slitting pattern.......................................................................................................159
6.5.2.1 Actual slitting pattern ....................................................................................160
6.5.2.2 Winding side .................................................................................................160
6.5.2.3 Knife .............................................................................................................163
6.5.2.4 winding head type.........................................................................................163
6.6 Characteristics ............................................................................................................................... 165
6.6.1 Tension characteristics ...................................................................................................165
6.6.1.1 Calculating the linear tension .......................................................................168
6.6.2 Contact pressure characteristic.......................................................................................169
6.6.2.1 Pressure calculation .....................................................................................172
6.6.3 Speed characteristic........................................................................................................173
6.7 Diagnostics .................................................................................................................................... 174
6.7.1 Rewinder drive friction.....................................................................................................174
6.7.1.1 Rewinder drive selection ..............................................................................175
6.7.1.2 History ..........................................................................................................176
6.7.2 Rewinder drives ..............................................................................................................178
6.7.2.1 Winding side .................................................................................................178
6.7.2.2 Rewinder drives error ...................................................................................179
6.7.3 Transport drives friction...................................................................................................180
6.7.3.1 Transport drives friction ................................................................................181
6.7.3.2 Transport drive selection ..............................................................................182
6.7.3.3 History ..........................................................................................................182
6.7.4 Transport drives ..............................................................................................................184
6.7.4.1 Machine ........................................................................................................185
6.7.4.2 Transport drives error ...................................................................................186
6.8 Service ........................................................................................................................................... 187
6.8.1 VisiPar.............................................................................................................................187
6.8.2 Machine parameters .......................................................................................................188
6.8.2.1 Winding side .................................................................................................189
6.8.2.2 Top knives ....................................................................................................190
6.8.2.3 Contact rolls..................................................................................................191
6.8.2.4 General.........................................................................................................192

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6.8.2.5 Setting the travel ranges...............................................................................193

6.8.2.6 Reset PLC position data...............................................................................194
6.8.3 Preset hardware..............................................................................................................195
6.8.3.1 Pivot position ................................................................................................195
6.8.3.2 Winding crossbar WS position......................................................................196
6.8.3.3 Diameter WS ................................................................................................196
6.8.3.4 Position of lift-in unit unwinder......................................................................197
6.8.4 Calibrate positioning........................................................................................................198
6.8.4.1 Setting the winding arm offsets ....................................................................200
6.8.4.2 Setting the knife offsets ................................................................................203
6.8.4.3 Copying offsets between VisuPC and PLC .................................................. 206
6.9 Alarm.............................................................................................................................................. 207
6.9.1 Alarms .............................................................................................................................207
6.9.2 Alarm archive ..................................................................................................................208
6.9.2.1 Filtering options ............................................................................................208
6.9.3 Logbook ..........................................................................................................................209
6.9.3.1 Filtering options ............................................................................................209
6.10 Machine status............................................................................................................................... 210
6.11 Statistics......................................................................................................................................... 211
6.11.1 Variable trending .............................................................................................................211
6.11.1.1 Table.............................................................................................................212
6.11.1.2 Diagram ........................................................................................................214
6.11.2 Rewinder trend................................................................................................................215
6.11.2.1 History ..........................................................................................................215
6.11.2.2 Station ..........................................................................................................217
6.11.3 Production data ...............................................................................................................218
6.11.3.1 Production information..................................................................................219
6.11.3.2 Unwuinder ....................................................................................................220
6.11.3.3 Winding side .................................................................................................220
6.11.4 Shift data .........................................................................................................................221
6.12 Help and documentation ................................................................................................................ 222
6.12.1 Help.................................................................................................................................222
6.12.2 Circuit diagrams ..............................................................................................................223
6.12.3 Kampf service portal .......................................................................................................224
6.12.4 Kampf spare parts...........................................................................................................225
6.13 VisiWinNET Text Manager............................................................................................................. 226
6.13.1 Selecting the project file ..................................................................................................227
6.13.2 Selecting groups .............................................................................................................228
6.13.2.1 FCentral........................................................................................................228
6.13.2.2 ItemSystem...................................................................................................229
6.13.2.3 AlarmSystem ................................................................................................229
6.13.2.4 Machine Conditions ......................................................................................230
6.13.3 Exporting text from display applications..........................................................................231
6.13.4 Importing text into display applications ...........................................................................232

7 Operation...................................................................................................................................................233
7.1 Operating elements and control elements ..................................................................................... 234
7.1.1 Overview of operating elements and control elements ...................................................235
7.1.2 Overview of the control panels........................................................................................237
7.1.3 Control panel +CD ..........................................................................................................238
7.1.4 Control panel +OB8 ........................................................................................................241
7.1.5 Control panel, web control ..............................................................................................242
7.1.6 Control panel +OB1 ........................................................................................................243
7.1.7 Control panel, unwinder remote control ..........................................................................244
7.1.8 Control panel +OB7 ........................................................................................................245
7.1.9 Control panel +OB2 ........................................................................................................246
7.1.10 Control panel +OB3 ........................................................................................................247
7.1.11 Control panel winding lever 1..........................................................................................248
7.1.12 Control panel winding lever WS 2 ...................................................................................249

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7.1.13 Pneumatics control panel: Shut-off valve and pressure reducer.....................................250

7.1.14 Control panel with main switch........................................................................................251
7.2 Preparing the machine for operation ............................................................................................. 251
7.3 Unwinder........................................................................................................................................ 252
7.3.1 Setting up the unwinder ..................................................................................................252
7.3.2 Installing/removing the chucking head ............................................................................254
7.3.3 Changing the parent roll..................................................................................................255
7.4 Base machine ................................................................................................................................ 257
7.4.1 Setting up the edge trim suction unit...............................................................................257
7.4.2 Threading the material ....................................................................................................258
7.5 Longitudinal slitting unit ................................................................................................................. 259
7.5.1 Removal and installation of the bottom knife shaft..........................................................259
7.5.2 Position the knife holders ................................................................................................261
7.5.3 Setting up the knife holders for blade cut........................................................................263
7.5.4 Check that there is no collision between the blade and bottom knife shaft.....................264
7.5.5 Swinging the blade holders in/out ...................................................................................265
7.5.6 Adjusting the slitting depth of the knife holders...............................................................266
7.5.7 Changing the slitting angle..............................................................................................267
7.6 Rewinder........................................................................................................................................ 268
7.6.1 Contact roll unit ...............................................................................................................268
7.6.1.1 Changing the control circuit ..........................................................................268
7.6.1.2 Setting up the contact rolls ...........................................................................268
7.6.1.3 Coupling the contact lever ............................................................................269
7.6.2 Installing/removing a winding head with central screw ...................................................271
7.6.3 Positioning the winding lever...........................................................................................273
7.6.4 Coupling a winding lever .................................................................................................274
7.6.5 Equipping the winding levers with cores .........................................................................278
7.6.6 Changing the finished roll in the rewinder .......................................................................278
7.7 Starting the machine ...................................................................................................................... 280
7.8 Shutting down the machine ........................................................................................................... 281
7.8.1 Shutting down using length selection and diameter selection for the unwinder..............281
7.8.2 Shutting down using length selection and diameter selection for the rewinder...............281
7.8.3 Shutting down using the pushbutton ...............................................................................282
7.8.4 Shutting down using the emergency stop function..........................................................282
7.9 Switching off the machine .............................................................................................................. 283
7.10 Fixing a web break......................................................................................................................... 284
7.11 Putting the machine out of operation ............................................................................................. 285

8 Maintenance ..............................................................................................................................................288
8.1 General information ....................................................................................................................... 288
8.2 Prerequisites for maintenance work .............................................................................................. 290
8.3 Maintenance switch ....................................................................................................................... 291
8.4 Routine action before maintenance work ...................................................................................... 292
8.5 Routine action after maintenance work ......................................................................................... 293
8.6 Lubricants ...................................................................................................................................... 294
8.7 Standard lubricants ........................................................................................................................ 295
8.8 Initial equipment............................................................................................................................. 296
8.9 Unwinder........................................................................................................................................ 297
8.9.1 Chucking head ................................................................................................................297
8.9.1.1 Lubricate the 3" chucking head ....................................................................297
8.9.1.2 Maintaining the chucking head .....................................................................298
8.9.2 Disk brake .......................................................................................................................298
8.9.2.1 Cleaning bearings and sliding surfaces........................................................298
8.9.2.2 Lubricating bearings and sliding surfaces .................................................... 299
8.9.2.3 Checking mobility .........................................................................................300

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8.9.2.4 Checking gap................................................................................................301

8.9.2.5 Adjusting the air gap.....................................................................................302
8.9.2.6 Checking the brake pads and the disc braken ............................................. 303
8.9.2.7 Checking the screw connections of the disk brake....................................... 304
8.9.2.8 Checking leak tightness................................................................................305
8.9.3 Parent roll clamping device .............................................................................................306
8.9.3.1 Lubricating the gear motor............................................................................306
8.9.3.2 Lubricating the roller chain ...........................................................................307
8.9.3.3 Lubricating the ball screw drive ....................................................................308
8.9.3.4 Lubricating the linear roller guide .................................................................309
8.9.4 Parent roll lift-in unit ........................................................................................................311
8.9.4.1 Lubricating the planetary gear ......................................................................311
8.9.4.2 Lubricating the toothed chain .......................................................................312
8.9.4.3 Lubricating the ball screw .............................................................................313
8.9.4.4 Lubricate the bolts of the locking unit ...........................................................314
8.9.5 Generator brake ..............................................................................................................315
8.9.5.1 Checking the belt tension of the electro-dynamic brake............................... 315
8.9.5.2 Adjusting belt tension ...................................................................................316
8.9.5.3 Replacing the belt.........................................................................................317
8.10 Base machine ................................................................................................................................ 319
8.10.1 Lubricating the linear roller guideway for web control .....................................................319
8.10.2 Material threading device ................................................................................................319
8.10.2.1 Lubricating the spur wheel gear motor .........................................................320
8.10.2.2 Lubricating the roller chain ...........................................................................321
8.10.3 Spreader roll....................................................................................................................322
8.10.3.1 Lubricating worm gear for the adjustment drive ........................................... 322
8.10.3.2 Lubricating the pivot bearing ........................................................................323
8.10.3.3 Adjusting the fine adjustment drive...............................................................323
8.10.4 Transport roll ...................................................................................................................325
8.10.4.1 Maintaining the spring-loaded multi-disc brake ............................................ 325
8.11 Longitudinal slitting unit ................................................................................................................. 326
8.11.1 Lubricate the connecting rod tighteners of the knife holders...........................................326
8.11.2 Lubricating the take-up mandrel linear roller guideway...................................................327
8.12 Rewinder........................................................................................................................................ 328
8.12.1 Contact roller unit ............................................................................................................328
8.12.1.1 Adjusting the contact lever brake force ........................................................328
8.12.2 Winding crossbar ............................................................................................................329
8.12.2.1 Swivel drive ..................................................................................................329
8.12.2.1.1 Greasing the planetary gear ...................................................... 329
8.12.2.1.2 Greasing the toothed chain........................................................ 330
8.12.2.1.3 Lubricating the ball screw .......................................................... 331
8.12.2.2 Displacement drive .......................................................................................332
8.12.2.2.1 Lubricating the gear motor ......................................................... 332
8.12.2.2.2 Lubricating the spindle-type lifting gear ..................................... 333
8.12.2.2.3 Lubricating the ball screw .......................................................... 334
8.12.2.2.4 Lubricating the anti-rotation device on the spindle-type lifting 335
gear............................................................................................
8.12.2.2.5 Winding traverse displacement belt tension .............................. 336
8.12.3 Winding heads ................................................................................................................339
8.12.3.1 Servicing the winding chuck .........................................................................339
8.12.3.2 Maintaining the 3" ET62 winding head .........................................................340
8.12.3.3 Winding head 3" ET62 - Replace friction linings .......................................... 341
8.12.3.4 Maintaining the 3" ET62 winding head .........................................................342
8.12.3.5 Winding head 3" ET62 - Replace friction linings .......................................... 343
8.12.3.6 Checking for wear on polygonal coupling between winding head and wind- 344
ing arm..........................................................................................................

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8.12.3.7 Checking polygonal coupling for wear..........................................................344

8.12.3.8 Checking mounting bolt tightening torque .................................................... 345
8.12.4 Winding lever 2000 kg.....................................................................................................346
8.12.4.1 Left winding lever belt tension ......................................................................347
8.12.4.2 Right winding lever belt tension....................................................................349
8.12.5 Winding lever 5000kg......................................................................................................350
8.12.5.1 Lubricating CARB bearings ..........................................................................351
8.12.5.2 Checking left winding lever belt tension ....................................................... 352
8.12.5.3 Checking right winding lever belt tension ..................................................... 354
8.13 Maintenance of edge trim suction unit ........................................................................................... 356
8.14 General maintenance .................................................................................................................... 357
8.14.1 Cleaning machine parts ..................................................................................................358
8.14.2 Clean work area ..............................................................................................................359
8.14.3 Check sensors systems ..................................................................................................360
8.14.4 Checking guides for cleanliness......................................................................................361
8.14.5 Checking pneumatic system ...........................................................................................362
8.14.5.1 Checking pneumatic connections.................................................................362
8.14.5.2 Checking and servicing pneumatic maintenance unit .................................. 363
8.14.6 Roll maintenance ............................................................................................................364
8.14.6.1 Checking roll surface ....................................................................................364
8.14.6.2 Cleaning cork-sheathed rolls ........................................................................365
8.14.6.3 Cleaning rubber-sheathed rolls ....................................................................366
8.14.6.4 Cleaning specially coated rolls .....................................................................366
8.14.6.5 Cleaning of CFRP rolls .................................................................................367
8.14.7 Checking filter pads.........................................................................................................369
8.14.8 Cleaning the cooling unit.................................................................................................370
8.14.9 Lubricating remaining bearings .......................................................................................371
8.14.10 Check roller chain drives for tension ...............................................................................372
8.14.11 Checking the emergency stop function ...........................................................................373
8.15 Belt drive maintenance .................................................................................................................. 373
8.15.1 Replacing flat belts..........................................................................................................373
8.15.2 Replacing toothed belts, Poly V belts and V-belts ..........................................................374
8.15.3 Link V-belt replacement ..................................................................................................374

Maintenance table ....................................................................................................................................375

9 Spare parts................................................................................................................................................378
9.1 Spare parts list ............................................................................................................................... 378
9.2 Identification of spare parts with ESPAC ....................................................................................... 379
9.3 Opening ESPAC ............................................................................................................................ 383

10 Drawings ...................................................................................................................................................384
10.1 Installation and foundation plan ..................................................................................................... 384
10.2 Safety devices ............................................................................................................................... 384
10.3 Maintenance drawings ................................................................................................................... 384
10.4 Pneumatic plan .............................................................................................................................. 384

11 Separate documentation..........................................................................................................................385
11.1 ACE: Shock absorber .................................................................................................................... 385
11.2 ACE: Profile damper ...................................................................................................................... 385
11.3 Ammeraal Beltech: Flat belt........................................................................................................... 385
11.4 Bauer: Gear motor ......................................................................................................................... 385
11.5 Block: Power supply ...................................................................................................................... 385
11.6 Boettcher: Grinding instructions..................................................................................................... 385
11.7 Bosch-Rexroth: Tooth chain drive ................................................................................................. 385
11.8 Clouth: Roller maintenance ........................................................................................................... 386

x 111101_en-US_2022-02-22_v1
 Table of contens

11.9 Elero: Linear drive.......................................................................................................................... 386

11.10 Erhardt + Leimer: Web controller................................................................................................... 386
11.11 Festo: Pressure switch................................................................................................................... 386
11.12 Flender: Coupling .......................................................................................................................... 386
11.13 Flender: Poly-V-belt / Toothed belt ................................................................................................ 386
11.14 Joucomatic: Pressure regulating valve .......................................................................................... 386
11.15 Kammerer: Ball screw.................................................................................................................... 387
11.16 Kampf: Chuck ................................................................................................................................ 387
11.17 Keyence: Digital laser sensor ........................................................................................................ 387
11.18 Kickert: Spreader roll ..................................................................................................................... 387
11.19 KTR: Coupling BOWEX AS ........................................................................................................... 387
11.20 KTR: Coupling BOWEX SD ........................................................................................................... 387
11.21 KTR: Torque limiter RUFLEX......................................................................................................... 387
11.22 Microsyst: Display .......................................................................................................................... 388
11.23 Moeller: Foot switch ....................................................................................................................... 388
11.24 Mönninghoff: Coupling SecMatic ................................................................................................... 388
11.25 Mönninghoff: Coupling ServoFlex.................................................................................................. 388
11.26 MTS: Position sensor..................................................................................................................... 388
11.27 Norgren: Pneumatic valve ............................................................................................................. 388
11.28 Norgren: Clamping cylinder unit .................................................................................................... 388
11.29 Norgren: Maintenance unit ............................................................................................................ 389
11.30 Optibelt: Link V-belt ....................................................................................................................... 389
11.31 Pfannenberg: Cooling unit ............................................................................................................. 389
11.32 Phoenix Contact: Isolation Amplifier .............................................................................................. 389
11.33 Rexnord: Roller chain drive ........................................................................................................... 389
11.34 Riegler: Safety valve ...................................................................................................................... 389
11.35 Ringspann: Brake calliper DV 20 FPM .......................................................................................... 390
11.36 Ringspann: Shrink disc RLK 608 ................................................................................................... 390
11.37 Schmersal: Safety-monitoring module ........................................................................................... 390
11.38 Schneider Electric: Signal tower XVB ............................................................................................ 390
11.39 Schuh: Suction............................................................................................................................... 390
11.40 Siemens: AC motor 1PH8.............................................................................................................. 390
11.41 Siemens: AC servomotor 1FK7 ..................................................................................................... 391
11.42 Siemens: Foot switch..................................................................................................................... 391
11.43 Siemens: Gear motor 1FG1........................................................................................................... 391
11.44 Simco: Ionisation ........................................................................................................................... 391
11.45 SMC: Pressure amplifier ................................................................................................................ 391
11.46 SMC: Precision regulator ............................................................................................................... 391
11.47 SPN: Planetary gear E2................................................................................................................. 391
11.48 Stromag: Brake KLB ...................................................................................................................... 392
11.49 Svecom: Chuck.............................................................................................................................. 392
11.50 Thomson Neff: Ball srew................................................................................................................ 392
11.51 Valeo Auto Electric: Worm gear..................................................................................................... 392
11.52 Zimm: Spindle lifting gear Z ........................................................................................................... 392

12 Electrical documentation.........................................................................................................................393

111101_en-US_2022-02-22_v1 xi
Table of contens

12.1 Circuit diagram............................................................................................................................... 394

13 Kampf Service Portal ...............................................................................................................................395

13.1 Log in to the KAMPF Service Portal .............................................................................................. 395
13.2 Changing the login password ........................................................................................................ 397
13.3 Structure of the KAMPF Service Portal ......................................................................................... 399
13.4 Sending a service request ............................................................................................................. 400
13.5 Conference Center ........................................................................................................................ 401
13.5.1 Participants .....................................................................................................................402
13.5.2 Text conference ..............................................................................................................403
13.5.3 Whiteboard......................................................................................................................403
13.6 Service Manager............................................................................................................................ 404
13.6.1 Information ......................................................................................................................404
13.6.2 Technician logins ............................................................................................................406
13.6.3 Comments.......................................................................................................................407
13.7 Machine record .............................................................................................................................. 408
13.8 Administration ................................................................................................................................ 409
13.8.1 Log in as administrator....................................................................................................409
13.8.2 User administration .........................................................................................................411

xii 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1 Important information in advance

Important!
Read carefully before use.
Keep for later reference.

1.1 Purpose of this user manual

This machine was built in accordance with current European standards and
regulations.
These operating instructions contain instructions on safe and proper use and
maintenance.
Anyone transporting, setting up, starting up, operating and/or maintaining the
machine should read and fully understand the following:
– Operating instructions
– Safety regulations
– Safety instructions in each section
To avoid improper use and ensure failure-free operation, the operating
instructions should always be available to operating personnel.

111101_en-US_2022-02-22_v1 13
1 | Important information in advance

1.2 How to use this document

1.2.1 Read chronologically

Read all chapters of this document completely before using the product for the
first time.
Do not operate the product until you have understood all the contents of this
document.

1.2.2 Document formats

This document is available as a digital document and, if applicable, also as a
printed document.
In this chapter you will learn what distinguishes the printed and digital versions
and how to use them.

1.2.2.1 Printed document

The printed version contains all information necessary with regard to operation,
safety and health protection. The printed version, however, does not contain
any separate documents, such as supplier documentation. Separate supplier
documentation can be found in the digital version in the following chapter: See
Separate documentation [} 385]

14 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1.2.2.2 Digital version

You will find the digital version of the document on the electronic storage
medium you received with this document. In the digital version, there are links
to all separate documents; separate supplier documentation can be found here,
for example: See Separate documentation [} 385]
Data backup

Back up data locally.

In order to have permanent access to all documents, back up the data

locally on the electronic storage medium. This allows you to restore
the data if it is lost.

Using the storage medium Please note the following instructions for handling the electronic storage
medium:
– Also safe the data locally.
– Do not write other data to the electronic storage medium.
– Do not delete the data on the electronic storage medium.
– Protect the electronic storage medium from high temperatures, humidity and
dust.
– Allow a storage medium that has become wet to dry completely before use.
– Avoid locations with high drop height such as table edges.
– Remove the electronic storage medium safely from the PC.
– Due to its design, the electronic storage medium stands out from the PC
when used on the PC. When using the electronic storage medium, be care-
ful not to break it off, for example by bumping it with your leg.

1.2.3 Scope of the document

This document consists of the chapters listed in the table of contents.
The scope of the digital version of the document differs from that of the printed
version.
See Document formats [} 14].
Depending on the scope of the printed document, it consists of several folders,
which can be identified based on the back label.

111101_en-US_2022-02-22_v1 15
1 | Important information in advance

1.2.4 Cross-references
There are cross-references within this document that refer to another document
or that give a page reference to another place in the document.

Internal cross-references
Internal cross-references refer to a location in the same document. The number
indicates the page number of the reference.
Example Information on the scope of the operating instructions can be found here:
See Scope of the document [} 15]
(NOTE: If you are using the electronic version of this document, clicking on the
link will take you to the page indicated.)

External cross-references
External cross-references refer to separate documents. Separate documents
can be found on the electronic medium.
External cross-references start with the words Corresponding documents
followed by the title of the separate document.
Example Corresponding documents:
PSE400.pdf
Accessing external cross-refer- If you are currently reading the printed version, you must open the digital
ences version on the electronic medium to access the separate document. In the
digital version, hold down the CTRL key and click on the link on the
corresponding page.

16 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1.2.5 Symbols/formatting
This document uses the following symbols and/or formats:

Instructions
Instructions are always in the same format. Not every element has to appear.
The possible elements in instructions are:
ü Requirement 1
ü Requirement 2
1. Action 1
ð Intermediate result
2. Action 2
ð Final result
Reference number Reference numbers are used in figures and serve as a reference between
figure and text/explanation. Reference numbers are circled numbers with a
white background.
Example of a reference number: (1)
Software button Software buttons are control elements within a software.
Example of a format for software buttons: Software button
Control element Control elements are control elements physically installed at control panels.
Example of a format for control elements: Control element
Dialog box Dialog boxes are windows or user interfaces within a display.
Example of a format for dialog boxes: Dialog box
Options/select The "options/select" display element is used to change settings to objects and
actions. They do not execute any actions.
Example of a format for options/select: [Option 1], [Option 2]

111101_en-US_2022-02-22_v1 17
1 | Important information in advance

Multimedia content

Figure 1: TheAdVanced
The marker indicates that additional content is available. Such content may for
instance be audio-visual media which cannot be displayed in the printed edition.

The display of such media requires the use of the integration platform
The@vanced

18 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1.2.6 Page layout

1 2 3

8 | Maintenance Maintenance | 8

Left side Right side

30 212xxx_en-US_2021-01-01_v1 212xxx_en-US_2021-01-01_v1 30

4 5
Figure 2: Page layout
1 Chapter number 2 Chapter name
3 Logo 4 Page number
5 Document title
Each main page of this manual has a header and footer. The header of a page
contains the chapter number and the chapter name as well as the logo.
The footer of the page contains the page number and the document title.

111101_en-US_2022-02-22_v1 19
1 | Important information in advance

1.3 Application as specified

This machine of type Unislit II 630 is intended for use exclusively for slitting and
winding material specified in the chapter Technical Data in non-explosive
environments. Any other use or use beyond this is considered to be unintended
use. The manufacturer does not accept liability for any damage arising from
unintended use. Such risks are borne solely by the operating company.
The machine is built to current technical standards and to recognized safety
rules. Nevertheless, hazards may arise affecting
– the life and limb of the user
– third parties and/or
– damage to the machine and other property
Before using the machine outside the scope of its intended use, the company
Kampf Schneid- und Wickeltechnik GmbH & Co. KG
must be consulted, otherwise the warranty will lapse.
Use the machine only when it is in technically faultless condition. Use it only for
the intended purpose, in full awareness of the safety rules and possible hazards
and in compliance with this user manual. In particular, faults which hay affect
safety must be immediately rectified by a competent person.

1.4 Foreseeable misuse

Any use other than that described in the intended use is not in accordance with
the intended use and is therefore not permitted. The owner alone bears the risk.
– Any changes to the machine (hardware and software) that require a new
placing on the market in accordance with EC Machinery Directive 2006/42/
EC due to the Product Safety Act / 9th ProdSV (Machinery Ordinance).
– Operation of the machine by untrained / uninstructed personnel
– Operation and control of the machine by persons who do not speak the lan-
guage(s) of the country of operation (or the operating instructions)
– Operation of the machine without the operators having unrestricted access
to the safety instructions and instructions in the operating instructions.
– Locking people into secured areas of the machine
– Operation of the machine although persons are in the protected area of the
machine and / or are locked in there.
– Unauthorized bypassing, bridging, dismantling or manipulation of the exist-
ing protective devices.
– Operation of the machine with non-specified products, auxiliary materials
and consumables
– Operation of the machine, although it is not regularly maintained / cleaned
– Operation of the machine with protective devices (partially) out of service

20 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1.5 Product identification

1 2
Figure 3: Kampf logo
1 Jagenberg logo 2 Kampf company logo

Kampf Schneid- und Wickeltechnik

GmbH & Co. KG
Muehlener Straße 36-42
51674 Wiehl
Germany

Wickelmaschine / Winding Machine / Bobineuse

Typ
Type Unislit II 630
Type
Baujahr Kom.
Year of construction 2022 Com. 111101
Année de fabrication Com.

Figure 4: Machine nameplate

111101_en-US_2022-02-22_v1 21
1 | Important information in advance

1.6 Liability and warranty

This document was originally written in German and reviewed by us for
accuracy. It has been translated into the applicable local language by a
recognized translation agency.
This document was compiled with the utmost care. If you discover errors and/or
incomplete information, please write us. Your suggestions will help us make our
operating instructions more user friendly.
Before commissioning the machine or using the product, read this document
and, if applicable, its applicable documents carefully.
We are not liable for damages or failures caused by not observing this
document.
Warranty claims must be submitted as soon as a defect is discovered.
Wear parts are not covered by warranty.
The warranty is voided in cases of:
– Improper use
– Improper connectors and drives not included in delivery
– Failure to use original spare parts and accessories
– Modification not discussed with us in writing

22 111101_en-US_2022-02-22_v1
 Important information in advance | 1

1.7 Reorder of the operating instructions

Further copies of these operating instructions may be ordered at the address
below. Please, take into consideration that a repeat order shall be at the
customer's expence.
Kampf Schneid- und Wickeltechnik GmbH & Co. KG
Mühlener Straße 36-42
51674 Wiehl
Germany
Telephone: +49 (0) 2262-81-0
Telefax: +49 (0) 2262-81-208
For spare part questions or orders:
Telephone: +49 (0) 2262-81-478
Telefax: +49 (0) 2262-81-356
E-Mail : [email protected]

1.8 Copyright
All rights explicitly reserved. Duplications or information to third parties, no
matter in which form, shall not be permitted without our written approval.

1.9 Provisos
Information on technical data, dimensions, pictures of the machine and changes
in safety standards are subject to continuous development and therefore are not
always binding.
Errors and omissions excepted.

1.10 Copyright protection

All documents are protected by copyright.
Any distribution or reproduction of documents, in whole or in part, or any
disclosure of contents without express consent is prohibited.

111101_en-US_2022-02-22_v1 23
2 | General safety instructions

2 General safety instructions

This machine meets the essential health and safety requirements of the
European Community. Nevertheless, hazardous situations can occur.
Always pay attention to moving parts. Moving parts can cause injury from being
in motion or suddenly moving.
Basic requirements Comprehension of the contents of this user manual is the basic requirement for
safely and properly operating the machine. Only an understanding of the
general safety instructions can keep risks to a minimum.
Local regulations Always follow local rules, regulations and laws, such as:
– Standard operating procedures
– Safety regulations
– Environmental regulations
– Accident prevention rules and regulations
– Technical standards for safe and professional work
Vendor components Read the safety instructions in the enclosed documentation for vendor
components in addition to the instructions in this user manual.

24 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.1 Symbols used

All safety instructions and hazard warnings on the machine should be kept
legible.

2.1.1 Warnings – layout and meaning

Warnings refer to hazards and their consequences to the user or nearby
persons. Warnings also describe the steps for avoiding the hazard.
Failure to observe these warnings can result in serious bodily harm,
including life-threatening injury or death.
The signal word is of vital importance, as it indicates the probability of
occurrence and the severity of the hazard if ignored.
Signal word Probability of occur- Severity of hazard if ig-
rence nored
DANGER Imminent danger Death or serious injury
WARNING Potentially imminent Death or serious injury
danger
CAUTION Possible dangerous Minor injury
situation
The example below shows the warning "Electric shock hazard" with the signal
word DANGER:

DANGER
Electric shock
Electric current can be fatal.
Even a low current can have serious effects on the body, e.g., spasms, burns or
muscle paralysis.
1. Only electricians should work on the electrical equipment.
2. Never use improper or defective connection cables.

111101_en-US_2022-02-22_v1 25
2 | General safety instructions

2.1.2 Symbols/formats in this user manual

This user manual uses the following symbols and/or formats:

Instructions
Operating instructions are always in the same format. Every element of such
instructions must be performed. The possible elements in instructions are:
ü Requirement 1
ü Requirement 2
1. Action 1
ð Intermediate result
2. Action 2
ð Final result
Reference numbers Reference numbers are used in figures and serve as a reference between
figure and text/explanation. Reference numbers are circled numbers with a
white background.
Example of a reference number: (1)
Software buttons Software buttons are operating elements inside a software.
Example of a format for software buttons: software button
Operating elements Operating elements are physical elements installed at operating points.
Example of a format for operating elements: Operating element
Dialog box Dialog boxes are windows or user interfaces within a display.
Example of a format for dialog boxes: Dialog box
Options/select The "options/select" display element is used to change settings to objects and
actions. They do not execute any actions.
Example of a format for options/select: [Option 1], [Option 2]

26 111101_en-US_2022-02-22_v1
 General safety instructions | 2

Multimedia content

Figure 5: TheAdVanced
The marker indicates that additional content is available. Such content may for
instance be audio-visual media which cannot be displayed in the printed edition.

The display of such media requires the use of the integration platform
The@vanced

111101_en-US_2022-02-22_v1 27
2 | General safety instructions

2.1.3 Symbols on the product

2.1.3.1 Warnings
Signs potentially present on the machine and their meaning:
Symbol Meaning
Load capacity of suspension gear
Note weight information

Add oil before start-up

Tighten bolts before start-up

Tighten all contact bolts and nuts be-
fore start-up since they may have
loosened during transport

During During operation

operation (only in combination with prohibition
signs)

28 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.1.3.2 Prohibition signs

Prohibition signs potentially present on the machine and their meaning:
Symbol Meaning
Do not walk or stand here!

No open flame; Fire, open ignition

source and smoking prohibited

No reaching in!

Authorized personnel only!

No access for people with active im-

planted cardiac devices!

2.1.3.3 Warning signs

Warning signs potentially present on the machine and their meaning:
Symbol Meaning
Fall hazard

Voltage

Flammable materials

Toxic substances

111101_en-US_2022-02-22_v1 29
2 | General safety instructions

Symbol Meaning
Hand injury

Hot surface

Identification of potential hazards

Laser beam

Crushing hazard

Entanglement hazard between rollers

rotating in opposite directions

Cutting hazard

Suspended load

Obstacles on floor

Slipping hazard

30 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.1.3.4 Mandatory signs

Mandatory signs potentially present on the machine and their meaning:
Symbol Meaning
Wear eye protection

Wear foot protection

Wear hearing protection

Wear hand protection

Wear head protection

Disconnect from power before main-

tenance or repair

2.1.3.5 Information signs

Information signs potentially present on the machine and their meaning:
Symbol Meaning
I
Main switch
O
(for turning main power on/off)

2.1.3.6 Exit signs

Evacuation signs potentially present on the machine and their meaning:
Symbol Meaning
Exit left
(only in combination with other exit
signs)
Exit right
(only in combination with other exit
signs)

111101_en-US_2022-02-22_v1 31
2 | General safety instructions

Symbol Meaning
Direction indicator
(only in combination with other exit
signs)

Direction indicator
(only in combination with other exit
signs)

32 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.1.4 Symbols on the packaging

The markings promote increased care during handling.
Below is an explanation of the markings used:
Symbol Meaning
Fragile

No hand hooks

Top

Keep cool (out of sunlight)

Attach here

Keep dry

Center of gravity

No forklift here

111101_en-US_2022-02-22_v1 33
2 | General safety instructions

2.2 Intended audience

The individual audiences are explained here.

2.2.1 Owner
The owner is responsible for the machine and uses it as intended, or has the
machine operated by suitable, instructed persons.

2.2.2 Necessity of operator training

Personnel who are entrusted with the operation of the machine must have
previously participated in operator training by KAMPF or instruction by the
operator. Participation must be documented in a written protocol..

2.2.3 Specialized personnel

Specialized personnel are able to perform the following based on their
specialized training, knowledge and experience, as well as their knowledge of
the relevant regulations in the respective field of activity:
– Safely performs assigned work and correctly assesses the scope of his/her
activities.
– Self-identifies potential hazards and takes necessary action to eliminate
them.
– Understanding of the present instructions due to his knowledge of the lan-
guage.
Personnel to be trained, instructed or undergoing general training may only
work on the machine under the constant supervision of an experienced
specialist. The legal minimum age must be respected.

2.2.4 Operating personnel / instructed operating

personnel
Operating personnel have been instructed by KAMPF in the work they are to
perform and possible dangers in the event of improper behavior. The instruction
must include the following points in particular:
– Instruction in the operation of the machine
– Instruction on the safety functions and protective features of the machine
Instructed operating personnel have been instructed by the owner about the
work they are to perform and the possible hazards of improper behavior.

2.2.5 Specially qualified operating personnel

Specially qualified operating personnel were trained by KAMPF in the operation
of the machine (in addition to instruction in the safety functions and protective
features of the machine).

34 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.2.6 Qualified electrician

A qualified electrician is (according to DGUV regulation 3 / DIN VDE 0105-100)
a person with suitable technical training, knowledge and experience so that he
or she can recognize and avoid hazards that can be caused by electricity.

111101_en-US_2022-02-22_v1 35
2 | General safety instructions

2.2.7 Personnel qualification according to activities on

the machine
The machine is used for its intended purpose for the first time when it is put into
operation, i.e. when the "key is handed over" to the operator. Therefore, these
operating instructions mainly consider the activities following putting into
operation, i.e. use (including starting, switching off, changing operation modes,
operation, cleaning, troubleshooting, maintenance, servicing), but also the
activities of disassembly, taking out of operation and disposal.
Activity Required qualification of the personnel
Transport – Specialized personnel with relevant professional
training
– Qualification for handling the hoists and trans-
port equipment used
– Experience in the transport of heavy and bulky
goods
Assemble (mechanical) – Specialized personnel with relevant professional
training
– Experience in mechanical assembly of industrial
equipment
Assemble (electric) – Specialized personnel with relevant professional
training
– Experience in the assembly of cables
– Experience in laying cables
– Experience with electrical connection work of
motor cables and sensor cables
Put into operation – Specialists from KAMPF
– Alternatively, specialists authorized by KAMPF
Set up and operate – Successful participation in a KAMPF operator
training course
– Instruction in the respective activity
– Instruction on the special dangers during the op-
eration of the machine
– Operating instructions completely read and un-
derstood
Eliminate malfunctions – Specially qualified operating personnel
– Instruction in the respective activity
– Instruction on the special dangers during the op-
eration of the machine
– Operating instructions completely read and un-
derstood
Maintain – Specialized personnel with relevant professional
training
– Specialized knowledge (maintenance work on
industrial plants)
– Instruction in the respective activity
– Instruction on the special dangers during the op-
eration of the machine
– Operating instructions completely read and un-
derstood

36 111101_en-US_2022-02-22_v1
 General safety instructions | 2

Activity Required qualification of the personnel

Repair – Specialized personnel with relevant professional
training
– Experience in the repair of industrial plants
– Instruction in the respective activity
– Instruction on the special dangers during the op-
eration of the machine
– Operating instructions completely read and un-
derstood
Clean – Instruction in the respective activity
– Cleaning of the machine is only permitted under
the supervision of operating personnel, mainten-
ance personnel or maintenance personnel
Take out of operation – Specialized personnel with relevant professional
training
– Qualification for handling the hoists and trans-
port equipment used.
– Experience in the transport of heavy and bulky
goods
– Knowledge of all regulations in force at the site
concerning environmental protection and the
disposal of plant components and operating ma-
terials.

111101_en-US_2022-02-22_v1 37
2 | General safety instructions

2.3 Notes on hazards

2.3.1 Hazards from electricity

DANGER
Electric shock
Electric current can be fatal.
Even a low current can have serious effects on the body, e.g., spasms, burns or
muscle paralysis.
1. Only electricians should work on the electrical equipment.
2. Never use improper or defective connection cables.
Using original fuses Only use original fuses with the specified amperage. Turn off the machine
immediately if there is a fault in the power supply.
Working on electrical systems Only an electrician or instructed person under the supervision of an electrician
should work on electrical systems or electrical equipment in accordance with
electrical engineering standards.
Working on machine parts Disconnect machine parts from power before inspecting, servicing or repairing.
Verify disconnected parts are dead, then ground, short and isolate from
adjacent live parts.
Regular inspection Inspect the machine's electrical equipment regularly to ensure it is in good
condition. Immediately remedy any deficiencies, such as loose connections,
damaged cables, etc.
Working on live parts If it is necessary to work on live parts, have a second person standing by to turn
off the main switch in an emergency. Cordon off the work area with a red and
white safety chain and warning sign. Only use insulated tools.
Static electricity Static electricity in the material can endanger the user. For this reason,
discharge the finished roll with an appropriately grounded discharging bar
before touching (for materials susceptible to static buildup). If this in inadequate,
then attach a suitable discharger upstream of every winding station if not
already included in the machine.
Ionizing equipment Ionizing equipment (chargers and dischargers) operate at high voltage. Do not
touch the emission tips on the electrodes. If the emission tips are energized,
touching them can result in electric shock.
The sudden reaction to this electric shock poses an additional risk of potentially
serious secondary injury.
Persons with pacemakers may be at risk when approaching or touching the
emission tips on the electrodes.
Even electrodes that are insulated during normal operation may carry
hazardous high voltage in case of a fault.
The emission tips on the electrodes can also cause injury even when off.
Operation of the ionizing equipment can generate ozone. The concentration of
ozone depends on numerous factors and cannot be specified. If necessary,
take measurements under operating conditions.
High voltage When working on high-voltage components, disconnect from power, connect
the power cable to ground and short the components, e.g., capacitors, with a
grounding electrode.
Handling electric motors Use caution when handling electric motors, as they become hot during
operation. Let the motors cool down before working on them. If this is not
possible, take suitable safety precautions, e.g., by wearing gloves.

38 111101_en-US_2022-02-22_v1
 General safety instructions | 2

2.3.2 Hazards from gas, dust, steam, smoke

DANGER
Burn and explosion hazard
Welding, torching and grinding can cause burns and explosions.
1. Weld, torch and grind only when expressly approved.
2. Before welding, torching or grinding, remove dust and flammable materi-
als from the machine and its surroundings, and ensure adequate ventila-
tion.
3. When working in confined spaces, observe any national regulations.
4. Do not use an open flame.

111101_en-US_2022-02-22_v1 39
2 | General safety instructions

2.3.3 Hazards from hydraulics, pneumatics

DANGER
Disassembly of hydraulic/pneumatic systems
Hydraulic and pneumatic systems are pressurized.
Improper disassembly can cause them to explode and result in serious injury.
1. Depressurize the system before disassembling.

Only persons with special knowledge of and experience with hydraulics/

pneumatics should work on hydraulic and pneumatic equipment.
Regularly inspect all pipes, hoses and fittings for leaks and visible damage.
Replace any damaged parts immediately. Escaping fluid can cause injury and
burns.
Depressurize the desired system sections and pressure lines (hydraulic,
pneumatic) according to the components' user manuals before beginning
repairs.
Properly route and install hydraulic and pneumatic lines. Do not confuse
connections. Select the fittings, hose length and hose quality that meet
requirements.
Observe the maximum service life of pipes/hoses.

2.3.4 Hazards from noise

Noise insulation equipment on the machine should be on during operation.

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 General safety instructions | 2

2.3.5 Hazards from fluids, oils, greases and other

chemical substances
When handling fluids, oils, greases and other chemical substances, observe the
safety regulations that apply to the product.
Avoid any contact with chemicals. Before working with these substances, read
and follow the directions for use on the packaging. This applies to all chemicals,
including cleaning agents.
Use caution when handling hot operating fluids, as these pose burn and
scalding hazards.
Do not allow explosive or highly flammable chemicals to come in contact with
hot parts.
Dispose of used substances properly and in an environmentally friendly
manner. Observe national regulations.

2.3.6 Hazards from inertial masses

When a mass is in motion, energy is required to decelerate that mass to a stop.
The larger the mass, the greater the energy required to bring the mass to a
standstill.
For example, the parent roll in the machine is such an inert mass. When the
parent roll rotates, energy is required to bring it to a standstill, for example in a
hazardous situation.
The greater the weight of the parent roll and the faster it rotates, the longer it
takes to slow it down to a standstill in a hazardous situation.
For this reason, special care is required. Inert masses, such as the parent roll,
may run on for some time even though a machine stop has been initiated. As
long as such inert masses rotate, they continue to pose residual hazards, such
as entrapment hazards.

111101_en-US_2022-02-22_v1 41
2 | General safety instructions

2.3.7 Dangers from batteries

The batteries, if installed, do not require maintenance by the operating or
maintenance personnel. Should work on or near the battery nevertheless be
necessary, observe the safety regulations applicable to the product!

Hazards
Signs and Acute haz- Do not open the battery. Avoid contact with internal
symptoms ards components. Internal components include lead and
of hazards electrolyte.
Electrolyte - Electrolyte is corrosive and can cause
skin irritation and burns on contact. Electrolyte
causes severe irritation and burns of the eyes, nose
and throat. Ingestion may cause severe burns and
vomiting.
Lead - Direct skin or eye contact may cause local irrit-
ation. Inhalation or ingestion of lead dust or vapors
can cause headaches, nausea, vomiting, abdominal
cramps, fatigue, insomnia, weight loss, anemia and
pain in legs, arms and joints.
Effects Electrolyte - Repeated contact with electrolyte will
cause irritation and skin burns. Repeated contact with
mist can lead to tooth erosion, chronic eye irritation
and/or chronic inflammation of the nose, throat and
lungs.
Lead - Prolonged exposure may have the following
effects:
Damage to the central nervous system, gastrointest-
inal disorders, anemia, irritability, metallic taste, in-
somnia, kidney dysfunction and disorders of the re-
productive system. Pregnant women should be pro-
tected from excessive exposure to prevent lead from
crossing the placental barrier and causing neurolo-
gical disorders in infants.
Wash your hands after touching the battery.

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 General safety instructions | 2

First aid measures

Emergency and first aid measures Contact with internal components if
the battery has been opened or is
defective.
Inhalation Go out into the fresh air and provide
medical oxygen if necessary or initiate
restocking measures.
Seek medical attention
Eyes Immediately flush with water for at
least 15 minutes, keeping the eyelids
open.
Seek medical attention.
Skin Rinse the contaminated area with large
amounts of water for at least
15 minutes.
Remove contaminated clothing.
Seek medical attention,
Ingestion Do not induce vomiting. Drink large
quantities of water/milk while con-
scious.
Get medical attention.
Never give anything such as water by
mouth to an unconscious person.

Handling and storage

Precautions for handling Store away from reactive materials, open flames
and storage and ignition sources. Store batteries in cool, dry,
well-ventilated rooms. Batteries should be stored
in a place protected from the weather.
Other precautions Good personal hygiene is a prerequisite. Do not
eat, drink or smoke near the battery. Before eat-
ing, drinking or smoking thoroughly wash your
hands, face, neck and arms. Wash soiled clothing
before reuse.

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2 | General safety instructions

2.3.8 Hazards from Laser

This machine can be fitted with Class 2 Lasers. If Class 2 laser units are fitted
to the machine, the information on this page mustbe read and understood.
Class 2 laser units are safe to use, but the following Safety Precautions must be
adhered to:
– The light emitted from these devices has been set in accordance with
EN60825
– Staring directly or indirectly into the laser beam must be avoided.
– Class 2 laser light is given a [Caution] rating. This is defined as visible laser
light less than 1,0 mW. Considered eye safe: Normal exposure to this type
of beam will not cause permanent damage to the retina; Class 2 lasers emit
low-power visible radiation that are not inherently safe, but for which eye
protection is normally afforded by the natural aversion response to bright
light, including the blink reflex. These lasers appear uncomfortably bright
when viewed directly but cannot cause harm in less than 0.25second which
is much longer than the time needed (usually no more than 0.1s) to involun-
tarily close the eyes and turn away, thus avoiding further exposure.

2.3.9 Hazards due to excessive core overhang

The core overhang indicates how much wider the core is compared to the slit
and rewound material web.

Core overhang Finished roll Core overhang

Core
Winding lever

Winding lever
Slit width
Core length

Figure 6: Core overhang

WARNING
Deformation of the winding cores due to excess length
Cores that are too long can be deformed. If cores are used that are too long, the
finished rolls to be wound could fall out of the winding station.
1. Only use cores with the maximum permissible excess length.
2. Only use cores with sufficient core strength according to the finished roll
weight.

Generally, the core length in the winding station should correspond to the
respective slitting width.
When tensioning cores that exceed the permissible overhang, there is a risk of
deformation of the core in the area of the core overhang. This can affect the
stability of the core to such an extent that a proper tensioning process can no
longer be guaranteed and the possibility of the finished roll to be wound falling
out of the winding station cannot be ruled out.

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 General safety instructions | 2

If the machine is operated with a greater core overhang than the

permissible core overhang, the operator assumes responsibility!

2.3.10 Hazards due to incorrect winding cores

Winding cores take up the total weight of the respective finished roll. For safe
production, note the following instructions:
– Do not use winding cores more than once.
Multiple use can cause winding cores to deform. As a result, the winding
core may no longer be able to take the load actually designed for.
– Select winding cores with sufficient strength and load capacity for the total
weight of the finished roll.
– Do not reuse worn winding cores, but dispose of them properly.
– Check the length of the winding core. The strength and load-bearing capa-
city of expanded winding cores is impaired.

111101_en-US_2022-02-22_v1 45
2 | General safety instructions

2.4 Information for the owner

2.4.1 Operating procedures

The machine owner is obligated to establish operating procedures based on this
user manual and operational circumstances. The operating procedures form the
basis for necessary instruction.
In addition to procedures for normal operation, procedures for the following
special operating modes should be established in particular:
– Setup
– Test run
– Troubleshooting
– Servicing
– Inspection
– Repair
Operating procedures can be established according to the following
classifications:
– Area of application
– Hazards and safety precautions for normal and special operation
– General personnel requirements
– Emergency procedures

Incident figures show fitters are exposed to as much risk as service technicians.
Only work on machines and systems once the following requirements have
been met:
– Hazardous movements have come to a stop.
– Unauthorized, inadvertent and unexpected operation is not possible (by
locking out the main controls or removing connectors and securing movable
parts, e.g., using a brake, backstop, check valve or brace).
– Stored energy cannot initiate hazardous movement (by depressurizing,
shutting off, lowering, slackening).
The owner should remind personnel of compliance with this regulation at
least once every six months.
If multiple persons are working on the machine, solid cooperation and precise
coordination of activities is necessary. The safe and effective use of the
machine is largely determined by these persons' expertise and sense of
responsibility.

2.4.2 Safety through regular servicing

The purpose of servicing is not only to ensure failure-free operation, but also to
ensure the machine is safe to operate through regular inspections, maintenance
and repairs.
Regularly inspect machines with hazardous movements, including their
protective equipment, for safety, at least, however, for visible damage or
deficiencies. This inspection should be done by a professional.
An inspection should take place when any of the following occurs:
– The machine is started up for the first time.
– Another inspection is due.

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 General safety instructions | 2

– Changes or repairs have been made.

Inspection intervals are set by the manufacturer, rules and regulations, or the
owner. Creating an inspection record is useful. An inspection should also be
performed by an expert.
Definition of "professional" Requirements of a professional:
– Possesses the technical training and experience necessary to have suffi-
cient knowledge of the machine, system or other equipment being inspec-
ted.
– Is sufficiently familiar with relevant national occupational safety regulations
and generally accepted codes of practice (e.g., national rules, standards,
VDE standards, technical rules of other EU Member States or EEA member
countries) to assess the safety of the machine, system or other equipment
being inspected.
For each inspection, the owner must verify that the inspector possesses the
necessary expertise.
Only perform inspections using checklists compiled in accordance with rules
and regulations, user manuals and operational experience.
The owner should ensure that repairs to safety-relevant parts are done
professionally in order to reestablish the necessary safety.

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2 | General safety instructions

2.4.3 Operator's responsibilities

The operator is responsible for the following:
– Checking the functioning of the protective equipment every day before start-
ing work. Protective equipment includes bumpers, emergency pull cords
and other emergency stop devices.
– If deficiencies are noticed that put persons at risk, stopping operations and
immediately notifying the owner or the owner's representative.
– Ensuring no one is in the hazard zones before starting the machine.
– Ensuring no one is in the hazard zones before pressing an enabling switch.
– Ensuring the machine and load-bearing equipment are not overloaded.
Always observing all Kampf technical specifications.

2.4.4 Prevention of unauthorized access

Unauthorized persons should not be allowed in the machine area. Place the
prohibition sign "Authorized personnel only" at the access points to the machine
area so it is clearly visible at all times.

Figure 7: "Authorized personnel only" prohibition sign

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 General safety instructions | 2

2.4.5 Adequate lighting

Inadequate lighting makes the condition of operating areas and traffic areas,
obstacles that can cause tripping, and soiling that can cause slipping, difficult or
impossible to see. Poor lighting also increases uncertainty when walking.

Guideline:
Lighting should ensure that the condition of operating and traffic areas, routes
and hazard zones can be sufficiently discerned.

2.4.6 Owner's responsibility to warn of hazard from

rotating rollers
What to do in case of web break In the event of a web break, the unbraked rollers will continue to rotate, even if
the machine is shut off by the emergency stop. Only enter hazard zones once
the rollers have come to a stop.
Residual hazard from coasting After a web break causing an emergency stop or an emergency stop with web
rollers break, the machine will be stopped as quickly as possible. However, the
unbraked rollers may continue to coast for a prolonged period and pose a
residual hazard with their rotation.
Stopping coasting rollers Do not attempt to stop these rotating rollers with your hands or a tool, rather
wait until the rollers stop rolling on their own. Only enter the hazard zones and/
or open protective equipment once the rollers have stopped.
Owner's responsibility to disclose The machine owner or owner's representative is hereby expressly notified of
hazard this residual hazard, and has a responsibility to instruct the operators of the
machine accordingly and establish procedures to avoid this hazard.

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2 | General safety instructions

2.5 Machine-specific information

2.5.1 Emergency stop

The machine is equipped with one or more emergency stop devices. An
emergency stop device is used to quickly put machine parts and plant
components into a safe state in the event of danger or to avert danger.

Figure 8: Emergency stop device

The emergency stop device locks into place when actuated and must be
unlocked by the operator before the machine is switched back on, possibly with
a key. The machine does not restart by itself after unlocking. Emergency stop
circuits are divided into stop categories depending on the technical conditions:
Stop category Meaning
0 Uncontrolled shutdown by immediate
removal of the energy supply to the
machine drive elements.
1 Controlled stop in which the energy
supply to the machine drive elements
is maintained in order to achieve the
stop. The energy supply is only inter-
rupted when standstill is reached.
2 Controlled shutdown in which the en-
ergy supply to the machine drive ele-
ments is maintained.
Tab. 1: Stop function category

The emergency stop function of this machine is according to stop

category 1.

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 General safety instructions | 2

In case of danger, actuate an emergency stop device. The effectiveness of

other safety devices and/or devices with safety-related functions is not impaired
by this.
Attachment locations The emergency stop devices are located within reach of the operator at several
easily accessible locations on the machine.
An overview of the safety devices of the machine can be found in chapter
Drawings.
See Drawings [} 384]
Consequences of an emergency By actuating an emergency stop device, the machine may subsequently be in
stop an undefined state.
Therefore, before restarting the machine, check all moving components and, if
necessary, bring them into the initial position. If necessary, remove incorrect
products and/or products that have fallen out of position.
Before the machine can finally be started, reset the emergency stop.
Testing the emergency stop cir- The emergency stop circuit must be checked regularly for correct function.
cuit See Checking the emergency stop function [} 373]

DANGER
Recreating the original hazardous situation
If the machine is reset after an emergency stop without the cause of the emer-
gency stop having been eliminated, the original hazardous situation is recre-
ated.
1. Do not reset the machine after an emergency stop until the cause of the
original hazardous situation has been eliminated.

The stopping of the machine by emergency stop is exclusively

intended for emergencies! Shutting down the machine via an
emergency stop device is associated with increased wear of the
brakes, etc. and is therefore not to be used for shutting down the
machine during operation.

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2 | General safety instructions

2.5.2 Work areas

2.5.2.1 Overview of the working areas

The personnel working areas needed to operate the machine are depicted in
the figure below.

Figure 9: Working areas

Hazard zones! Never stand near the

machine whilst it is running!

Working areas (operating and control

areas)

Since the user needs access to the working areas, they should be kept free of
obstructions.
To ensure safety, it is imperative that only the proper personnel are ever in the
machine working areas.

2.5.2.2 Safety mark

Recommendation: Place safety markings (yellow) on the floor at intervals of at
least 1,000 mm around the maximum points of projection and swivel of all
machine equipment. Do not enter this marked area while the machine is in
operation.

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 General safety instructions | 2

2.6 Personal protective equipment

Observe the following clothing guidelines:
To avoid clothing being caught, do not wear baggy and/or loose-fitting clothing.
Pay special attention to ties, long hair and jewelry. Observe national
regulations.
For certain types of work on the machine, the owner should provide personal
protective equipment, such as:
– Protective gloves
– Safety glasses
The need for personal protective equipment is illustrated by the mandatory
signs in this user manual, for example:

NOTE
Wear hand protection

Cutting hazard on edge of mater- Use caution when handling the material web. The edge of the material web
ial web poses a cutting hazard.

2.7 Notes on setting up the machine

Observe the following information when setting up the machine:
– Do not exceed the maximum load capacity of lifting equipment, assembly
equipment and forklifts.
– Follow the safety regulations for handling lifting equipment.
– When installing and removing heavy parts or assemblies, use suitable sup-
ports and securing devices to prevent hazardous situations.
– Always follow the rules listed in the "Transport, storage and assembly" sec-
tion.

111101_en-US_2022-02-22_v1 53
2 | General safety instructions

2.8 Notes on working on the machine

Read and observe these notes on performing any work on the machine:
– Follow the safety instructions in these operating instructions.
– Ensure all protective devices, such as paneling, protective grids, etc. are al-
ways properly installed.
Protective devices should only be removed/deactivated by authorized per-
sons and only when absolutely necessary to perform certain work. Reinstall/
enable protective devices immediately after this work is complete and test
their function.
Only use the original fastening materials for the protective devices.
– Do not bypass protection circuits.
– Test the function of safety units, such as the emergency stop, once per day.
Only test the safety units when the machine is off to avoid tearing the mater-
ial web.
– If the safety units are malfunctioning, immediately stop the machine and no-
tify the supervisor.
– Do not perform maintenance, repairs or troubleshooting, nor clean the ma-
chine while it is in operation. Only perform this type of work when the ma-
chine is off and secured against restarting.
– When working on the machine, follow all national safety and accident pre-
vention regulations, as well as other generally accepted occupational health
and safety standards.
– KAMPF is not liable for any consequences resulting from the use of addi-
tional equipment that does not meet KAMPF specifications. Such use will
also void the warranty.
– When installing and removing heavy parts or assemblies, use suitable sup-
ports and securing devices to prevent dangerous situations.

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 General safety instructions | 2

– Do not open the switch cabinet doors while the machine is in operation. Be-
fore opening the switch cabinet doors, switch off the optional switch cabinet
cooling unit! After the switch cabinet cooling unit has been disconnected
from power, wait at least five minutes before turning it back on!
– If the machine needs to be tested with the protective devices removed (e.g.,
paneling) or with live parts, take the following safety precautions:
1. Identify danger areas, e.g., by setting up or placing signs with a clear
warning ("Do not activate machine!").
2. Assign a person to secure the work area and surroundings.

111101_en-US_2022-02-22_v1 55
2 | General safety instructions

2.9 Residual risks

Residual risks remain present, even if all safety precautions have been taken
and the machine is used in compliance with the regulations:

Component Source of hazard Residual hazard

Entire Machine Failure of control systems Unexpected overrunning
or starting of hazardous
movements
Unexpected movement of
machine parts
Pneumatic system Malfunction of pneumatic Unexpected movement of
system machine parts
Human Neglecting ergonomic Hazards resulting from
principles unfavourable posture or
excess efforts
Noise Hearing impairment
Interference with speech
communication or with
the perception of acoustic
signals
Unwinder Rotation of the parent roll Pulling in between roll
and floor
Clamping/releasing the Crushing/shearing
parent roll/core between moving machine
parts or the floor
Lateral displacement of Crushing/shearing
the unwind arms/scan- between winding arms
ning roller/complete un- and side frame
winder
Material Threading Movement of the thread- Drawing-in/crushing
Device ing chain between threading chain
and sprockets
All Rolls Rotation of rolls Drawing-in and trapping
Even after an emergency
stop function has been
triggered, the danger per-
sists until the rolls come
to a standstill.
Dancer roll Swiveling of the dancer Crushing/shearing
roll between moving and
fixed machine parts
Cutting tools Cutting edge of the cut- Cutting
ting tools
Cutting process Drawing-in between ma-
terial web and moving
and fixed machine parts
Knife change/blade Cutting/Crushing
change, conversion, set- between moving and
ting/maintenance of cut- fixed machine parts
ting device
Ionizing device Electrode(s) on Electric shock

Emission tips Hazard of puncture

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 General safety instructions | 2

Component Source of hazard Residual hazard

Finished roll removal Placing finished rolls on Crushing/shearing
carts removal carts between moving and
fixed machine parts
Crushing/shearing
between finished rolls
and fixed machine parts
All travel movements Crushing/shearing
between moving and
fixed machine parts and
floor
Laser sensor unit Laser beams Laser radiation
Rewinder When using rewinding Various hazards due to
cores that are longer than roll falling out of the wind-
the assigned web width. ing station
Rotation of the rolls in the Drawing-in between ma-
winding process terial web and moving
and fixed machine parts
Winding levers moving Crushing/shearing
between moving and
fixed machine parts
Moving the rewind cores Crushing/shearing
onto the contact rolls between moving and
fixed machine parts
Edge trim suction unit Rotation of the blower Crushing/shearing
wheel between stationary and
moving machine parts
Cutting the chopper rotor Cutting
blades
Rotation of the chopper Crushing/shearing
rotor blades between stationary and
moving machine parts
Material web Electrostatic charging of Electrical discharge of the
the material web material web
Running material web Cutting at the edge of the
material web

111101_en-US_2022-02-22_v1 57
3 | Technical data

3 Technical data

3.1 General
Machine type Unislit II 630
Working width 3050 mm
Material width max. 3050 mm
min. 800 mm
Machine speed 1200 m/min
Depending on the material type, mater-
ial thickness, slitting width and core
quality
Materials to be processed BOPET 8 – 50 µm
Machine sound pressure level (without 79 dB(A) +/- 3 dB(A)
suction unit) according to EN ISO 11201
Machine dimensions See Drawings [} 384]

3.2 Driven side and operating side

Driven side On the right as viewed in the material
running direction
Operator side On the left as viewed in the material
running direction

3.3 Unwinder
Type AKEG 30/13
Parent roll
– Diameter max. 1300 mm
– Weight including core max. 4000 kg with 6" chucking heads
max. 2500 kg with 3" chucking heads
and 6" adapters (optional)
– Core take-up 3" and 6" mechanical-pneumatic ex-
panding chucking heads
Unwind core
– Material Cardboard, plastic or steel
– Diameter 3" and 6"
– Length max. 3350 mm
min. 800 mm

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 Technical data | 3

3.4 Web control

Type Erhardt + Leimer
Switching system Automatic material web guide
Scanning Ultra-sonic edge sensor FX 4260
Scanning mode Edge
Edge control working stroke +/- 100 mm
Working stroke, oscillation mode +/- 75 mm (included in the working
stroke of the edge control)
Oscillation speed 9 mm/s at maximum machine speed
Scanning head
– Oscillating drive Electromotive linear drive
– Displacement Manually

3.5 Base machine

Slitting system Blade cut in air
Bottom knife shaft/transport roll Can be rolled out
(net weight approx. 180 kg)
Knife holder 5 manually operated blade holders
Slitting width min. 325 mm
Top knife positioning unit Manually according to digital display
The minimum slitting width depends on the nominal size of the winding lever,
the clamping stroke of the winding lever, the diameter of the winding chucks
and the insertion depth of the winding chucks (mechanically expanding winding
chucks, take-up disks, free-wheel heads).
Winding arm size Minimum web Winding head in- Winding head
width for 50/80 sertion depth diameter
mm clamping [mm] [in]
stroke
[mm]
2000 230**/260** 15 3
2000 290/350 40 3
2000 -/350 62 3
2000 230**/260** 15 4,7 (120 mm)
2000 230**/260** 15 6
2000 290/350 44 6
2000 -/350 70 6
2000 -/350 55 8
2000 -/350 55 10
5000 -/400** 15 3
5000 -/525 40 3
5000 -/525 62 3
5000 -400** 15 6
5000 -/525 44 6
5000 -/525 70 6
5000 -/525 55 8
5000 -/525 75 8

111101_en-US_2022-02-22_v1 59
3 | Technical data

Winding arm size Minimum web Winding head in- Winding head
width for 50/80 sertion depth diameter
mm clamping [mm] [in]
stroke
[mm]
5000 -/525 55 10
5000 -/525 75 10
5000 -/525 75 11

* = if automatic winding lever positioning is in use, the minimum slitting widths

can be reduced, if necessary
** = feasible with a lifting limit of 20 mm
Max. 800 m/min, max. roll width 1000 mm, limited bearing service life

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 Technical data | 3

3.6 Winder
Winding concept Single winding stations with central
drive
Type of winding Contact winding
Positioning Manually according to digital display
Arrangement of winding stations on 2 winding stations 27 Nm, 2000 kg,
winding side 1 driven on one side
Arrangement of winding stations on 1 winding station 27 Nm, 2000 kg,
winding side 2 driven on one side
1 winding station 36 Nm, 5000 kg,
driven on both sides
Core take-up: 3" and 6" mechanically expanding
winding heads
3" and 6" take-up disks for the non-
driven levers
Finished roll diameter min. 300 mm
max. 1200 mm
Finished roll weight max. 4000 kg
Winding core
– Material Cardboard and plastic
– Inner diameter/tolerance 3" - 0/+0.4 mm
6" - 0/+0.6 mm
– Outer diameter min. 92 mm
– Length Equal to slitting width
– Core protrusion on each side max. 5 mm at winding head insertion
depth < 40 mm
max. 10 mm at winding head insertion
depth >= 40 mm

Winding arm size Maximum per- Winding head in- Winding head
missible roll sertion depth diameter
weight [mm] [in]
[kg]
2000 250 15 3
2000 600 40 3
2000 1600 62 3
2000 400 15 4,7 (120 mm)
2000 500 15 6
2000 2000 44 6
2000 2000 70 6
2000 2000 55 8
2000 2000 55 10
5000 250 15 3
5000 600 40 3
5000 1600 62 3
5000 500 15 6
5000 2000 44 6
5000 4000 70 6
5000 3000 55 8

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3 | Technical data

Winding arm size Maximum per- Winding head in- Winding head
missible roll sertion depth diameter
weight [mm] [in]
[kg]
5000 5000 75 8
5000 3000 55 10
5000 5000 75 10

3.7 Power requirements

Electrical system: See Circuit diagram [} 394]
Pneumatic system
– Compressed air quality acc. to Pneurop recommendation
(6611) ISO 8573-1, quality class 3-4
– Air pressure 5.5 bar (gauge pressure)
– Air consumption approx. 3 m3/h (in the standard state)

3.8 Data for the installation site

Altitude max. 1000 m above sea level
Room temperature max. 45°C
Relative humidity max. 90% (non-condensing)

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 Transport-storage-installation | 4

4 Transport-storage-installation

4.1 Transport

4.1.1 Scope of supply

Check the scope of suppy immediately upon its arrival.
ü The machine has arrived.
ü The packaging list is available.
1. For the scope of supply, refer to the packaging list.
2. Check the complete supply for completeness and possible transport dam-
age immediately upon its arrival.
3. If the scope of supply does not correspond to the packaging list:
Claims shall only be considered if they have been reported to the carri-
ers/manufacturer on the day of the arrival of the machine.

Machine unpacking
The packing material should be used several times if possible or disposed in a
professional and ecologically friendly way according to the locally valid
regulations. The machine requires an acclimatization time of 24 hours to
exclude malfunctions due to condensation humidity. Possible condensation
products have to be removed.

111101_en-US_2022-02-22_v1 63
4 | Transport-storage-installation

4.1.2 Transport instructions

DANGER
Danger from falling or swinging loads!
When transporting loads, a fall or pendulum movements of the load may occur
in the event of misconduct.
ü Only use the crane after instruction.
1. Choose transport equipment with adequate load capacity.
2. Do not walk under elevated loads or stand underneath.
3. Keep enough safety distance from elevated loads.
4. When transporting loads by crane, secure the ropes on the crane hook to
prevent the load from being turned over.
5. Lift the load vertically; Avoid pendulum movement of the load due to diag-
onal pull.
6. Determine the weight a and center of gravity of the load; Do not overload
the crane.
7. Transport the load on the specified paths.
8. Only fasten the transport meands to the eyes/shackles which are at-
tached to the machine.

Authorized personnel for trans- The transport may only be carried out by personnel who - due to its knowledge
port and experience in the field of transport - is able to carry out such jobs.
At the beginning as well as immediately after the completion of loading, the
transport guards have to be applied to/removed from the machine parts.
Transport of individual machine The individual machine components may only be transported through the eyes/
components shackles at the machine and according to the definite assembly position with
utmost caution, by no means in horizontal position.
Transport devices Possible red transport devices at the machine for movable parts must only be
removed after installation.

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4.2 Storage
Observe the following points for storing the machine prior to installation:
– Store the machine in such a way that damages will be prevented.
– After transport, the packed machine/individual components have to be
stored in a closed room at temperatures of +5°C to +40°C.
– Protect the machine/individual components against humidity.
– The machine/individual components must be stored horizontally in corres-
pondence to their final assembly position. Moreover, the packed machine
parts must be placed separately.

NOTE
Material weakening due to weather conditions
Damage to property due to defective packaging and preservation of the ma-
chine!
1. Keep packaging and preservation intact.

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4.3 Rolls
This chapter provides information on the correct transport and storage of rolls.

4.3.1 Loading instructions with wooden boxes

This chapter provides instructions for loading rolls into wooden crates.

4.3.1.1 Transport of rolls in wooden boxes

Rolls, especially rolls made of carbon fiber reinforced plastic (CFRP),

may only be transported in wooden crates. The wooden box must
have sufficient rigidity through appropriate beams.

Use a forklift only if the wooden box does not exceed 2.5 times the
width of the fork. If the wooden box exceeds 2.5 times the width of the
fork, use a lifting crane for unloading and transportation.

A lifting crane is generally recommended for boxes with rolls longer

than 6 m.

Auxiliary materials Use lifting cranes or forklifts for transport.

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4.3.1.2 Lifting instructions for rolls in wooden boxes

Instructions for lifting rolls are provided here.

4.3.1.2.1 Wooden crates when loading with a crane

Always transport boxes with rolls or similar slim components with two trolleys or
a crossbar.
The following conditions must be met during the lifting process.
– Position the ropes according to the following figure.
– The loading area of the truck must allow horizontal loading and storage of
the wooden box.
– The tarpaulin of the truck on the roof must be able to be opened.
– The crate must be marked for crane loading, see the figure below.

Contact points

Figure 10: Rope positioning for loading wooden crates

Markings
Umbrella
No stapler
Caution fragile goods
(distributed on top and side)

Figure 11: Marking wooden boxes for crane loading

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4.3.1.2.2 Wooden crates when loading with a forklift

Wooden boxes with rolls for loading with a forklift must be made as follows:

max. 5-6m

Figure 12: Wooden box for loading with a forklift truck

The following conditions must be met during the lifting process:
– Load wooden boxes with rolls 2.4 m long or greater exclusively from the
side.
– The means of transport must be freely accessible for side loading.
– The wooden box must not be lifted or moved on one side.

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4.3.2 Transporting rolls

NOTE
Damage to rolls due to incorrect handling.
If rolls are lifted incorrectly, for example with only one rope, the rolls can be
damaged, for example they can become out-of-round.
1. Lift the rolls with two support points.
2. If lifting with two support points is not possible, short-term lifting with a
crane crossbar is possible, see the following pictures.
Auxiliary materials For transport, use cranes, transport ropes or, in exceptional cases, crane
crossbars.

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4.3.3 Lifting instruction for rolls

Pay attention to the following conditions during the lifting process:
– The contact surfaces of the transport ropes on the roll body or journal body
are protected against dirt marks, drag marks and pressure points.
– Always transport rolls with two load ropes suitable for the weight. Use fabric
ropes or nylon ropes for this purpose, not unprotected steel ropes.
– Position the ropes according to the figure
Positioning ropes for lifting rolls .
– Transport with a crane traverse according to the figure
Positioning of ropes for lifting with a crane traverse is only permitted in
exceptional cases, for example for installation.
– Any longer transport must be done according to the figure
Positioning of ropes for lifting rolls with a crane traverse.

Figure 13: Positioning of ropes for lifting rolls

L/4

20 cm 20 cm

L/2

Figure 14: Positioning of ropes for lifting rolls with a crane traverse

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4.3.4 Storing rolls

Rolls and similar slim components must be stored in wooden boxes!

The wooden box must have sufficient rigidity through appropriate
beams.

Wooden box The roll is to be stored in the wooden box on supports according to the following
figure. The supports should be at least 40 mm thick and as close as possible to
the roll body.
Contact points

Figure 15: Design of the wooden boxes

Storage conditions Pay attention to the following instructions during storage:
– Storage is to be in a dry and ventilated room.
– The storage temperature should be between 5°C and 45°C.
– Avoid rapid temperature changes.
– In case of high humidity, corrosion may occur on carbon steel elements of
the roll, for example the journal. These elements must be protected by ap-
propriate conservation measures.
– Exclude external influences.
– Regular movement of CFRP rolls is not required.

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4.3.5 Rubberized rolls

This chapter refers to rubberized rolls.

4.3.5.1 Transport of rubberized rolls

Packaging Pay attention to the following conditions during transport:
– Protect rubber covers from mechanical damage by using suitable boxes
with sturdy peg supports.
– Store the rolls in a way, that they are supported on the journals in such a
way that the rubber cover does not touch the floor or the side walls.
– When lifting rolls with lifting equipment, avoid contact with the coating by us-
ing suitable aids. Pay particular attention to avoiding jerky movements,
knocks and impacts as well as mechanical stress on the cover faces.

Chemical influences
Exclude chemical influences, if they exceed the guaranteed resistance of the
covers. Ensure protection against UV radiation and ozone exposure!
Temperature influences during – Temperatures of > 0°C do not require special precautions during transport.
transport
– Subzero temperatures require special precautions: Rubber covers become
brittle in the cold and their sensitivity to mechanical damage increases
sharply.
– At temperatures of < 0° C ispecial frost-protection packaging or, in the case
of covers harder than 5 points P &J thermal containers must be provided to
prevent cover damage due to frost.
– Shock-like temperature changes must be avoided by box insulation.
– Before using a roll, it is absolutely necessary to bring the entire roll body to
room temperature; ensure slow heating (max. 5°C in 24 hours)..

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4.3.5.2 Storage of rubberized rolls

Packaging Pay attention to the following conditions during storage:
– Never place the rolls on the coating!
– To avoid damage to the rubber cover, leave the rolls in the transport boxes
until use.
– Many rubber covers are subject to natural aging, which often leads to sur-
face hardening and microfine cracking. Storage temperatures above 30°C
and exposure to ozone and UV radiation accelerate this process. Rolls that
have been stored for longer than 6 months should be checked for micro-
cracks in particular and, if necessary, ground over before use.
– To prevent excessive wear of the rubber cover, check the roll surface regu-
larly for contamination, aging and damage. Measures such as cleaning, re-
pairing and grinding can significantly extend the service life of rubber-
covered rollers.

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4.3.6 AD-Rolls
This chapter refers to AD rolls.
AD means anti deflection. AD rolls have an inner tube and an outer tube. The
inner tube can be adjusted separately from the outer tube.

4.3.6.1 Storage of AD-Rolls

This chapter refers to AD-Rolls.
AD means anti deflection.
The roll can actively counteract the inherent deflection caused by the applied
pressure.
AD rolls have an inner tube and an outer tube. The inner tube can be adjusted
separately from the outer tube. As a result, the contact line remains constant
and there is no sharp drop in contact pressure in the middle of the roll.
If AD rolls are stored for a long time without moving, the inner tube may be
deformed during prolonged storage, since the roll only rests on the bearing
journals of the outer tube. The centering rings support the bearing point of the
inner tube on the outer tube, thus transmitting the force from the bearing point in
the box to the inner tube. As a result, both tubes run concentrically even after
long storage.

Only store AD rolls temporarily without moving them. Use centering

rings for longer storage periods. The centering rings support the
bearing point of the inner tube on the outer tube. This transfers the
force from the bearing point (e.g. in the box) to the inner tube. This
ensures that both tubes remain permanently concentric.
The centering ring can be ordered from the company KAMPF.

See
2 Spare parts [} 378]

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4.3.6.2 Transport of AD rolls

Centering rings must be used to transport AD rolls.
See Centering rings [} 75]

4.3.6.3 Centering rings

The centering rings support the bearing position of the inner tube on the outer
tube. This transmits the force from the bearing position (for example, in the box)
to the inner tube. This keeps both tubes permanently concentric.
Ordering

Centering rings can be obtained from KAMPF by stating the serial

number of the roll.
See Spare parts [} 378]

Defective rolls

Centering rings must also be used for defective rolls. Transport and/or
storage without centering rings reduces the possibility of a later
successful repair.

Figure 16: Centering rings

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4.4 Installation
Erection of the machine When the machine is installed, a clearance of 500 mm minimum for machine
operation must be kept between the maximum parent/finished roll diameter and
all movable machine parts (e.g. in case of axial shifting of the unwind unit or
parent roll shifting through edge controller) and stationary building parts. Should
this not be possible (e.g. due to a hall column), this place must be secured
separately.

4.4.1 Installation tools

The following mounting tools are required for the duration of the assembly:
1. Hand drill (hammer drill) for a clamping range up to at least 15 mm dia-
meter.
2. Roller spirit level and frame spirit level with prism (tolerance 0.05 mm per m)
3. Leveling device
4. High strength steel wire with a diameter of 1 mm.
5. Auxiliary devices according to installation sketches.
6. The usual fitting tools and power tools for installation.

4.4.2 Installation material

The following installation material must be available in sufficient quantity:
1. Various supporting sheets in the thicknesses:
0.1 mm; 0.2 mm; 0.5 mm; 1 mm; 2 mm.
2. Various steel plates in thicknesses of 6 - 15 mm, depending on the nature of
the foundation. Size of the plates as specified by the installation manager.
3. Heavy duty anchors and/or foundation bolts according to the foundation
plan.

4.4.3 Installation instructions

The following conditions must be satisfied before installation:
– The foundations must be prepared as shown on the attached foundation
plan so that they fully support the entire supporting surfaces of the respect-
ive machine parts.
– In addition, for installations to be performed by KAMPF a sufficient number
of appropriately qualified fitters and electricians must be provided as re-
quired during the entire installation period.
– All machine power units in the scope of delivery must be directly present at
the installation location. If this is not possible due to lack of space, the cus-
tomer is responsible for transporting the units correctly from the storage
area to the installation location.
– A sufficient quantity of all power and utility supplies required for installation
must be available at the respective installation location.
– The reference lines must have been created.
– All electrical components are ready wired and connected to terminal strips.
These terminal strips must be connected by technical specialists according
to our cable and terminal strip lists.

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– The main supply cable must be provided and installed by the customer in
accordance with the specified power consumption and the local require-
ments.
– The customer is to provide the lubricants required for initial commissioning
of the machine.
– The hydraulic cylinders must be bled and any cylinder damping must be ad-
justed before starting up the machine with a hydraulic supply. Any resulting
loss of volume in the hydraulic reservoir must be compensated. The system
must always be bled after replacing a hydraulic part.
– After the machine has been successfully installed and connected to the sup-
ply utilities it must be degreased and cleaned.

4.4.4 Benchmark
To ensure a precise and exact installation of this machine, you have to start out
from the reference lines as given in the foundation plan.
The reference points are used to align the machine and its attachments. They
must be mounted in the foundation exactly in the axial direction and at right
angles to each other outside the machine.

4.4.5 Rough alignment of the individual machine units

ü The indivdiual machine units are provided with coloured brackets or lugs to
apply the ropes of the transport devices.
1. By means of the available transport devices, the individual machine units
are positioned according to the installation plan.
2. At the same time, the support plates (recommended height 20 mm)
have to be placed underneath the machine frames. These plates are
provided underneath the frames of the individual machine units to support
the pressure of the adjusting screws for the alignment by means of a wa-
ter level. The support plates must be provided by the customer and have
to be fabricated according to the measures of the supporting surfaces.

Frame Lower surface of frame

Shim Floor +0 /-2 mm

Figure 17: Installation sketch

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4.4.6 Adjustment of the individual machine units

In order to be able to meet the length measures of the line precisely, all
measures must be taken from a fixed point. It is advisable to optically mark this
fixed point at the first machine unit. However, you in any case have to select a
machine surface for measuring.

Fixed point
(machine surface)

Distance measures

Figure 18: Installation sketch

Align the machine elements to the reference points and roughly adjust the
height (+/- 1 mm).

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1 Reference point

Frame

Roller

1 1 3 Theodolite

2 2

Roller

Frame

1 Reference point
Figure 19: Tolerances
Maximum tolerances for installation:
1 Position of the machine racks 2 Position of the rollers horizontally
0.1 mm/m 0.1 mm/m
3 Horizontal angular deviation
0.1 mm/m
When tightening the fastening screws and the pressure screws at the same
time, all machine units will be firmly anchored. At this, a control through a water
level and a check-up of the alignment toward the rollers is required.
Ensure that all foundation plates are fully supported after alignment.

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4.4.7 Fastening the machine to the ground

The machine is fastened to the ground as indicated in the foundation plan
supplied. Welding plates can be used for larger machine types (e.g. Universal,
Imperial or EcoLiner). Observe the notes on welding in the foundation plan.

4.4.8 Installation/pipework
ü All distance measures have been defined.
1. If applicable, install the pneumatic and hydraulic units. The connections
for feed and return flow are marked at the individual machine units.
For embedding of the pipework please refer to the pneumatic/hydraulic plan.

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4.5 Disassembly of the machine

At the completion of the application, the machine will be disassembled in
reverse order of the assembly.

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5 | Product description

5 Product description

5.1 Definitions
The definitions of the terms used are based on a view from the unwinder to the
rewinder in the material running direction. The terms for left, right, 1, 2
frequently seen in these operating instructions are based on this view.
The elements are numbered in the material running direction and from top to
bottom. Thus, the term 1 is also used for top and the term 2 for bottom .
For example rewinder 1 is the side facing the unwinder, and rewinder 2 is the
side facing away from the unwinder.
If there is only one rewinder or unwinder, numbering is omitted for reasons of
readability.
Rewinder 1 Rewinder 2
Unwinder 1 Unwinder 2
Rewinder 1
(top) Unwinder 1 Unwinder 2

Rewinder 2
(bottom)

Material running direction

Material running direction
Left
Left

Right Right

Figure 20: Definitions

5.2 Mode of Operation

TheUnislit II 630 winding machine packages the materials specified in the
technical data. It is designed as a machine with individual winding stations.
An unwinder holds the parent roll to be processed. The material web is fed from
the unwinder over a roll bridge of the longitudinal slitting unit. At the winding
stations the slit material webs are then wound up again into rolls of the desired
width and diameter. Once the machine stops, the finished rolls are placed on
finished roll removal carriages for transport.
The trimmed edges are extracted by suction through a pipe system by an edge
trim suction unit and recycled.

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5.3 Machine overview

3 2 1

Figure 21: Machine overview

1 Unwinder 2 Base machine
3 Edge trim suction unit

5.4 Material web path

5 7
4 8
3 6
9

10

14
11 13
2 18 16 17 19
12 15
1

Figure 22: Material web path

1 Parent roll 2 Adjustable idler roll
3 Idler roll 4 Dancer roll
5 Idler roll 6 Transport roll
7 Transport roll 8 Spreader roll
9 Adjustable idler roll 10 Bottom knife shaft
11 Adjustable idler roll 12 Transport roll
13 Transport roll 14 Idler roll
15 Idler roll 16 Contact roll WS1
17 Contact roll WS2 18 Rewinder WS1
19 Rewinder WS2

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5.5 Unwinder
The unwinder holds the parent roll. The material web is fed to the base machine
from the unwinder.
The unwinder is separate, i.e. it is not connected directly to the base machine
mechanically. That prevents any vibration that develops during handling of the
parent roll being transferred to the base machine.
The unwinder consists of a base frame with two unwind arms that can be
moved along linear roller guideways across the material feed direction of the
material.

3 1

Figure 23: Unwinder

1 Generator brake 2 Chucking head
3 Parent roll clamping device 4 Parent roll lift-in unit
5 Idler roll, adjustable at one end

5.5.1 Parent roll lift-in unit

The parent role lift-in unit is used for move the parent roll from the floor or a
transport unit into the unwinding position. For this purpose, the unwind arms
can be swiveled electrically using a spindle-type lifting gear. The parent roll is
grasped and clamped between the swiveled-out arms. After this, the unwind
arms carrying the parent roll are swiveled into the unwinding position.

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1 1

Figure 24: Parent roll lift-in unit

1 Unwind arm 2 Spindle-type lifting gear

5.5.2 Locking unit of the lifting-in unit

Bolts fix the unwinding arms in their upper position. For this purpose, the bolts
are pushed through the lateral frame of the unwinder into the base frame of the
lift-in unit via a toggle lever system. The bolt movements are carried out
pneumatically via pneumatic cylinders.

2
1

Figure 25: Locking unit

1 Toggle lever 2 Bolt
3 Pneumatic cylindrer

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5.5.3 Parent roll clamping device

The parent roll clamping mechanism clamps the parent roll.

3
1
4

2
4

Figure 26: Parent roll clamping device

1 Gear motor 2 Threaded spindle
3 Roller chain drive 4 Limit switch
The unwind arms are mounted on linear roller guides. For the parent roll
change, the unwind arms can be moved transversely to the running direction of
the material web.
The respective end positions are limited by limit switches.
A threaded spindle is driven by a gear motor and a roller chain drive. The
unwind arms are moved together or apart by the threaded spindle. In this way,
the parent roll can be clamped at the center with respect to the machine axis.
The motor and threaded spindle are connected by a coupling. The coupling
works torque-dependent when the unwinding arms are moved together and as
a rigid connection when they are moved apart.

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5.5.4 Chucking head

Two chucking heads clamp and center the core with the attached parent roll.
Clamping of the parent roll The clamping elements in the chucking head are expanded by spring force.
Releasing of the parent roll The clamping elements in the chucking head are retracted by compressed air.

Figure 27: Chucking head

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5.5.5 Dynamic brake

To generate a certain level of material tension, the parent roll is braked inside
the core. This prevents the parent roll continuing to unwind if the machine slows
down. A three-phase motor acts as a dynamic brake to brake the parent roll.
Web tension develops in the unwinding material, and keeps the material taut
depending on the braking effect.

Figure 28: Unwinder, driven side

1 Three-phase motor 2 Toothed belt drive
3 Pneumatically actuated brake
caliper

The web tension is applied to the dancer roll and is absorbed. The level
provided, together with the preselected setpoint for the brake tension, is used to
regulate the dynamic brake. The dynamic brake is automatically regulated by
comparing the actual level with the setpoint entered.
In addition the unwinder has a diameter monitor and a length counter. The
diameter monitor automatically shuts down the machine drives once the
minimum set diameter is reached, and the length counter does this once the set
run length is reached.

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5.5.6 Emergency brake

The emergency stop brake stops rotation of the machine in the shortest
possible time during an emergency stop.
The emergency stop brake consists of a brake caliper and brake disk. The
brake caliper is spring tensioned and brakes the rotary motion of the brake disk.
The brake caliper releases the brake disk when pneumatically charged.
When the machine is at a standstill, the emergency stop brake prevents
individual machine components from moving when they are actuated.

Figure 29: Emergency stop brake (disk brake)

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5.5.7 Idler roll, adjustable at one end

An idler roll is an undriven roll around which the material web wraps. The idler
roll guides the material web through the machine and is driven by the moving
material.
With this roll, thickness differences in the material web can be compensated for
to a certain extent, for example.
For this purpose, the bearing of this roll can be moved radially on one side.
Each material web guide depends on the material and must be determined by
means of practical tests.

Figure 30: Idler roll, adjustable at one end

1 Idler roll 2 Handwheel

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5.6 Base machine

5.6.1 Web control

The web control positions the moving material web moving from the parent roll
to the base machine by tracking the web edge in order to prevent lateral
movement of the web.
To control the material web, the web is scanned by a sensor (scanning head). A
controller evaluates the signals from the sensors. If the material web deviates
from its intended position, the unwinder is moved an appropriate distance
axially by a adjusting unit. By this means the material web is brought back into
its intended position.

Figure 31: Web control

1 Scanning head 2 Actuator

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5.6.2 Light box

The light box is used to inspect the material. Light strips in the light box radiate
light through a pane onto the material web.

Figure 32: Light box

5.6.3 Idler roll

An idler roll is an undriven roll around which the material web wraps. The idler
roll guides the material web through the machine and is driven by the moving
material.

Figure 33: Idler roll

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5.6.4 Dancer roll

The dancer roll maintains a constant web tension.
The dancer roll acts as a web accumulator that compensates for loops in the
material and keeps the web taut.

2
3

Figure 34: Dancer roll

1 Rocking lever 2 Dancer roll
3 Material web tension 4 Pneumatic cylinder pressure
The dancer roll is mounted to rocking levers to form a pendulum. The material
web wraps around the dancer roll and, due to the tension in the web, exerts a
force on the pendulum, causing it to deflect accordingly.
The rocking lever is supported against the tension of the material web by one or
more pneumatic cylinders. The preselected material web tension (brake
tension) determines the amount of pneumatic load required and, with it, the
resulting pressure in the pneumatic cylinder(s). This keeps the dancer roll in the
set position.
As the material web tension changes, e.g., due to an untrue parent roll, the
pendulum deflects. The degree of this deflection is monitored by a sensor
(angle sensor). The angle output from the sensor, together with the preselected
setpoint for the brake tension, is used to regulate the dynamic brake. This
allows the pendulum to return to its setpoint and the tension in the material web
to be kept as constant as possible.
The operator enters the required setpoint using the keyboard.
The pressure in the pneumatic cylinder(s) is automatically regulated during
winding by a proportional pressure relief valve.
If the dancer roll remains at either end position for a prolonged period, an error
notification is triggered and an emergency stop is initiated.

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5.6.5 Spreader roller

Spreader rolls are used to prevent longitudinal folds in the material web, slack
edges or sagging in the middle of the web.

1
4

Figure 35: Spreader roll

1 Spreader roll 2 Gear motor, swivel drive
3 Sheet position adjusting unit 4 Thrust bearing
The rotating roller head of an spreader roll has a curved shape. This stretches
material webs running through this spreader roll in an axial direction or
separates individual webs from one another. As the curve height of the
spreader roll increases, the stretching effect increases.
Run-in and run-out distance (distance between the spreader roll and the
upstream and downstream rolls), wrap angle (angle at which the material web
wraps around the spreader roll), and pivot angle (angle between material web
and curve) also influence the stretching effect.
The material web runs in on the concave side and runs out on the convex side
of the spreader roll. Pivoting the curve of the spreader roll into the material web
can prevent sagging in the middle of the web. Pivoting the curve of the spreader
roll away from the material web can offset slack web edges.
The spreader roll is provided with a fixed sheet height. The sheet can be
pivoted by an electric motor. The spreader roll is driven by a belt drive.

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5.6.6 Transport roll

A transport roll is a driven web-wrapped roll that pulls the material web by
means of surface contact.

5.6.7 Material threading device

The material inlet has a threading chain with driving dog on one side of the
machine that is driven by a gear motor. The maximum tensile force is limited by
a slip clutch. The entanglement points of the sprocket wheels are protected by
protective plates.

1
4

Figure 36: Material threading device

1 Threading chain 2 Protective plate
3 Chain tightener 4 Driving dog

Figure 37: Material threading device drive

1 Gear motor 2 Slip clutch

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5.6.8 Main drive

The material web is fed from the unwinder to the winders via transport rolls.
The main drive drives the following assemblies via an AC motor:
– Bottom knife shaft
– Transport rolls
– Spreader roll
The bottom knife shaft is directly driven.
The transport rolls and the spreader roll are driven by the bottom knife shaft via
flat belts.
The transport of the material web through the machine is achieved by the S-
wrapping around the transport rolls. The S-wrapping is the fixed point inside the
machine. The S-wrapping is where the web tension in the winder is decoupled
from the brake tension in the unwinder.

5
6

2
1

4 6

Figure 38: Main drive

1 Three-phase motor 2 Bottom knife shaft
3 Flat belt 4 Tensioner pulley
5 Spreader roll 6 Transport roll

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5.6.9 Spring-loaded multi-disc brake

A compressed air-filled spring-loaded multi-disc brake operates as an
emergency stop brake. When an emergency stop function is triggered, the
spring-loaded multi-disc brake brakes the roll so that the main drive can be
braked to zero speed and switched off in the shortest possible time.

Figure 39: Spring-loaded multi-disc brake

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5.6.10 Linearly adjustable idler roll

An idler roll is an undriven roll around which the material web wraps. The idler
roll guides the material web through the machine and is driven by the moving
material.
With this roll, the angle of the material web to upstream and downstream rollers
can be modified.

2
1

Figure 40: Linearly adjustable idler roll

1 Idler roll 2 Bearing plate
3 Guide strip

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5.6.11 Eccentrically adjustable idler roll

An idler roll is an undriven roll around which the material web wraps. The idler
roll guides the material web through the machine and is driven by the moving
material.
With this roll, the angle of the material web to upstream and downstream rollers
can be modified.
The bearing plates can be swiveled on both sides for this, thus changing the
position of the roll.
Each material web guide depends on the material and must be determined by
means of practical tests.

Figure 41: Eccentrically adjustable idler roll

1 Idler roll 2 Bearing plate

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5.6.12 Ionizing device

When working with film, it is very easy for static electricity to build up in the
material web. This can cause disruptions in the production process (e.g.,
electric shock or trouble with winding the material web) as well as disruptions in
downstream processing machines. These disruptions can be minimized with an
ionizing device.
The ionizing device discharges static electricity on the material web and consist
of an ionizing electrode connected to a high-voltage mains adapter.

Figure 42: Ionizing electrode

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5.7 Longitudinal slitting unit

The longitudinal slitting unit continuously slits the material in a longitudinal
direction.

5.7.1 Blade cut in air

With this cutting principle, the blades cut the material web between two support
points, e. g. Idler roll and bottom knife shaft. The material web is slit as it passes
by without being supported at the slitting point.

5.7.2 Top knife unit

5.7.2.1 Knife carriage for top knife

The knife carriage carries a cutting tool.
The knife carriage is mounted on linear roller guideways of the top knife
crossbar. The knife carriage can be moved at right angles to the material
running direction.
The position of the knife carriage is detected by a solenoid on the knife carriage
and a measuring rod.
The knife carriage is fixed by a connecting rod tightener.

Figure 43: Knife carriage

1 Linear roller guideway 2 Connecting rod tightener
3 Cutting tools

5.7.2.2 Knife holder for razor blade

The razor blade holder holds the razor blades required for razor cutting. The
razor blade is held by a solenoid. The cutting angle can be adjusted.

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Figure 44: Razor blade holder

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5.8 Rewinder
For rewinding the processed material, the machine is equipped with double-arm
winding stations on a central drive. The winding stations each consist of two
winding levers and are mounted on two opposing winding crossbars (Rewinder
1 and Rewinder 2). Based on web width, the winding stations can be moved
together horizontally on linear roller guides.
The slit webs are routed to Winding Side 1 and Winding Side 2, where they are
rewound.
The number of winding stations used depends on the number of slit webs.
Each winding lever is individually labeled with a three-digit number: The first
digit indicates the winding side, the second the winding station and the third the
winding lever. The first and second digits are separated by a period.
Accordingly, from the material feed direction, the first winding station (consisting
of winding levers 1.11 and 1.12) is located on the left side of Winding Side 1.
The first winding station on Winding Side 2 (consisting of winding levers 2.11
and 2.12) also starts on the left, but offset by the slitting width.

4 3
1

Figure 45: Rewinder

1 Winding crossbar 2 Winding lever
3 AC servomotor winding drive 4 Linear roller guideway

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5.8.1 Winding crossbar

The crossbars with winding stations can be moved horizontally by servo gear
motors and spindle-type lifting units on linear roller guideways, and can also be
pivoted.
The horizontal movement guides the rewinding cores up to the contact rolls and
back again as the finished roll diameter increases.
To remove the finished rolls from the machine, the crossbar is swiveled with the
winding stations until the finished rolls are unloaded on to a finished roll removal
carriage.

5
4
6

4
3

7 8
1

Figure 46: Winding crossbar

1 Winding crossbar 2 Servo gear motor (linear drive)
3 Synchronous shaft 4 Spindle-type lifting gear
5 Toothed belt drive 6 Swivel drive
7 Swiveling movement pivot point 8 Linear roller guideway

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5.8.2 Winding arm

Every winding station on the machine has two winding levers that are mounted
on linear roller guideways on the winding crossbars. Based on web width, the
winding levers on the winding crossbar can be moved together horizontally on
linear roller guideways.

2
3

Figure 47: Winding lever

1 Winding crossbar 2 Winding lever
3 Three-phase servo motor 4 Linear roller guideway

Number of winding levers The number of winding levers used depends on the number of winding stations
needed and the required drive output of those winding stations.
Unneeded winding levers Unneeded winding levers are disabled according to the computed slitting
pattern and moved into the parked area.
Winding lever drive The winding core in a winding station is driven by a three-phase servo motor
that uses a toothed belt drive to act on the drive shaft of a winding chuck, thus
turning the winding core.
Depending on the version, the winding stations can be driven on one side or
two sides.
Connecting multiple winding If the drive for a single winding station is insufficient for rewinding finished rolls
levers at the desired slitting width or finished roll diameter, the winding levers of this
winding station can be connected to the adjacent driven winding levers of an
unused winding station via a coupling. In this way, the winding sleeve can be
driven by up to four three-phase servo motors.

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1 1

2 2

Figure 48: Coupled winding station

1 Coupling 2 Winding lever

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5.8.3 Locking unit

There is a locking unit on each winding lever. The locking unit fixes the winding
lever to the winding crossbar.
The locking unit is mounted on linear roller guideways on the winding crossbar
and can be moved horizontally. A clamping lever is used to fix the locking unit
and with it the winding lever on the winding crossbar.
A pneumatic cylinder moves the winding lever to the clamp and releases the
core.

1
2

Figure 49: Locking unit

1 Clamping lever 2 Pneumatic cylinder
3 Linear roller guideway

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5.8.4 Winding head

The winding heads mechanically clamp and center the pushed-on cores using
clamping jaws that are pushed outward when the base element rotates.
Flat springs push the clamping jaws back when the machine is idle.

Figure 50: Winding head

1 Base element 2 Flat spring
3 Clamping jaw with friction lining

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5.8.5 Contact roller unit

Each winding station has a separate pneumatic control circuit and contact roll
unit. The purpose of the contact roll is to apply a regulated amount of pressure
to the finished roll during winding and to turn out when finished roll diameters
are untrue.

1 2

Figure 51: Contact roller unit

1 Contact roller 2 Bearing cap
3 Contact lever 4 Contact lever
5 Nut 6 Pneumatic cylinder
7 Pneumatic cylinder 8 Star handle
9 Star handle
The pivoting contact rollers are pneumatically pressed against the outside
diameter of the finished rolls. To do this, each contact lever is equipped with a
pneumatic cylinder.
As the finished roll diameter increases, each contact roll is pushed back. On
each winding side, a magnetic switch scans the position of a specific contact
lever and thus the position of the contact roll. If the contact roll position
changes, the output signal from the magnetic switch starts up a servo gear
motor. This gear motor uses spindle-type lifting units and linear roller guideways
to position the winding crossbar and winding stations in proportion to the
increasing diameter.
Since the rewinder moves instead of the contact rolls, the constant geometry
means the length of the material web does not change from the longitudinal
slitting unit to the contact roll during production. This results in virtually ideal
web guidance.

Number of contact roll units

The number of contact roll units used and the length of the contact rolls depend
on the number of winding stations used and the slitting width. Unneeded contact
levers are moved into the parking area during setup and secured.

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5.9 Edge trim suction unit

The edge trim suction unit at the nozzles cleans up any edge trimmings
produced during operation. These nozzles can be moved across the material
feed direction.
The nozzles are connected to the suction blower by a pipe system that carries
the edge trimmings away immediately.

1 2

Figure 52: Edge trim suction unit

1 Suction nozzle 2 Piping
3 Suction fan

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6 Processing and automation

technology

6.1 General information about operating the

individual pages
The following screens show an overview of the screens shown on the display.
Explanations are given according to screen function.
Depending on the functionality of a screen, some functions that are not
implemented in the actual machine may be presented and explained.
Top global toolbar Every normal control screen has a global toolbar at the top edge of the screen.

Continuous global actions can be displayed via this toolbar.

Clicking on the two left arrow keys switches to the last or previously opened
screen.
Clicking the Home button at any time opens the main menu.
Clicking the Navigation button opens an overview of all available screen pages
in order of topic\.
Clicking the Alarm button opens a table with an overview of all current fault
messages.
Clicking the Help button opens the Help screen from which it is also possible
to retrieve technical information about the machine.
Language Selection

Clicking on this button allows you to select the language at any time.
Print Screen

Clicking on this button allows you to print out screenshots as well as the
settings for a connected printer.
System of units

Clicking on this button allows you to preselect the system of units – SI or US.
General operation The various screens all contain the same structure. Input or output fields, pop-
up or action keys, status requests, confirmations, etc.

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An overview of the various controls is also shown.

Switching between screens with
“Tab operation”
Thematically related screens can be accessed using tabs. The active tab
(screen) is highlighted.
Hotkeys

If certain functions need to be accessed quickly, the top right corner of every
screen contains hotkeys that allow the respective screens to be selected
quickly.
Entry field (numeric/alphanu-
meric)

Input fields are identified by the fact that the range of values is shown lighter
than the area around it. Clicking with the mouse or selecting via the
touchscreen changes the color to pale blue. This makes it easy to see the input
value.
Output field (numeric/alphanu-
meric)

Output fields are identified by the fact that the entire field, description, value and
unit are grayed out.
Status indicator The various function units of the machine have status indicators that show

yellow or green to indicate the status of the function unit. Green indicates

"ready”, yellow indicates "not ready". Clicking the status indicator opens
a pop-up window. This contains more detailed information on the respective
status.
Enable indicator The various function units of the machine have enable indicators that show

yellow or green to indicate whether the function unit is enabled. Green

indicates "enabled', yellow indicates "not enabled". Clicking the enable

indicator opens a pop-up window.
This contains detailed information on the respective enable status.

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Input fields accept either numeric or alphanumeric input depending on their

function. The number range is shown directly at the top of the numeric input.

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Pop-Up ”Extended input/output”

Pop-up windows can be opened depending on the function unit of the machine,
e.g., Rewinder, Winding shaft or Unwinder. Additional entries to the
corresponding function can be made in these pop-up windows.
Closing the pop-up window

Clicking the Close button closes the open pop-up window.

Close all pop-up windows

Clicking the Close window button closes all the current pop-up windows.

6.1.1 Storage location for screenshots

ü One or more screenshots have been created via the Print button.
1. Open the User Administration page in the visualization.

2. Log in as a user in the [Administrator] user group.

3. In the visualization, open the Main Menu page.

4. Close the visualization program via the X button.
5. Open drive 'C:'.
6. Open the PrintOut folder under the path 'VisiWinNet/Projekte'.
ð This opened folder contains the screenshots.

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6.2 Navigation

Figure 53: Navigation

Clicking the Navigation button in the top global toolbar switches to the view of
all available screens. From here, the clear overview makes it possible to switch
quickly to any desired screen. The screens are divided into different groups of
topics.
General All screens that are necessary for basic machine operation are shown here.
Recipes Screens that are used for saving machine parameters for reuse or saving
product-specific data are found here.
Slitting pattern These screens are used to enter and configure the slitting pattern, as well as to
inquire on data related to the slitting pattern.
Characteristics Various screens for adjusting machine parameters such as winding tension,
contact pressure, set speed and unwinder oscillation can be set here using
various screens so as to influence the roll diameters and speeds.
Diagnostics Evaluation of machine conditions, detection of malfunctions and optimization of
drive controllers can be performed via various diagnostic screens.
Service The settings of individual machine components are made on various screens
that are accessible to maintenance personnel only.
Alarm Current and past alarms can be interrogated here.
Machine status If various machine functions or processes are unavailable or interrupted,
various status screens provide corresponding information.

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Statistics Various analyses for status checks and advanced machine diagnostics are
provided in the statistics area.
Help and documentation Help screens, additional documentation and access to the Kampf Service Portal
(optional) and access to the spare parts catalog (ESPAC) are available here.

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6.3 General

6.3.1 Machine (main menu)

Figure 54: Machine (Main menu)

Once the computer is turned on, all initialization routines are performed
automatically. The main menu (machine) then appears and the Kampf display
system is ready to start.

When the machine is switched on, an entry becomes effective

immediately if all conditions for it are fulfilled!

Shutting down the visualization Clicking the "X" at the top right of the display shuts down the visualization
application.
If the user who is logged in has the appropriate rights, only the visualization
application is shut down, the user then finds himself at the Windows level.
If the user who is logged in does not have the appropriate rights, after he clicks
on the “X” a query screen is displayed in which the user must confirm that he
wishes to shut down the visualization PC. If confirmed, the display application
closes and the PC shuts down.
If whilst an application is running the control voltage is switched off (key switch),
the PC shuts down completely.

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6.3.1.1 Machine

Figure 55: Machine

Input fields
Target speed This is the target machine speed.

Output fields
Actual speed Shows the actual machine speed.
Next stop in Shows the time remaining until the next stop.

Pop-up window

Clicking the button opens the following pop up window:

Figure 56: Machine pop-up window

Input fields
Acceleration time The machine accelerates from V0 (standstill) to Vmax (maximum speed) during
this time.
Deceleration time The machine decelerates from Vmax (maximum speed) to V0 (standstill) during
this time.
Ramp time 1 This is the time in which the machine does not accelerate suddenly, rather
during which the machine speed is gradually increased. The greater this time,
the slower the machine begins to accelerate. The same ramp time is also used
at the end of acceleration before the set speed is reached.

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Ramp time 3 This is the time in which the machine does not decelerate suddenly, rather
during which the machine speed is gradually decreased. The greater this time,
the slower the machine begins to decelerate. The same ramp time is also used
at the end of braking before standstill is reached.
Maximum machine speed This is the maximum speed that can be selected for this material in the main
menu. Limiting the speed is designed to prevent excessive speeds from being
selected.
This value is also used to calculate the number of motors needed for the
rewinder.

6.3.1.2 Rewinder

Figure 57: Rewinder

Input fields
Rewinder linear tension This is the basic tension for the rewinder in relation to the respective slitting
width. (for calculating the material web tension force: See Tension
characteristics [} 165]).
Rewinder linear pressure This is the basic contact pressure exerted by the contact roll on the finished roll
in relation to the respective slitting width. (for calculating the contact force: See
Contact pressure characteristic [} 169]).

Pop-up window

Clicking the button opens the following pop up window:

Figure 58: Rewinder pop up window

Input fields
Speed-dependent rewinder linear This is the tension force for the rewinder , which is added to the rewinder basic
tension tension according to the speed characteristic in relation to the respective slitting
width. (for calculating the material web tension force: See Tension
characteristics [} 165]).
Speed-dependent rewinder linear This is the contact pressure for the rewinder, which is added to the rewinder
contact pressure basic contact pressure according to the speed characteristic in relation to the
respective slitting width. (for calculating the contact force: See Contact pressure
characteristic [} 169]).

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6.3.1.3 Unwinder

Figure 59: Unwinder

Input fields
Linear tension This is the basic tension for the unwinder in relation to the current material
width.

Output fields
Current tension force This is the current tension force.
Working width This is the width of the parent roll pre-selected in the slitting pattern.

Pop-up window

Clicking the button opens the following pop up window:

Figure 60: Unwinder pop-up window

Input fields
Material thickness The material thickness is required for calculating the expected diameters.
Roll density This is the material density of the respective material. This is used to calculate
the mass moments of inertia required for compensation during the acceleration
and deceleration phases.

Output fields
Current torque The current torque of the unwinder drive is displayed here.

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Current pressure of dancer roll The current pressure applied to the dancer roll is displayed here.

Figure 61: Unwinder

Input fields
Stop length This is the target unwinding length for the unwinder. The machine stops
automatically when the set value is reached. This function can be used if the
material length of the parent roll is known or e.g. if splices in the roll are to be
approached. The corresponding input field starts flashing to indicate braking.
The corresponding pop up window is used to reset the actual run lengths.
Stop diameter This is the target unwinding diameter for the unwinder. The machine stops
automatically when the set value is reached. The corresponding input field
starts flashing to indicate braking.

Output fields
Current winding length Shows the current unwinding length since the last reset.
Current diameter Shows the current parent roll diameter.
Core empty in Shows the time until the next stop (reaching the stop length or reaching the stop
diameter).

Pop-up window

Clicking the button opens the following pop up window:

Figure 62: Unwinder pop-up window

Input fields
Preselect diameter The diameter of the parent roll is entered here. Clicking the
Preselect unwinding diameter button applies this value as the current parent
roll diameter (only when the machine is at a standstill).

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Action buttons
Preselect unwinder diameter Clicking the Preselect button applies the entered diameter as the current
parent roll diameter (only when the machine is at a standstill).
Reset unwinder length Clicking the Reset button resets the current run length of the unwinder.

6.3.1.4 Winding side

Figure 63: Winding side

Input fields
Stop length This is the target winding length for the rewinder. The machine stops
automatically when the set value is reached. The corresponding input field
starts flashing to indicate braking.
The corresponding pop up window is used to reset the actual run lengths.
Stop diameter This is the target winding diameter for the rewinder. The machine stops
automatically when the set value is reached. The corresponding input field
starts flashing to indicate braking.

Output fields
Current winding length Shows the current winding length since the last reset.
Current diameter Shows the current diameter of the finished roll.
Winding finished in Shows the time until the next stop (reaching the stop length or reaching the stop
diameter).

Pop-up window

Clicking the button opens the following pop up window:

Figure 64: Winding side pop-up window

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Input fields
Core diameter The core diameter is required to calculate the finished roll diameter and the
finished roll mass for the respective rewinder.
Contact roll diameter The contact roll diameter is used for calculating the finished roll diameter on
each rewinder.

Action buttons
Reset winding length Clicking the Reset button resets the current run length of the rewinder.

6.3.1.5 Oscillation

Figure 65: Oscillation

Oscillation Shows whether the unwinder oscillation is switched on or switched off.

Pop-up window

Clicking the button opens the following pop up window:

Figure 66: Unwinder oscillation pop-up window

Input fields
Range The oscillation range for the unwinder is entered here.
Speed The oscillation speed for the unwinder is entered here. The input is performed in
percent; the current oscillation speed is the result of this percentage applied to
the current machine speed.

Output fields
Unwinder position Shows the current position of the unwinder.
Scanning head position Shows the current position of the scanning head.

Action buttons
Scanning head after the center Clicking the Center button brings the scanning head, and with it the unwinder,
position into the center position.

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6.3.1.6 Operating mode

Figure 67: Operating status

Operating status Shows the machine operating status.

Pop-up window

Clicking the button opens the following pop up window:

Figure 68: Operating status pop-up window

Output fields
Operating hours cycle Shows the duration of the last run.
Total operating hours Shows the total operating hours of the machine.
Total length Shows the total run length of the machine.

6.3.1.7 Machine status

Figure 69: Machine status

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Pop-up window

Clicking the button opens the following pop up window:

Figure 70: Machine status pop-up window

Machine status Chows the status of various functional units. A yellow color indicates a missing
condition; a green color indicates a satisfied condition.

6.3.1.8 Edge trim suction unit

Figure 71: Edge trim suction unit

Pop-up window

Clicking the button opens the following pop up window:

Figure 72: Edge trim suction unit pop-up window

Edge trim suction unit Changes to the suction speed can be made and displayed using curve display.
The curve shows the suction speed as a function of the machine speed.
After the curve progression has been changed, clicking the Apply button saves
the changes and sends them to the machine.

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Input fields
Free input of the curves For establishing the suction speed as a function of the machine speed, 12 data
points can be freely selected. A percentage from 0 to 100% can be entered for
each data point. 100 percent corresponds to the maximum speed of the suction
fan.
The following input facilities are available:
– Inputting values directly
– Moving data points with the mouse
– Use the mouse to click on the appropriate button. The color of this but-
ton changes and the data point is displayed on the curve as a red dot.
– Click and hold the left mouse button, then move the mouse in the de-
sired direction. The data point moves in the x-direction and y-direction
accordingly.
Determination by parameters Entering the following parameters can allow the curve to be calculated
automatically:
– Start of curve in percent
– Shape of curve in percent
– End of curve in percent
Reset curve Pressing the Reset curve button sets all the data points to 100 %.

6.3.2 Manual control

The switching elements required to operate the machine but not implemented
as hardware switching elements on the operator panels are displayed on this
screen page.

6.3.2.1 Edge trimming suction

Figure 73: Edge trimming suction

Clicking the On button switches the edge trimming suction on. Clicking the
Off button switches the edge trimming suction off.

6.3.2.2 Change contact roll

Figure 74: Replacing the contact roll

Clicking the On button applies maximum pressure to the contact roll cylinders.
The cylinders extend and the contact rolls can more easily be replaced.
Clicking the Off button restores service pressure to the contact roll cylinders.

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6.3.2.3 Ionization
Ionization
- -
- ++ +

Off On

Figure 75: Ionization

On Clicking the On button switches the ionization on.
Off Clicking the Off button switches the ionization off.

6.3.2.4 Braking the transport rolls

Brakes of the transport
rolls

Off On

Figure 76: Braking the transport rolls

Clicking on Release and Apply releases or applies the transport roll brakes.
This allows you to rotate the transport rolls by hand, e.g. for cleaning purposes.
This function is enabled only in Service mode.

6.3.2.5 Machine lighting

Figure 77: Machine lighting

Clicking the On button switches the machine lighting on. Clicking the Off
button switches the machine lighting off.

6.3.2.6 Winding side Direction of rotation

Figure 78: Winding side 1 direction of rotation

By clicking the On button, the direction of rotation of the winding stations on
the corresponding winding side can be changed.
By clicking the Off button, the winding direction is reset to the default value.
The material web must be guided according to the preselected winding direction
and glued to the core.

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6.3.3 User administration

Figure 79: User management

The purpose of user management is to assign usage rights on a personal basis
within the visualization application. Control input elements can be blocked,
access to information about output control elements and control screens can be
withheld.
User management supports a rights-oriented user management system.

Rights-oriented user management

Each of the control elements (control input elements, control output elements,
control screens) in the visualization application is assigned an access right that
must be allocated to the user to allow him to access the control element (such
as “Edit Recipe”).
Rights are allocated to the users that are allowed to perform those tasks.
The management of users is performed by means of three definitions in the
database:
User group Collects users into a group and contains the characteristic parameters of all the
users in the group.
Allocation of the necessary rights to access the control elements are managed
via the user groups.

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User Contains the access information (login name and password and the activation
status of a user.
Right Rights define the information that is assigned to the control elements of the
application. A right to access a control element is assigned via the right
characteristic. A user that is logged is must have a reference to this right in his
user group definition in order that he can access the control element.
Rights are used only in rights-oriented user management.

6.3.3.1 Overview of users

Figure 80: Overview of users

The Overview of users table shows the users that exist. Click on the relevant
line to select the desired user. The line is then highlighted in blue.
Name This is the login name with which the user logs in to the system.
Full name Description of the person.
User group Shows the assignment to a certain user group.
Note Free-format notes for definition of the user.

6.3.3.2 Overview of user rights

Figure 81: Overview of user rights

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The rights assigned for a pre-selected user are shown in the table. To view the
display,click on the respective user in the Overview of users table.

6.3.3.3 User login/logout

Figure 82: User login/logout

Clicking the Login button allows users who are already registered in user
management to log in.
Clicking the Logout button logs out a user who is currently logged in.
Clicking the Login button opens the following pop-up window:

Figure 83: User login pop-up window

After the user name and the associated password have been entered, the user
is logged in by clicking the OK button.

6.3.3.4 Change user

Figure 84: Change user

Clicking the Change , Add or Remove button allows you to change user
data, add new users or delete existing users.

Change user
Clicking the Change button opens the following pop-up window:

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Figure 85: Change user pop-up window

This pop-up window allows the data of users who are already registered to be
changed.
Click the corresponding check boxes to change the code or the password. This
activates the input lines and the new code or new password can then be
entered.
Clicking the OK button accepts the changes.

Add user
Clicking the Add button opens the following pop-up window:

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Figure 86: Add user pop-up window

This pop-up window allows additional users to be registered on the system for
the visualization application.
Name This is the login name with which the user logs in to the system.
Full name Description of the person.
Code Alternative information for automatic logging in of a user.
User group Collects users into a group and contains the characteristic parameters of all the
users in the group.
Allocation of the necessary rights to access the control elements are
administered via the user groups.
Password The entry of a password ensures each user personalized access to the system.
Users must identify themselves with their login name and verify their identity via
their password.
Repeat password Repeat input of the password.
Status Determines whether and how the user can log in during a period.
Deactivation – Never: The existing user is never deactivated.
– At a point in time: The existing user is automatically deactivated from the
system at a specified date and time.
– After the 1st login: After the first login to the system, the existing user is
automatically deactivated from the system after a specified number of days
and hours.
Comments Free-format notes for definition of the user.

Remove user
Clicking the Remove button allows removal of the previously selected user.
The following pop-up window opens with a confirmation prompt:

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Figure 87: Remove user pop-up window

Clicking the Yes button in response to the confirmation prompt confirms that
the action will proceed. Clicking the No button cancels the action.

6.3.3.5 Rights

Figure 88: Rights

Clicking the Change rights button allows you to change the user rights.
Clicking the Change rights button opens the following pop-up window:

Figure 89: Change rights pop-up window

This pop-up window contains a table with an overview of the available rights.
Select the desired rights by clicking on the line in the table to select it.

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Clicking the Assign rights button opens the following pop-up window:

Figure 90: Assign rights pop-up window

The selected rights can be assigned here to the desired user group by clicking
on the respective checkbox. The rights are updated only after confirmation by
clicking the OK button.

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6.4 Recipes
The recipe screens are used for saving machine parameters or product-specific
data for later reuse.

6.4.1 Recipe list

Figure 91: Recipe list

The Recipe List screen contains a collection of all the recipes that are stored
on the hard drive. In addition, it contains action keys for loading, saving or
deleting recipes.
The recipes are differentiated into the categories Material recipes und
Slitting recipes. The two categories can be combined with each other as
required. The respective hot keys permit a quick change of overviews.

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6.4.1.1 Overview of recipes

Figure 92: Overview of recipes

The overview screen contains a listing of all the recipes that are stored on the
hard disk. The file name (recipe name), a description (if specified) and the last
modification date are shown. Click to select a recipe – the recipe is then
highlighted in blue.

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6.4.1.2 Material recipes

Figure 93: Material recipes

The material recipes contain the primary machine setpoints without the selected
slitting arrangement. The specific parameters concerned are shown on the
Running data (Recipe View) screen.

Loading a recipe to the machine

Load to Machine Clicking the Load to Machine button loads the selected material recipe to the
machine control system. Selecting this function opens the following confirmation
prompt:

Figure 94: Load into Machine

Clicking Yes loads the recipes into the machine control system. This means
that all the setpoints of the recipe are written as the respective setpoints of the
machine. Clicking No cancels the action.

Saving machine data as a recipe

Save to recipe The current machine setpoints are loaded as a materials recipe. Clicking the
Save to recipe button opens a pop-up window which allows further inputs to
be made:

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Figure 95: Save to recipe

Name The name of the previously selected recipe appears here; however a new name
for it can be entered. After it has been saved to the recipe list, it is listed as a
new recipe.
Description A description can be entered here. After it has been saved to the recipe list, it is
listed as “Description”.
Clicking Save writes the recipe to the hard disk. Clicking Delete deletes the
recipe from the hard disk.

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6.4.1.3 Slitting recipes

Figure 96: Slitting recipes

The slitting recipes contain the slitting arrangement setpoints found on the
Slitting Pattern screen.
Selecting the slitting recipes changes the display and the action keys for loading
the recipe to make it clear that the slitting recipes are not loaded directly to the
machine, only to the Slitting Pattern screen.

Loading a recipe to the Slitting Pattern screen

Load to Slitting Pattern Clicking the Load to Slitting Pattern button loads the selected slitting pattern
recipe to the Slitting Pattern screen. Selecting this function opens a
confirmation prompt:

Figure 97: Load to Slitting Pattern

Clicking Yes loads the recipes into the Slitting Pattern screen. All the
setpoints of the slitting pattern are loaded to the slitting pattern screen. On this
screen, the selected slitting pattern can be reviewed and, if necessary,
configured on the machine.
Clicking No cancels the action.

Saving machine data as a recipe

Save to recipe The current slitting pattern setpoints are loaded as a slitting pattern recipe.
Clicking the Save to recipe button opens the following pop-up window which
allows further inputs to be made:

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Figure 98: Save to recipe

Name The name of the previously selected recipe appears here; however a new name
for it can be entered. After it has been saved to the recipe list, it is listed as a
new recipe.
Description A description can be entered here. After it has been saved to the recipe list, it is
listed as “Description”.
Clicking Save writes the recipe to the hard disk. Clicking Delete deletes the
recipe from the hard disk.

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6.4.1.4 Save/load recipes

Figure 99: BackUp/load recipes

Recipes can be loaded here from an external drive or saved to an external
drive.
Clicking the Backup All button opens the following pop-up window:

Figure 100: BackUp all recipes

The source path of the current project is shown here. The destination directory
path can be selected from a selection window. Clicking the Save all button
saves the recipes from the selected project into the destination directory.
Clicking the Delete button deletes the selected recipes from the destination
directory, after confirmation by replying to a confirmation prompt.
Clicking the Load all button opens the following pop-up window:

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Figure 101: Restore recipes

The destination directory path of the current project is shown here. The source
path can be selected from a selection window. Clicking the Load all button
loads the recipes from the selected source directory into the destination
directory.
Clicking the Delete button deletes the selected recipes from the source
directory, after confirmation by replying to a confirmation prompt.

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6.4.1.5 Running data

Figure 102: Recipe View

Clicking the Load to View button loads the contents of the selected recipe into
the Recipe view menu. This is one of the screens described below where the
content of a recipe can be displayed and edited without having to load the
recipe to the machine. In other words, the current machine parameters are not
altered. Selecting this function opens a confirmation prompt:

Figure 103: Load Recipe

Clicking Yes loads the recipes into the Recipe View manu. Clicking No
cancels the action

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6.4.2 Recipe view

Figure 104: Running data

The Running data screen contains all data that can be saved to the recipes. It
is also possible here to view, edit and overwrite recipe content. The data is
grouped into categories such as Machine, Transport, Characteristics etc. The
respective hot keys permit a quick change of overviews.
The recipe data that are displayed can be saved and loaded at any time, that is
to say:
– From the view into the recipe list
– From the recipe list into the view
– From the view into the machine
– From the machine into the view.

Pop up window
Clicking the Recipe text files button opens the following pop up window:

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Figure 105: Recipe Text Files

This window displays the saved recipe files in text form. The various recipes
can be selected and the respective text file displayed on the corresponding
screen. Clicking the Print File button prints the text file.

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6.4.2.1 Recipe list

Figure 106: Recipe List

Saving the running data into an recipe

Save to Recipe List The recipe values shown in the running data view are saved under a recipe
name. Clicking the Save to recipe list button opens the following pop-up
window which allows further inputs to be made:

Figure 107: Save running data as

Name The name of the previously selected recipe appears here; however a new name
for it can be entered. After it has been saved to the recipe list, it is listed as a
new recipe.
Description A description can be entered here. After it has been saved to the recipe list, it is
listed as “Description”.
Clicking Save writes the recipe to the hard disk. Clicking Delete deletes the
recipe from the hard disk.

Load recipe into in the running data view

Load to View A recipe on the hard disk is opened in the running data view. This does not
overwrite any machine setpoints. Clicking the Load to View button opens the
following pop-up window:

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Figure 108: Load running data from recipe

The overview screen contains a listing of all the recipes that are stored on the
hard disk. The file name (recipe name), a description (if specified) and the last
modification date are shown. Click to select a recipe – the recipe is then
highlighted in blue.
Clicking the Load button loads the recipe into the running data view.

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6.4.2.2 Machine

Figure 109: Machine

Load View into the machine

View to machine The recipe values shown in the running data view are loaded to the machine.
Clicking the View to machine button opens the following confirmation prompt:

Figure 110: Recipe View ==> Machine

Clicking Yes loads the recipes into the machine control system. This means
that all the setpoints of the recipe are written as the respective setpoints of the
machine. Clicking No cancels the action.

Load Machine to Recipe View

Machine to Recipe View Die aktuellen Sollwerte der Maschine werden in die Fahrdatenansicht geladen.
Durch Klicken der Taste Maschine nach Fahrdatenansicht erfolgt folgende
Sicherheitsabfrage:

Figure 111: Machine ==> Recipe View

Clicking >Yes the data from the running data view with the data from the
machine control system. Clicking No cancels the action.

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6.5 Slitting pattern

6.5.1 Enter slitting pattern

Figure 112: Enter Slitting Pattern

This slitting pattern screen is used to prepare the slitting arrangement on the
machine. The various slitting widths can be entered here to determine the
desired widths of the finished rolls. Once the slitting widths are entered, the
entries are checked. If this is successful, you can take over the slitting pattern
and then position the winding levers and knife holders accordingly.
An illustration of the slitting pattern entered appears in the center of the screen.
This is updated when the entries have been verified successfully.
The overview is divided into Winding Side 1, Winding Side 2 and Knives.
Pop-up windows can be opened in the various areas of the screen and these
are explained below.

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6.5.1.1 Slitting pattern

Figure 113: Slitting pattern

Slitting pattern
The critical setpoints for the slitting pattern can be entered here.

Input fields
Number of webs The number of webs to be slit. The edge trims are not included here.
Unwinding width The available material width. The edge trim width is the total of this value minus
the sum of the slitting widths.
Identical webs If a value is entered (edited) here, all web widths are set to this value. This is
used to simplify the entry.
First web on side The winding side on which the first web is located is entered here.

Webs
The web widths for the slitting pattern can be entered here. A core width can
also be specified for each web width. It is specified depending on the core
protrusion (see above) by default. The Offset column allows the web to be
wound off-center around the core.
The resulting webs total and the calculated edge trims are shown in the lower
area. The left edge trim can be changed and the right edge trim is then
recalculated accordingly. This causes the slitting pattern to shift accordingly.
Below this is the Calculate Slitting Pattern button.
Calculating the slitting pattern The configured slitting pattern is verified. The lower status bar shows
information on the calculation. Once the slitting pattern has been verified, this is
indicated by a message highlighted in green. An illustration of the slitting pattern
entered appears at the center of the screen. This is updated when the entries
have been verified successfully. In the event of an error, an orange status bar
appears and additional information is displayed in an info box.

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Pop-up window

Clicking the button opens the following pop up window:

Figure 114: Slitting patterns pop-up window

Input fields
Slitting pattern offset This entry is used to move the entire slitting pattern in the machine. A negative
value moves it to the left (as viewed in the material running direction) and a
positive value moves it to the right.

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Core protrusion The distance entered here is used as the default core length. If the user
specifies a web width, the core length is set by default to the web width plus
twice the core protrusion. This saves time when entering the slitting pattern.
That means that e.g. for a desired core protrusion of 5 mm, a value of 10 mm
must be entered for each side.

WARNING
Deformation of the winding cores due to excess length
Cores that are too long can be deformed. If cores are used that are too long, the
finished rolls to be wound could fall out of the winding station.
1. Only use cores with the maximum permissible excess length.
2. Only use cores with sufficient core strength according to the finished roll
weight.

The winding core length in the winding station should generally match the
corresponding slitting width.
When tensioning winding cores that exceed the permissible excess length,
there is a risk of deformation of the winding core in the core protrusion area.
This can impair the stability of the winding core so severely that correct
clamping is no longer assured and the risk of the finished roll dropping out of
the winding station cannot be ruled out.

Permissible core protrusion

Core material Maximum core protrusion per side in [mm]
Winding head insertion Winding head insertion
depth < 40 mm depth >= 40 mm
Cardboard 5 10
Aluminum/ 5 10
plastic
Steel 5 10
Tab. 2: Permissible core protrusion
WARNING! The operator is responsible for operating the machine with any
core protrusion that exceeds the permissible core protrusion!

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Clamping stroke The value entered here is the distance between winding chuck and finished roll
after opening the station. A large clamping stroke leaves plenty of space
between the lever and finished roll when unloading the station, but may make
tight slitting patterns impossible.
Blade thickness The thickness of the blade being used. This value is used to correct the blade
position in a slitting slot.
Use idle heads If idle heads are available, this option can be used. The program then, if
possible, only uses one motor at the corresponding winding station. The unused
motors are then labeled on the screen with No motor. Idle heads must then be
used at these points.
Knife selection If multiple slitting systems are available, the knife type used can be preselected
here. The various knife types can then be automatically taken into account
during positioning.

Pop-up window

Clicking the button opens the following pop up window:

Figure 115: Webs pop-up

This window is updated every time the slitting pattern is verified.
Additional information on the selected webs can be viewed here.
Web Consecutive number of the web from left to right as viewed in the material
running direction.
Web width As entered.
Core width As entered.
Winding side Determined by “First web at end” (see above). After this it alternates.
Station The program determines what web is at what station. This depends on several
factors (web width, number of motors, etc.).
Diameter The expected diameter of the finished roll when the run length is reached.
Weight The expected weight of the finished roll when the run length is reached.
Torque The maximum motor torque required to wind this finished roll with the current
machine parameters.
Motor load The load of the motors involved, in percent.
Contact pressure The contact roll contact pressure required with the current machine parameters.
Motors The number of motors required to establish the necessary torque.
Lever The number of levers required to establish the necessary contact pressure.

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6.5.1.2 Knife type

Figure 116: Knife type

The display shows which type of knife must be used. Equip the knife holder
correspondingly.

6.5.1.3 Winding head type

Figure 117: winding head type

The display shows which type of winding head must be used. Equip the winding
arm correspondingly.

6.5.1.4 Knife

Figure 118: Knife

Current slitting pattern with active (green) and inactive (gray) knives.

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Pop-up window

Clicking the button opens the following pop up window:

Figure 119: Knife positions

The current positions and nominal positions of the knives are shown here. The
Status column displays the usage type of the knife:
Knife is disabled

Knife is parked

Knife is slitting

Knife information
Clicking the button opens the following pop up window with knife
information:

Figure 120: Knife information pop-up window

This info box appears when clicking directly on the image of a knife. It contains
all information about that knife. The knife can also be “disabled” by clicking on
the corresponding checkbox. This causes the machine to attempt to park the
knife the next time the slitting pattern is verified. This can be used to determine
what knives are active in the slitting pattern. This is useful for instance if the
knives are blunt.

Note: Disabled knives are still moved into a parking position (not
slitting).

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6.5.1.5 Winding side

Figure 121: Winding side

Current arrangement of the winding stations at the corresponding winding side.

Output fields
Slitting width This is the slitting width at the respective winding station.
Contact roll This is the contact roll width at the respective winding station.

Pop-up window

Clicking the button opens the following pop up window:

Figure 122: Winding side pop-up positions

The current positions and nominal positions of the winding arms are shown
here. The nominal positions are divided into a position for when a station is in a
clamped state (core clamped) and a position for when a station is in a released
state. The Status column displays the usage type of the winding lever:

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Winder logged off

Winder parked

Winder without motor

Winder is winding
Winder is connected to another station
and is winding

Pop-up window

Clicking the button opens the following pop up window:

Figure 123: Winding side disable pop-up window

Allows enabling or disabling of levers. This causes the machine to attempt to
park the lever the next time the slitting pattern is verified. This can be used to
determine what levers are active in the slitting pattern. This is useful for
instance if the winding motors are faulty.

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Winding arm information

Clicking the button opens the following pop up window with winding
arm information:

Figure 124: Winding lever information

This info box appears when clicking directly on the image of a winding lever. It
contains all information on the respective winding lever. The lever can also be
“disabled”. This causes the machine to attempt to park the lever the next time
the slitting pattern is verified. This can be used to determine what levers are
active in the slitting pattern. This is useful for instance if the winding motors are
faulty.
Clicking on the corresponding checkbox deselects the heavy-duty winding
chucks specified by the slitting pattern for the winding station.

Note: Disabled winding levers are still positioned, but into the parking
position (not winding).

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6.5.2 Actual slitting pattern

Figure 125: Current Slitting Pattern

This screen shows the slitting pattern currently set on the machine. The
overview is divided into Winding Side 1, Winding Side 2 and Knives (in the
center).
Click the Percentage Bars and Slitting Widths buttons to choose between
two display types.
Pop up windows can be opened in the various areas of the screens; these are
explained below. The pop up windows for the winding sides and knives are the
same as in the Enter Slitting Pattern screen with the exception that the
nominal positions are those of the current slitting pattern and do not change
when a new slitting pattern is verified. Only when the new slitting pattern is set
on the machine is it applied on the Actual Slitting Pattern screen.
The pop up windows for arm information and knife information are also the
same as those on the Enter Slitting Pattern screen with the exception that the
nominal positions are those of the slitting pattern currently on the machine.
Arms or knives can only be disabled in the pop up windows on the
Enter Slitting Pattern screen.

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6.5.2.1 Actual slitting pattern

Figure 126: Current slitting pattern

6.5.2.2 Winding side

Figure 127: Winding side (percentage bar display)

Figure 128: Winding side (slitting widths display)

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Pop-up window

Clicking the button opens the following pop up window:

Figure 129: Positions of winding sides pop-up window

Winding arm information

Clicking the button opens the following pop up window with winding
arm information:

Figure 130: Winding lever information pop up window

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Winding station information

Clicking the button opens the following pop up window with winding station
information:

Figure 131: Winding station information pop up window

Input fields
Tension correction A correction (plus or minus) to the tension at this station can be entered in
percent. The change takes effect immediately when the machine is running.
Contact pressure correction A correction (plus or minus) to the contact pressure at this station can be
entered in percent. The change takes effect immediately when the machine is
running.
Switch off station This selection switches off the affected station, i.e. winding tension is no longer
present. This is primarily used to be able to jog the machine after a web break
without having all winding stations run as well. Once enough material has been
jogged out, the broken web can be placed in the station again and the station
switched back on.
The current values displayed refer to the respective station.

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6.5.2.3 Knife

Figure 132: Knife

Pop-up window

Clicking the button opens the following pop up window:

Figure 133: Knife positions pop up window

6.5.2.4 winding head type

Figure 134: Winding chuck type

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The display shows which type of winding chuck must be used. Equip the
winding lever correspondingly.

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6.6 Characteristics

6.6.1 Tension characteristics

Figure 135: Tension characteristics

Changes to the rewinding tension can be made and displayed using three
curves. The curves show the dependence of the diameter (1st curve), the
machine speed (2nd curve) and the web width (3rd curve).
After the curve progression has been changed, clicking the Apply button saves
the changes and sends them to the machine. During the machine run, each
percentage is multiplied by the tension for each diameter and speed.

Input fields
Free input of the curves Depending on diameter and speed, 12 data points can be freely selected for the
rewinding tension. For the web width, the two possible data points are fixed
(minimum and maximum web width). A percentage from 0 to 100% can be
entered for each data point. Data points at 100 percent correspond to the
preselected rewinding tension.
The following input facilities are available:
– Inputting values directly
– Moving data points with the mouse

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– Use the mouse to click on the appropriate button. The color of this but-
ton changes and the data point is displayed on the curve as a red dot.
– Click and hold the left mouse button, then move the mouse in the de-
sired direction. The data point moves in the x-direction and y-direction
accordingly.

When entering values as well as moving data points with the mouse,
the adjacent data points form the entry limits for the diameter. When
entering values, this means you should start with the greater data
point.

Determination by parameters Entering the following parameters can allow the curve to be calculated
automatically:
– Start of curve in percent
– Shape of curve in percent
– End of curve in percent
Once these values have been entered, they can be applied and calculated by
clicking the Calculate button.
The Form factor entry value returns the shape of the curve:
– 0...49% = concave curve
– 50% = linear curve
– 51..100% = convex curve
Linear tension rewinder diameter This is the basic tension for the rewinder. The linear tension diameter is
Zo multiplied by the diameter characteristic.
Linear tension rewinder speed This is another component of the tension for the rewinder. The linear tension
Zov speed is multiplied by the speed characteristic.
The resulting tension at the winding station (Fz) is calculated using the following
formula

SB
Fz[N] = Zo *
1000
[ f(d)
100
[%] f(SB) [%]
100
( Kn100[%] +1)] +
SB f(v) [%]
+ Zov * *
1000 100

Fz [N] Set tension for this station

Zo [N/M] Diameter-based linear tension for rewinder
SB [mm] Web width for this station
f(d) [%] Current diameter curve percentage
F(SB) [%] Slitting width curve percentage
Kn [%] Tension correction
Zov [%] Speed-based linear tension for the rewinder
F(v) [%] Current speed curve percentage

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Pop-up window
Clicking the Simulator opens a pop-up window.

Figure 136: Simulator pop-up window

The simulator is a graphic in which the winding processes are simulated and
depicted.
The desired winding side and winding station to which the simulation relates
can be pre-selected. The simulation shows the winding diameter, winding
length, speed, rewinding rotational speed, rewinding tension and rewinding
contact pressure as a function of time.
To find the process values for the specific time, use the mouse/touchscreen to
set the cursor at the desired position. The exact time is displayed next to the
cursor. The process values for that time can then be read in the Marked values
column in the table.

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6.6.1.1 Calculating the linear tension

Figure 137: Calculating the linear tension

Input fields
Diameter Input fields for the diameter.
Speed Input field for the speed.

Output fields
Diameter-dependent value Display of the calculated diameter-dependent value.
Speed-dependent value Display of the calculated speed-dependent value.
Overall value Output of the overall value. The overall value is the sum of the calculated
diameter-dependent and speed-dependent values.

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6.6.2 Contact pressure characteristic

Figure 138: Contact pressure characteristic

Changes to the rewinding contact pressure can be made and displayed using
three curves. The curves show the dependence of the diameter (1st curve), the
machine speed (2nd curve) and the web width (3rd curve).
After the curve progression has been changed, clicking the Apply button saves
the changes and sends them to the machine. During the machine run, each
percentage is multiplied by the tension for each diameter and speed.

Input fields
Free input of the curves Depending on diameter and speed, 12 data points can be freely selected for the
rewinding contact pressure. For the web width, the two possible data points are
fixed (minimum and maximum web width). A percentage from 0 to 100% can be
entered for each data point. Data points at 100 percent correspond to the
preselected rewinding tension.
The following input facilities are available:
– Inputting values directly
– Moving data points with the mouse
– Use the mouse to click on the appropriate button. The color of this but-
ton changes and the data point is displayed on the curve as a red dot.

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– Click and hold the left mouse button, then move the mouse in the de-
sired direction. The data point moves in the x-direction and y-direction
accordingly.

When entering values as well as moving data points with the mouse,
the adjacent data points form the entry limits for the diameter. When
entering values, this means you should start with the greater data
point.

Determination by parameters Entering the following parameters can allow the curve to be calculated
automatically.
– Start of curve in percent
– Shape of curve in percent
– End of curve in percent
Once these values have been entered, they can be applied and calculated by
clicking the Calculate button.
The Form factor entry value returns the shape of the curve:
– 0...49% = concave curve
– 50% = linear curve
– 51..100% = convex curve
Linear contact pressure rewinder This is the basic contact pressure for the rewinder. The linear contact pressure
diameter Zo diameter is multiplied by the diameter characteristic.
Linear contact pressure rewinder This is another component of the contact pressure for the rewinder. The linear
speed Zov contact pressure speed is multiplied by the speed characteristic.
The resulting contact pressure at the winding station (Fz) is calculated using the
following formula

SB
Fz[N] = Zo *
1000
[ f(d)
100
[%] f(SB) [%]
100
( Kn100[%] +1)] +
SB f(v) [%]
+ Zov * *
1000 100

Fz [N] Set contact pressure for this station

Zo [N/M] Diameter-based linear pressure for the rewinder
SB [mm] Web width for this station
f(d) [%] Current diameter curve percentage
F(SB) [%] Slitting width curve percentage
Kn [%] Pressure correction
Zov [%] Speed-based linear contact pressure for the rewinder
F(v) [%] Current speed curve percentage

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Pop-up window
Clicking the Simulator opens a pop-up window.

Figure 139: Simulator pop-up window

The simulator is a graphic in which the winding processes are simulated and
depicted.
The desired winding side and winding station to which the simulation relates
can be pre-selected. The simulation shows the winding diameter, winding
length, speed, rewinding rotational speed, rewinding tension and rewinding
contact pressure as a function of time.
To find the process values for the specific time, use the mouse/touchscreen to
set the cursor at the desired position. The exact time is displayed next to the
cursor. The process values for that time can then be read in the Marked values
column in the table.

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6.6.2.1 Pressure calculation

Figure 140: Pressure calculation

Input fields
Diameter Input fields for the diameter.
Speed Input field for the speed.

Output fields
Diameter-dependent value Display of the calculated diameter-dependent value.
Speed-dependent value Display of the calculated speed-dependent value.
Overall value Output of the overall value. The overall value is the sum of the calculated
diameter-dependent and speed-dependent values.

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6.6.3 Speed characteristic

Figure 141: Characteristic Speed

In this screen, the machine speed can be specified in 12 steps depending on
the rewinding diameter. If the rewinding diameter reaches the next step, the
machine automatically switches to the corresponding set speed.
The function can be switched off and on even during operation, by clicking on
the set speed curve Off/On In this case, the preselected set speed from the
main menu and the acceleration/deceleration time from the Basic Settings
menu are applied.

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6.7 Diagnostics

6.7.1 Rewinder drive friction

Figure 142: Rewinder Drive Friction

This screen is used both to display and test the friction of the rewinder drives.
The determined friction is offset exactly for each rewinder drive during machine
operation. This ensures that the friction losses do not affect the control of the
rewinding tension.
The current values of the selected drive, as well as both the old and new friction
coefficient curve progressions, are shown on the bottom part of the screen.

Action buttons
Start Frict. Test Clicking the Start Frict, Test button starts recording of the friction curve. The
drive is operated at various speeds, thereby determining the compensation
values.
Start Acc.Test Clicking the Start Acc. Test button begins testing the compensation values
during acceleration. Here, the drive is accelerated to a moderate speed and
then decelerated.
Apply Values Clicking the Apply Values button applies the tested values as the current
friction curve. These are then saved to the machine.

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Pop-up window
List WS1 and list WS2 Clicking the List WS1 and List WS2 buttons displays a table with the friction
coefficients for each rewinder drive.

Figure 143: Friction coefficients pop-up window - Winding side 1

6.7.1.1 Rewinder drive selection

Figure 144: Rewinder drive selection table

The desired drives can be selected for a friction test by clicking the
corresponding checkbox.

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Selecting/deselecting all Clicking the Select/deselect all button selects all rewinder drives on both
winding sides for a friction test.
Selecting/deselecting a group Clicking the Select/deselect button selects all rewinder drives on the
corresponding winding side for a friction test.

Clicking on a drive in the selection table or a button displays data on

the selected drive the lower area of the screen.

Figure 145: Rewinder drive data

6.7.1.2 History

Figure 146: History

The recorded values are saved in files and can be viewed later in this pop up
window.

Pop-up window

Clicking the button opens the following pop up window:

Figure 147: Example of file view

To view the data for a specific rewinder drive, first navigate to the desired date
in the directory structure on the left. All saved files for this day are then
displayed in the center. These correspond to all friction tests of rewinder drives
performed on this day. The file name can then be used to select the desired
rewinder drive.

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The file name contains the following information: Date_Time_Rewinder_Drive.

The contents of the file are shown on the right. Below, the recorded values are
displayed in a graph.
Clicking the Delete Directory button deletes directories, thus removing days,
months or entire years from the tree.
Since CVS files are used to store the data, they can also easily be opened with
external programs such as Microsoft Excel.
It may also be expedient to connect the machine PC to your network to be able
to access the archived data from an external workstation.

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6.7.2 Rewinder drives

Figure 148: Rewinder drives

The rewinder drives on the machine are represented as icons with an "M" in the
overview.

6.7.2.1 Winding side

Figure 149: Rewinder drives

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Drives information

Clicking the button opens the following pop up window with drive
information:

Figure 150: Rewinding drive information pop-up window

The yellow and black button operates the corresponding drive independently of
the machine.

6.7.2.2 Rewinder drives error

The drive controllers are equipped with a warning and malfunction notification
system. In the event of a malfunction, a corresponding fault number with
description is output for the respective drive.
This information appears in a list in the bottom half of the screen.

Figure 151: Overview of rewinder drive errors

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6.7.3 Transport drives friction

Figure 152: Transport drives friction

This screen is used both to display and test the friction of the transport drives.
The determined friction is offset exactly for each drive during machine
operation. This ensures that the friction losses do not affect the control of the
transport drives.

Action buttons
Start Frict. Test Pressing the Start Frict. Test function key starts recording the friction curve.
The drive is operated at different speeds, thus determining the compensation
values.
Start Acc.Test Pressing the Start Acc. Test function key starts recording the compensation
values during acceleration. Here, the drive is accelerated to a moderate speed
and then decelerated.
Apply Values Pressing the Apply Values function key applies the newly recorded values as
the current friction curve. They are then saved to the machine.
Friction List Pressing the Friction List function key displays a list of the friction values. The
list can be printed out.

Pop-up window
Clicking the Friction List button opens a pop-up window.

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Figure 153: Friction list pop-up window

The current values of the selected drive, as well as both the old and new friction
value curve progressions, are shown at the bottom of the screen.

6.7.3.1 Transport drives friction

Figure 154: Transport drives friction

If the button is pressed, data for the selected drive is displayed at the
bottom of the screen.

Figure 155: Transport drive data

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6.7.3.2 Transport drive selection

Figure 156: Transport drive selection

Double-clicking on/touching the drive selects it for a friction test. The selection is
indicated by a check.

6.7.3.3 History

Figure 157: History

The recorded values are saved in files and can be viewed later in this pop up
window.

Pop-up window

Clicking the button opens the following pop up window:

Figure 158: Example of file view

To view the data for a specific transport drive, first navigate to the desired date
in the directory structure on the left. All saved files for this day are then
displayed in the center. These correspond to all friction tests of transport drives
performed on this day. The file name can then be used to select the desired
transport drive.
The file name contains the following information: Date_Time_Transport_Drive.
To view the data for a specific transport drive, first navigate to the desired date
in the directory structure on the left. All saved files for this day are then
displayed in the center. These correspond to all friction tests of transport drives
performed on this day. The file name can then be used to select the desired
transport drive.

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The file name contains the following information: Date_Time_Transport_Drive.

The contents of the file are shown on the right. Below, the recorded values are
displayed in a graph.
Clicking the Delete Directory button deletes directories, thus removing days,
months or entire years from the tree.
Since CVS files are used to store the data, they can also easily be opened with
external programs such as Microsoft Excel.
It may also be expedient to connect the machine PC to your network to be able
to access the archived data from an external workstation.

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6.7.4 Transport drives

Figure 159: Transport drives

The transport drives on the machine are represented as symbols with an “M” in
the overview.

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6.7.4.1 Machine

Figure 160: Transport drive diagnostics

Drives information

Clicking the button opens the following pop up window with drive
information:

Figure 161: Transport drive information pop-up window

The yellow and black button operates the corresponding drive independently of
the machine.

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Pop-up window

Clicking the button opens the following pop up window:

Figure 162: Winding side pop-up window

Output fields
Light barrier Status of the light barrier for scanning the contact roll lever.
To adjust the light barriers for activating the winding crossbars, the trigger point
of the light barrier on the contact lever should be set to the vertical position.
Winding crossbar linear position Current position of the winding crossbar (dependent on the winding diameter
that has been wound on).
Winding crossbar rotational posi- Current angle when the winding crossbar is swung out.
tion

6.7.4.2 Transport drives error

The drive controllers are equipped with a warning and malfunction notification
system. In the event of a malfunction, a corresponding fault number with
description is output for the respective drive.
This information appears in a list in the bottom half of the screen.

Figure 163: Overview of drive errors

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6.8 Service

6.8.1 VisiPar

Figure 164: VisiPar

This screen is for setting the machine parameters and is only available to start-
up personnel.
The minimum and maximum machine settings can be configured here.
The right part of the screen shows the available transport drives on the machine
for selection and the maximum overspeed.
In addition you can select which optional components are present on this
machine, and thereby activate the software for them.

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6.8.2 Machine parameters

Figure 165: Machine parameters

This screen is for setting the machine parameters and is only available to start-
up personnel.
Setting the travel ranges

Figure 166: Writing the travel ranges

Clicking the Write button enters the travel ranges of the winding arms and
knives. See Setting the travel ranges [} 193]
Resetting PLC position data

Figure 167: Resetting PLC position data

Clicking the Write button transfers input lists from the PC to the PLC. See
Reset PLC position data [} 194]

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See
2 Setting the travel ranges [} 193]
2 Reset PLC position data [} 194]

6.8.2.1 Winding side

Figure 168: Winding side

Min. position Max. position These are the minimum and maximum positions to which a winding arm can
travel. To determine these values, see Set Travel Limits below. The value is
entered in units of 1/100 mm, so 100 equals 1 mm.
Internal width / external width This refers to the dimensions of the individual winding arms. The [internal width]
is measured from the core holding point inwards; the [external width] is
measured from the core holding point to the back of the respective arm. The
sum is the total width of a winding arm. The value is entered in units of 1/100
mm, so 100 equals 1 mm.
Clamping width This is the dimension of the winding head, i.e. the depth of penetration of the
winding head into the core. The entire distance an arm travels when clamping
or releasing a core is the product of this value and the clamping stroke selected
on the Enter Slitting Pattern screen. The value is entered in units of 1/100
mm, so 100 equals 1 mm.

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Maximum torque This is the maximum torque exerted by the respective winding motor on the
core.

It is essential to enter zero for winding arms that have no winding

motor.

Maximum weight This is the maximum weight a winding arm can support. This value is input per
arm, i.e. 1000 kg for a 2 ton station.
Maximum contact pressure This is the maximum pressure the corresponding contact arm can produce. The
entry refers to one contact lever.

6.8.2.2 Top knives

Figure 169: Top knife

Min. position/Max. position These are the minimum and maximum positions to which a knife can travel. To
determine these values, see Set Travel Limits below. The value is entered in
units of 1/100 mm, so 100 equals 1 mm.
Left width/Right width This refers to the dimensions of the individual knives. The [left width] is
measured from the knife slitting point to the left viewed in the direction of
running of the machine and the [right width] is measured from the slitting point
to the right. The sum gives the total width of a knife. The value is entered in
units of 1/100 mm, so 100 equals 1 mm.

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6.8.2.3 Contact rolls

Figure 170: Contact rolls

The Contact Rolls tab is for specifying the various contact roll widths and
assigning them a color.
The width and color are then used on the Actual Slitting Pattern screen. This
allows the user to easily assign the correct contact roll.
Clicking on a color in the Color column opens a color pop-up.

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6.8.2.4 General

Figure 171: General

The General tab is for entering the following parameters:
Max. torque load This is the maximum load on the motors. When this percentage value is
reached, the system attempts to link motors.
Maximum number of motors This is the maximum number of motors that can be used at one station.
Maximum number of contact This is the maximum number of contact levers that can be used at one station.
levers
External coupling distance This is the distance between a coupled winding arm and the master station
when a coupling pin is used (winding arms are back to back). The value is
entered in units of 1/100 mm, so 100 equals 1 mm.
Internal coupling distance This is the distance between a coupled winding arm and the adjacent arm when
a coupling core is used (winding arms are positioned like normal stations). The
value is entered in units of 1/100 mm, so 100 equals 1 mm.
Parking distance This is the distance maintained when arms are being parked. The value is
entered in units of 1/100 mm, so 100 equals 1 mm.
Parking distance This is the distance maintained when arms are being parked. The value is
entered in units of 1/100 mm, so 100 equals 1 mm.
Difference between 3 / 6 inch Here the difference between the core mounting point of the 3” winding head and
clamping heads that of the 6” winding head. The positioning takes into account the dependence
between the individual winding heads that are used.

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6.8.2.5 Setting the travel ranges

Figure 172: Writing the travel ranges

Clicking the Write button offers an easy way to input the travel ranges for the
winding arms and knives in the tables described above.

Pop-up window
Clicking the Write button opens the following pop-up window:

Figure 173: Write travel ranges pop-up window

Entering the movement range of 1. Move all winding arms to their maximum position (left and right, viewed in
the winding arms the material running direction).
2. Click the corresponding Write button.
ð A prompt appears asking whether all winding arms are in their max-
imum position .
3. Confirm by clicking the Yes button.
ð The current positions are then written as the [minimum position]/
[maximum position].
Entering the movement range of 1. Perform [Find knives].
the knife
ð The actual positions of the knives will be sensed.
2. Release the knife brakes.
3. Move all knives by hand to their maximum position (left and right, viewed
in the material running direction).
4. Perform [Find knives].
ð The actual positions of the knives will be sensed.
5. Click the corresponding Write button.
ð A prompt appears asking whether all knives are in their maximum posi-
tion .
6. Confirm by clicking the Yes button.
ð The current positions are then written as the [minimum position]/
[maximum position].

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6.8.2.6 Reset PLC position data

Figure 174: Reset PLC position data

Clicking the Write button loads the following input lists from the PC to the PLC
(for instance after a CPU error or replacement):
– Winding side 1
– Winding side 2
– Top knife.
The in the data available in the PLC will be overwritten.

Pop up window
Clicking the Write button opens the following pop up window:

Figure 175: Reset PLC position data pop-up window

In order to replace the existing data with new data, the visualization program
must be restarted by clicking the OK button.

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6.8.3 Preset hardware

Figure 176: Preset hardware

6.8.3.1 Pivot position

Figure 177: Pivot position WS

Pivot position winding crossbar To set the winding crossbar pivot position encoder to a defined value, the
winding crossbar must be moved to a specific position. This is the maximum
vertical position (0.0 degrees) before switching to the pivot movement.
1. Move the winding crossbar into the corresponding position.
2. Click the Set button.
ð The encoder is set to the value determined during initial commissioning at
KAMPF.

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6.8.3.2 Winding crossbar WS position

Figure 178: Winding crossbar WS position

Winding crossbar position To set the winding crossbar position encoder to a defined value, the winding
crossbar must be moved to a specific position. This is the control position for a
minimum sleeve diameter.
1. Move the winding crossbar into the corresponding position.
2. Click the Set button.
ð The encoder is set to the value determined during initial commissioning at
KAMPF. This significantly simplifies setting, for example after a defective
encoder has been replaced or after disassembly.

Drives information

Clicking the button opens the following pop up window with drive
information:

Figure 179: Winding crossbar drive information pop-up window

The yellow and black button operates the corresponding drive independently of
the machine.

6.8.3.3 Diameter WS

Figure 180: Diameter WS

Rewinding diameter correction If the actual diameter differs from the display, this function can be used to make
a correction easily.

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1. Measure the actual diameter using a tape measure for instance.

2. Enter the measured value in the Diameter correction field.
3. Click the Set button.
ð A correction value is determined once (corr. = Din – Dcurr). This correction is
then continually summed so the display shows the actual diameter (Ddis-
play = Dcurr + corr.).

6.8.3.4 Position of lift-in unit unwinder

Figure 181: Position of lift-in unit unwinder

Lifting/lowering the unwinder In order to set the encoder for the unwinder lift-in unit to a defined value, the
unwind arms must be swiveled to the unwinding position, in the maximum top
position.
1. Move the unwind arms into the respective position.
2. Click the Set button.
ð The encoder is set to the value determined during start-up at KAMPF. This
significantly simplifies setting, for example after a defective encoder has
been replaced or after disassembly.

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6.8.4 Calibrate positioning

Figure 182: Calibrate positioning

This screen is used for calibrating the positioning of the knives and winding
levers.

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Winding side

Pop-up window

Clicking the button opens the following pop up window:

Figure 183: Calibrate positioning of winding side pop-up window

Winding arm information

Clicking the button opens the following pop up window with winding
arm information:

Figure 184: Winding lever information pop-up window

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Knife

Pop-up window

Clicking the button opens the following pop up window:

Figure 185: Calibrate positioning of top knife pop-up window

Knife information
Clicking the button opens the following pop up window with knife
information:

Figure 186: Knife information pop-up window

6.8.4.1 Setting the winding arm offsets

Setting the winding arm offset is divided into coarse adjustment and fine
adjustment.

Coarse adjustment
1. In the visualization, call up the Enter slitting pattern screen.
2. Enter a slitting pattern that is as evenly spaced as possible. A slitting pat-
tern with the maximum number of webs and equal slitting widths, such as
14 x 500 mm, is recommended.

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If the machine also has to be capable of carrying heavy-duty winding

heads, the slitting pattern selected must be one for which those heavy-
duty winding heads can be used. In this case the winding arms must be
equipped with the heavy-duty winding heads.
3. Check the slitting pattern.
4. Accept the slitting pattern.
5. In the visualization, call up the Calibrate positioning page.
6. Call up the pop-up window Winding side 1 or Winding side 2 and if ne-
cessary make further adjustments.

Figure 187: Winding arm positioning calibration pop-up window

ð The Set position column contains the set positions of the previously
verified slitting pattern.
7. Change the values so that the value "0" is shown throughout the Offsets
column.
ð The Target position column contains the distances of the individual
winding arms from each other.
8. On the visualization, call up the Manual Control screen.
9. Change the positioning to [Manual].
10. Move the winding arms manually so that the previously calculated slitting
pattern is generated.
11. Use a tape measure to check the slitting pattern.
12. Define the position of the first winding arm.

The machine zero position is given by the maximum material width

that can be entered. If this maximum material width is within the
machine, the left edge of the material is the machine zero position.
Example: The maximum material width is 8700 mm. The space
between the two sides of the machine frame is 9200 mm. The zero
position is then (9200 mm – 8700 mm)/2 = 250 mm from the left hand
side of the machine.

ð The position of the first lever is distant from the zero position by the
readable set position.
ð All winding arm positions are now calibrated.
ð All winding arms are in their correct position.

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13. In the Offset column, input the offset value of the respective winding arm.
The offset value is calculated as the difference between the target posi-
tion and the actual position (shown in the Actual positioncolumn).
ð This completes the coarse adjustment

Fine adjustment
Fine adjustment of the winding arms can be performed at any time and need
not be preceded by coarse adjustment.
ü Suitable offsets have been entered.
1. In the visualization, call up the Enter slitting pattern screen.
2. Enter a slitting pattern that is as evenly spaced as possible. A slitting pat-
tern with the maximum number of webs and equal slitting widths, such as
14 x 500 mm, is recommended.
If the machine also has to be capable of carrying heavy-duty winding
heads, the slitting pattern selected must be one for which those heavy-
duty winding heads can be used. In this case the winding arms must be
equipped with the heavy-duty winding heads.
3. Check the slitting pattern.
4. Accept the slitting pattern.
5. In the visualization, call up the Calibrate positioning page.
6. Call up the pop-up window Winding side 1 or Winding side 2 or the
pop-up window for an individual winding arm.

Figure 188: Winding arm positioning calibration pop-up window

Figure 189: Winding lever information pop-up window

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7. Use a tape measure to measure the positions of the winding arms and
compare the measurements with the values in the Set position column
(find the difference).
8. If differences from the actual measured distances are found, enter these
into the Correction column. The correction is entered in units of 1/100
mm, i.e. 100 equals 1 mm. A positive value moves the respective lever to
the right as seen from the material running direction and a negative value
moves the respective arm to the left.
9. Apply the correction values by clicking the Set Correction button.
ð When the winding arms are positioned again, their positions are corrected
accordingly.

6.8.4.2 Setting the knife offsets

Setting the knife offsets is divided into coarse adjustment and fine adjustment.

Coarse adjustment
1. In the visualization, call up the Input slitting pattern screen.
2. Select a slitting pattern that is as evenly spaced as possible. A slitting
pattern with the maximum number of webs and equal slitting widths, such
as 8 x 350 mm, is recommended.
3. Checking the slitting pattern.
4. Loading the slitting pattern.
5. In the visualization, call up the Calibrate positioning screen.
6. Call up the pop-up window Knife and if necessary make further adjust-
ments.

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Figure 190: Calibrating top knife positioning

ð The Set position column contains the set positions of the previously
verified slitting pattern.
7. Change the values so that the value “0” is shown throughout the Offsets
column.
ð The Set position column contains the distances of the individual
knives from each other.
8. Move the knives manually so that the previously calculated slitting pattern
is generated.
9. Use a tape measure to check the slitting pattern.
10. Define the position of the first knife.

The machine zero position is given by the maximum material width

that can be entered. If this maximum material width is within the
machine, the left edge of the material is the machine zero position.
Example: The maximum material width is 8700 mm. The space
between the two sides of the machine frame is 9200 mm. The zero
position is then (9200 mm - 8700 mm)/2 = 250 mm from the left hand
side of the frame.

ð The position of the first knife is distant from the zero position by the
readable set position.
ð All knife positions are measured.
ð All knives are in their correct position.

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11. In the Offset column, input the offset value of the respective knife. The
offset value is calculated as the difference between the set position and
the actual position (shown in the Actual position column).
ð This completes the coarse adjustment

Fine adjustment
Fine adjustment of the knives can be performed at any time and need not be
preceded by coarse adjustment.
ü Suitable offsets are input.
1. In the visualization, call up the Input slitting pattern screen.
2. Select a slitting pattern that is as evenly spaced as possible. A slitting
pattern with the maximum number of webs and equal slitting widths, such
as 8 x 350 mm, is recommended.
3. Checking the slitting pattern.
4. Loading the slitting pattern.
5. In the visualization, call up the Calibrate positioning screen.
6. Use a tape measure to measure the positions of the knives and compare
the measurements with the values in the Set position column (find the dif-
ference).
7. If differences from the actual measured distances are found, compensate
these in the Correction column. The correction is entered in units of 1/100
mm, i.e. 100 equals 1 mm. A positive value moves the knife to the right
as seen from the material feed direction and a negative value moves the
knife to the left.
8. Apply the correction values by clicking the Apply Correction button.
ð When the knives are positioned again, their positions are corrected accord-
ingly.

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6.8.4.3 Copying offsets between VisuPC and PLC

This function allows offsets to be copied between the hard disk and the
application. This is useful if it is necessary to restore the offsets either from the
hard disk or from the application.

Figure 191: Copying offsets between hard disk and application

Figure 192: Copying procedure pop-up window

Figure 193: Offsets pop-up window

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6.9 Alarm

6.9.1 Alarms

Figure 194: Alarms

The Alarms screen shows the currently pending alarms and warning messages.
The messages are displayed in different colors according to the reporting
category. This enables messages to be filtered accordingly. The action buttons
are used to select the reporting category.
If not statically set by the machine, existing messages can be reset by clicking
the Ackn. all or Ackn. Selection button.
The messages are sorted by date and time of entry.

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6.9.2 Alarm archive

Figure 195: Alarm archive

Using the archive files, it is possible to track the various message sequences at
a later time
The archive files are time stamped, i.e. one file is generated per day. The name
of the file is that day's date.
Each message in the archive is also time stamped.

6.9.2.1 Filtering options

Figure 196: Filtering options

The filtering settings permit selection and display of messages by specific
periods of time, by groups, classes or statuses.

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6.9.3 Logbook

Figure 197: Log book

The logbook shows the record of changes in the values and changes in the
status.
The messages are sorted by date and time of entry.

6.9.3.1 Filtering options

Figure 198: Filtering options

The filtering settings in the upper part of the screen permit selection and display
of messages by specific periods of time, by categories and events.

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6.10 Machine status

Figure 199: Conditions

This screen contains all the conditions for the machine.
The conditions shown here can also appear on other screens where
appropriate.
The various function units of the machine have conditions that show yellow or
green to indicate whether the function unit is enabled. Green
indicates[condition present], yellow [condition not present].

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6.11 Statistics

6.11.1 Variable trending

Figure 200: Trend variabel

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6.11.1.1 Table
The process values are selected by entering the appropriate PLC address in the
DB no. and DBD no. columns. The necessary addresses can be found in the
data block lists in the PLC program. The Name, Unit and Maximum columns
should also be populated.

Figure 201: Table

Pop-up window
Clicking the Save Table button opens the following pop-up window:

Figure 202: Save Table pop-up window

Clicking the Save saves the entered table under a freely selectable name.
Clicking the Load Table button opens the following pop-up window:

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Figure 203: Load Table pop-up window

Clicking the Load button loads a table selected from the list.

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6.11.1.2 Diagram
The Variables Trending graph continuously records up to 6 different process
values and displays them as a curve.
Because process values with different units and maximum values are shown in
a graph, the y-axis is shown scaled in percent [%]. This means 100%
corresponds to the value in the Maximum column.

Figure 204: Diagram

Once a table is loaded/an address changes, the corresponding process value is
recorded. This should be taken into account when looking at the historical trend.
Clicking the Pause / Play button switches between [Online mode] (graph is
continuously updated) and [Offline mode] (graph is frozen).
In [Offline Mode] the scroll buttons can be used to select the desired period.
The zoom buttons can be used to expand both the time axis and the y-axis.
To find the process values for the specific time, use the mouse/touchscreen to
set the cursor at the desired position. The exact time is displayed next to the
cursor. The process values for that time can then be read in the Marked values
column in the table.

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6.11.2 Rewinder trend

Figure 205: Rewinder trend

During a rewinding cycle, the current winding tension and contact pressure of
each roll are recorded and shown on graphs.
Only the winding stations being used for the current slitting pattern are shown.

6.11.2.1 History

Figure 206: History

The recorded values are saved in files so they can be viewed later.

Pop-up window

Clicking the button opens the following pop up window:

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Figure 207: File view pop-up window

To view the data for a specific roll, first navigate to the desired date in the
directory structure on the left. All saved files for this day are then displayed in
the center. These correspond to all finished rolls wound on this day. The file
name can then be used to select the desired roll.
The file name contains the following information:
Date_Time_Winding_Side_Station.
The contents of the file are shown at right. Below, the recorded values are
displayed in a graph.
Clicking the Delete Dir button deletes directories, thus removing days, months
or entire years from the tree.
Since CVS files are used to store the data, they can also easily be opened with
external programs such as Microsoft EXCEL.
It may also be expedient to connect the machine PC to your network to be able
to access the archived data from an external workstation.

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6.11.2.2 Station

Figure 208: Station

The X-axis is automatically scaled based on the set run length and specified
rewinding diameter.
The Y-axis is dynamically scaled during winding based on the maximum values
recorded.
The displays for rewinders 1 and 2 are shown on two independent screens.

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6.11.3 Production data

Figure 209: Production data

The Production data screen allows you to display the production data for the
current machine run.

Pop-up window
Clicking on Production files opens a pop-up window.

Figure 210: Production files pop-up window

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Selection fields
File name/date of change Based on the file name or date of change, the pop-up window allows stored
production reports to be selected and displayed.

Function keys
Print File Pressing the Print File button allows the selected reports to be printed.

6.11.3.1 Production information

Figure 211: Production information

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6.11.3.2 Unwuinder

Figure 212: Unwuinder

6.11.3.3 Winding side

Figure 213: Winding side

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6.11.4 Shift data

Figure 214: Shift data

The Shift data screen breaks down work shifts and allows you to track
production data for each shift.
The shifts are tailored to the operator, for example day shift, late shift and night
shift.

Selection fields
Team The team for the corresponding shift is selected here.

Input fields
Start time The start time of the corresponding shift is entered here.
Shift end The time for the end of the corresponding shift is entered here.

Action buttons
Reset By clicking the respective Reset button, the displayed shift reports, daily report
or monthly report are reset.

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6.12 Help and documentation

6.12.1 Help
A description of the display from the operating instructions of the machine is
given here.
Individual screens or the entire file can be printed.

Figure 215: Help

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6.12.2 Circuit diagrams

Circuit diagrams for the machine are shown here.
Individual screens or the entire file can be printed.

Figure 216: Circuit diagrams

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6.12.3 Kampf service portal

This screen provides access to online help from Kampf service technicians
(Internet connection required).
After opening the Kampf Service Portal (KSP), a new window appears where
access information is entered.

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6.12.4 Kampf spare parts

This function key allows you to start the spare parts catalog (ESPAC).

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6.13 VisiWinNET Text Manager

NOTE
Self-made changes/translations of texts can lead to misunderstand-
ings and incorrect operation!
Self-made changes/translations can lead to incorrect or misleading terms in the
visualization. There is a risk that operators will not understand terms and oper-
ate the machine incorrectly. The reference between the visualization and the
operating instructions can be lost.
KAMPF assumes no liability for self changed or translated texts in the
visualization.
Be aware of the dangers of changing or translating texts yourself.
Change texts so that the meaning of the text is not changed.
Make sure that the operating personnel understand the self changed or trans-
lated terms.

Figure 217: Desktop

Start the VisiWinNET TextManager by clicking the appropriate icon on the
screen

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6.13.1 Selecting the project file

Figure 218: Selecting the project file

Selecting the project file: The name of the project file is always 'C:\VisiwinNet\Projects\XXXXXX
\XXXXXX.VWN', where 'XXXXXX' is the commissioning number of the machine.

Exporting the text from the display application:

1. Click the button.

ð A dialog box opens.
2. Select a project file.
3. Click the Export tab.
4. Select the languages to be exported. For translation, these should be the
source language and the target language.
5. Click the Select Text Groups button.
ð A dialog box opens.
6. Select the text to be exported.
ð The texts are exported.

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6.13.2 Selecting groups

Figure 219: Selecting groups

Selecting all groups

1. Click the All button.
ð All text groups are selected for export.

Selecting no group
1. Click the None button.
ð All text groups are deselected.

Selecting certain groups

It is also possible to select only certain text groups for export. This offers the
advantage that the export file contains only the desired text and thus is clear.

6.13.2.1 FCentral

Figure 220: FCentral

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In this example, only the [FCentral] screen (home screen) is selected. The
Application group contains all screen text (labels, buttons, etc.). The various
screens appear under their heading in the Application group.

6.13.2.2 ItemSystem

Figure 221: ItemSystem

In this example, [ItemSystem] is selected. This group contains all the
designations of the input/output values, e.g. [Unwinder linear draw],
[Current machine speed], etc.

6.13.2.3 AlarmSystem

Figure 222: Alarm System

In this example, [Alarm System] is selected. This group contains all alarms.

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6.13.2.4 Machine Conditions

Figure 223: Machine Conditions

In this example, the [Application/FMchCond] group is selected. This group
contains all text relating to machine conditions. The machine condition ([Cond1],
[Cond2], etc.) to be exported can also be selected or deselected.
After the desired text group has been selected, the file with the exported text
can be named. This file is a Microsoft Excel file and can be edited using
Microsoft Excel, Open Office or other program capable of editing Excel files.

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6.13.3 Exporting text from display applications

Figure 224: Exporting text

ü A project file has been selected.
ü The languages to be exported have been selected.
ü The texts to be exported have been selected.
1. Click the Export button.
ð The file is written.
ð The export file can then be copied and edited using Microsoft Excel, Open
Office or other program capable of editing Excel files.
Once editing is complete, the edited text can be re-imported into the display
application.

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6.13.4 Importing text into display applications

The import program can import text, processing only the lines that are identical
in the specified language. These identical lines are imported for the target
language.

Example:
There is a project in German and English. A text file has been selected for
translation into [French] as the target language. In the meantime, texts in
English have been modified. When you re-import the file, you only want to
import the text that is still unchanged in English (because otherwise the French
text would be wrong). This scenario is feasible for alarm notifications for which
the cross-reference changes.

Figure 225: Importing text

1. Select the Import tab.

2. Click the button.

ð A dialog box opens.
3. Select a project file.
4. Select the languages to be imported.
For a translation, this should be the target language. In general, it is ne-
cessary (and safer) to import only the languages that have been modi-
fied.
5. Click the Import button.
ð The import is executed.
ð The new texts have been imported into the visualization program.

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7 Operation
Heed the following information when operating the machine:
– Observe and comply with the instructions listed in the Safety chapter.
– Ensure without exception compliance with the technical specificationsstated
in the Technical Data chapter.
– Do not change factory-set control parameters.
Prior to initial commissioning:
– Check the oil level and lubricating devices. Set all operating and con-
troldevices at the operating stations to their home position.
– Check that electrical and pneumatic connections are functioningproperly.

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7.1 Operating elements and control elements

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 Operation | 7

7.1.1 Overview of operating elements and control

elements
Symbol Meaning Explanation
Spare

Indicator lamp

Pushbutton

Quick stop

Illuminated pushbutton

Selector switch

Illuminated selector
switch

Selector switch

Illuminated lockable se-

lector switch

Key switch or
lockable key switch
USB-Interface
USB

Emergency stop control

device
I
Main switch
O

Potentiometer
Analog

Display Analog

Display Digital
8888

Rocker switch

Rotary handle

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7 | Operation

Symbol Meaning Explanation

Manual lever valve

Pushbutton valve

Foot switch

Tab. 3: Operating elements

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 Operation | 7

7.1.2 Overview of the control panels

3 2 1

4
5

9 10

6 11 12 7 8

Figure 226: Overview of the control panels

1 Control panel +CD 2 Control panel +OB8
3 Control panel, web edge control 4 Control panel +OB1
5 Control panel, unwinder remote 6 Control panel +OB7
control
7 Control panel +OB2 8 Control panel +OB3
9 Control panel, WS 1 winding 10 Control panel, WS 2 winding
lever lever
11 Control panel, pneumatics: Shut- 12 Control panel, main switch
off valve and pressure-reducing
valve

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7 | Operation

7.1.3 Control panel +CD

3
USB

4 5

6 7 8 9

10 11 12 13 14 15

16 17 18 19 20 21
2

22 23 24 25 26 27

28 29 30 31 32 33

34

Figure 227: Control panel +CD

No. Label Explanation

1 - Screen
2 - Keyboard
3 - USB interface
4 - Emergency stop device. Triggers the emergency
stop function.
5 - Emergency stop device. Triggers the emergency
stop function.

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 Operation | 7

No. Label Explanation

6 Control voltage 0/I Switches the control voltage off or on.
7 Fault Lights up in the event of a fault.
8 Reset Must be actuated after a fault is corrected.
9 Jog machine Machine drives run at jog speed.
10 - Spare
11 - Spare
12 - Spare
13 Machine on Flashing slowly: The machine can be switched on.
An audible signal is emitted when pressed. Flash-
ing quickly: Press again to switch on. Lights up:
The machine is switched on.
14 - Spare
15 Setup/production Operating mode selection. Setup: Operation is pos-
sible with open safety doors at jogging speed. Pro-
duction: The security doors must be closed.
16 - Spare
17 - Spare
18 - Spare
19 Machine off All drives are reduced to zero speed and switched
off.
20 - Spare
21 - Spare
22 WS 2 On Switches on all rewinder drives on winding side 2
selected by the slitting pattern. Flashes when the
rewinder drives on winding side 2 can be switched
on. Lights up when the rewinder drives are on.
23 - Spare
24 WS 2 swivel in Winding crossbar on winding side 2 is swiveled in
and positioned horizontally. Lights up when the
winding crossbar is in web handing position.
25 WS 1 swivel in Winding crossbar on winding side 1 is swiveled in
and positioned horizontally. Lights up when the
winding crossbar is in web handing position.
26 - Spare
27 WS 1 On Switches on all rewinder drives on winding side 1
selected by the slitting pattern. Flashes when the
rewinder drives on winding side 1 can be switched
on. Lights up when the rewinder drives are on.
28 WS 2 Off Switches off all rewinder drives on winding side 2
selected by the slitting pattern. All rewinder drives
on winding side 2 are reduced to zero speed and
switched off.
29 WS 2 Clamp all All winding stations on winding side 2 for the slitting
pattern are clamped.
30 WS 2 swivel out Winding crossbar on winding side 2 is retracted ho-
rizontally and swiveled out.
31 WS 1 swivel out Winding crossbar on winding side 1 is retracted ho-
rizontally and swiveled out.
32 WS 1 Clamp all All winding stations on winding side 1 for the slitting
pattern are clamped.

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7 | Operation

No. Label Explanation

33 WS 1 Off Switches off all rewinder drives on winding side 1
selected by the slitting pattern. All rewinder drives
on winding side 1 are reduced to zero speed and
switched off.
34 Service 0/I Switches the "Service" mode off or on.

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 Operation | 7

7.1.4 Control panel +OB8

1 2

3 4

5 6

7 8

Figure 228: Control panel +OB8

No. Label Explanation

1 Swiveling the dan- -
cer roll out/in
2 Spreader roll -/+ Changes the swivel angle of the spreader roll.
3 Jogging the Moves the threading chain at jog speed.
threading chain
4 Light table Off/On Switches the lighting of the light table off or on.
5 Scanning head os- Switches the oscillation of the scanning head off or
cillation off/on on.
6 - Spare
7 Scanning head ←/ Moves the scanning head to the left or right.
→
8 Centering the Centers the scanning head. Lights up when the
scanning head scanning head is centered.
9 - Emergency stop device. Triggers the emergency
stop function.

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7.1.5 Control panel, web control

Figure 229: E+L control unit

The web control can operate in three modes:
– Automatic mode
– Center position
– Manual mode
Automatic mode The lateral displacement of the unwinder and thus of the material web usually
takes place automatically based on the unwinding line or material edge. To do
this, press the button (automatic). Web displacement can be performed
using the or buttons (web displacement/manual adjustment).
Center position When setting up the unwinder, you can automatically align it centrally to the
machine axis. To do this, press the button (center position). After
centering has been carried out, the system normally switches back to automatic
mode before starting a new winding process, otherwise no automatic lateral
shift will be performed.
Manual mode
For manual mode, press the button (manual mode). The or
buttons (web displacement/manual adjustment) can then be used to initiate the
desired lateral shift of the unwinder. This may be necessary for instance in
order to align the parent roll with the material in the machine after a parent roll
change.

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7.1.6 Control panel +OB1

2 3 4 5 6

7 8 9 10 11

12 13 14 15 16

17 18 19 20 21

Figure 230: Control panel +OB1

No. Label Explanation

1 - Emergency stop device. Triggers the emergency
stop function.
2 Release unwinder Releases the brake in the unwinder.
brake
3 - Spare
4 - Spare
5 - Spare
6 - Spare
7 - Spare
8 Chuck cones -
9 Unwind from top/ Material unwinds from top or bottom.
bottom
10 - Spare
11 - Spare
12 Machine speed -/+ Adjusts the machine speed.
13 Loosen cones -
14 Unwinder lowering/ The unwind arms of the unwinder are swiveled
lifting down or up.
15 - Spare
16 Jog unwinder Unwinder drives move at jog speed.
17 Jog machine Machine drives run at jog speed.
18 - Spare
19 - Spare
20 - Spare
21 - Spare
22 Machine off All drives are reduced to zero speed and switched
off.

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7 | Operation

7.1.7 Control panel, unwinder remote control

Figure 231: Remote control, unwinder

No. Label Explanation

1 → The unwind arms of the unwinder move together.
2 ← The unwind arms of the unwinder move apart.
3 ↑ The unwind arms of the unwinder are swiveled up.
4 ↓ The unwind arms of the unwinder are swung down.

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7.1.8 Control panel +OB7

Figure 232: Control panel, emergency stop device

No. Label Explanation

1 - Emergency stop device. Triggers the emergency
stop function.

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7 | Operation

7.1.9 Control panel +OB2

8888 1

2
3

4 5

6 7

Figure 233: Control panel +OB2

No. Label Explanation

1 - Position display for preselected knife holder or
winding lever on winding side 1 (preselection via
movement).
2 - Spare
3 - Preselection of knife holder or winding lever
4 - Spare
5 - Spare
6 - Spare
7 - Spare
8 - Emergency stop device. Triggers the emergency
stop function.

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 Operation | 7

7.1.10 Control panel +OB3

8888 1

3
2

Figure 234: Control panel OB 3

No. Label Explanation

1 Position of winding Position display for preselected winding lever on
lever WS 2 winding side 2 (preselection via movement).
2 - Preselection winding lever
3 - Spare
4 - Emergency stop device. Triggers the emergency
stop function.

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7 | Operation

7.1.11 Control panel winding lever 1

1 2

Figure 235: Control panel winding lever 1

No. Label Explanation

1 ←→ Moves the winding lever.
2 Machine drives run at jog speed.

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7.1.12 Control panel winding lever WS 2

1 2

Figure 236: Control panel winding lever WS 2

No. Label Explanation

1 ←→ Moves the winding lever.
2 Machine drives run at jog speed.

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7 | Operation

7.1.13 Pneumatics control panel: Shut-off valve and

pressure reducer
1

Figure 237: Control Panel pneumatics

No. Label Explanation

1 - Pressure reducer. Adjusts the pneumatic pressure.
2 - Shut-off valve. Switches the pressure supply to the
machine on or off.

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7.1.14 Control panel with main switch

Figure 238: Control panel with main switch

No. Label Explanation

1 - Pressure reducer. Adjusts the pneumatic pres-
sure.

7.2 Preparing the machine for operation

CAUTION
Moving machine parts
Moving parts can cause crushing and cutting injuries.
1. Do not reach into the work area.
2. Do not open or remove protective devices while the machine is operating.

ü All selector switches and control pendants are in the zero or home position.
ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Open the pneumatic pipe shut-off valve.
2. Set the system pressure at the pressure reducer.
3. Switch on the main power.
ð The PC boots, the main menu appears on the screen (main control
console).
ð Hardware control panels are not yet functional.
4. Switch on the control voltage.
ð The indicator lamp Trouble lights up.
ð All hardware control panels are functional.
5. Release all emergency stop control devices.
6. Reset faults; if necessary, check warnings in the visualization and rectify
remaining faults.
ð The indicator lamp Trouble goes off.
ð The lamp Control Voltage On lights up.
ð The machine is prepared for operation.

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7.3 Unwinder

7.3.1 Setting up the unwinder

CAUTION
Moving machine parts
Moving parts can cause crushing and cutting injuries.
1. Do not reach into the work area.
2. Do not open or remove protective devices while the machine is operating.

ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü There is no parent roll or empty core in the unwinder.
1. Open the unwinder brake.
2. Equip the unwind arms with chucking heads/adapters according to the
core inside diameter.
3. Center the web edge control using the control panel for the web edge
control.
4. Set the web edge control to [0] on the control panel for the web edge con-
trol.
5. Lower the unwind arms.
6. Release the chucking heads (not applicable when equipped with chuck-
ing cones).
ð The clamping jaws move into the chucking head. The chucking head
can now accept a new core.
7. Move the unwind arms apart.
ð The unwind arms are sufficiently far apart that a new core can be taken
up.
8. Raise and center a new parent roll axially and radially between the
chucking heads.
NOTE! The web guide can be damaged if the unwind core is not
centered axially and radially between the chucking heads.
9. Move the unwind arms together.
ð The chucking heads are now inserted correctly in the core.
10. Clamp the chucking heads (not applicable when equipped with chucking
cones).
11. Raise the unwind arms until the parent roll is in the unwind position.
12. Remove every handling device from the unwinder area.
13. Center the parent roll with respect to the machine axis.
14. Close the brake in the unwinder.
15. Adapt the visualization screen to the material being processed, e.g.
- length and diameter selections for the unwinder
- parent roll width
- material thickness
- brake tension

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- material density
- starting diameter of the new parent roll.
- Parent roll direction of rotation
16. Select the direction of rotation of the parent roll.
ð The unwinder is now set up.

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7.3.2 Installing/removing the chucking head

The unwinder must be equipped with chucking heads corresponding to the
inside diameter of the unwind core.

NOTE
Only use chucking heads with a clamping range that matches the
inside diameter of the core.
Failure to comply will result in functional failure and the premature wear or fail-
ure of components.
1. Measure the inside diameter of the core.
2. Select and mount suitable chucking heads.

The following tools are needed:

– Torque wrench (80 – 150 Nm, not included with delivery of the machine)
2

Figure 239: Chucking head (e.g. 3" chucking head)

1 Chucking head 2 Cylinder head screw
ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Switch off the control voltage and remove the key.
NOTE! Secure the unit against being switched on again, which means
that the key must not be accessible to unauthorized individuals.
2. Secure both chucking heads against falling.
CAUTION! Crushing hazard! The chucking heads can fall down after
releasing the screw connections. Be aware of the net weight of the
chucking heads (see table)!
3. Release all cylinder head screws.
4. Remove both chucking heads from the drive shafts.

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5. Inspect the following factors of the chucking heads to be installed, prior to

installation:
- Expansion and retraction of the clamping segments.
- Clamping segment wear.
- Visible inspection for any damage that may be present.
6. Clean and lubricate the fitting surfaces of the chucking heads.
7. Push the chucking heads onto the drive shafts.
8. Mount the cylinder head screws again.
9. Use a torque wrench to tighten the cylinder head screws to the specified
tightening torque (see table).
10. Switch on the control voltage.
ð The chucking heads have now been changed.

NOTE
Observe the tightening torque for the screws!
Failure to comply will result in functional failure and the premature wear or fail-
ure of components.

Tightening torques and strength class of the cylinder head

screws for chucking heads
Chucking head Cylinder head Tightening torque Net weight
type screw
Thread x length
in mm Strength
class
3" chucking head M10x45 12.9 83 Nm 20 kg
6" chucking head M10x45 12.9 83 Nm 15 kg
8" chucking head M12x50 12.9 145 Nm 25 kg
Stepped chucking M10x45 12.9 83 Nm 30 kg
head, 3" and 6"
Stepped chucking M12x90 12.9 145 Nm 44 kg
head, 3" and 6"

7.3.3 Changing the parent roll

To change the parent roll in the unwinder, the machine speed is reduced to zero
using one of the following options and the center drive is switched off:
– Pre-selection of length for the unwinder
– Pre-selection of diameter for the unwinder
– Pressing a Machine Off push button.

CAUTION
Moving machine parts
Moving parts can cause crushing and cutting injuries.
1. Do not reach into the work area.
2. Do not open or remove protective devices while the machine is operating.

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7 | Operation

ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Release the unwinder brake.
2. Lower the unwind arms.
ð The unwind arms are lowered to the point at which a new parent roll
can be loaded.
3. Relax the chucking head (not necessary when equipped with clamping
cones).
CAUTION! Crushing hazard. A falling core can crush limbs. Secure the
unwind core against falling.
4. Move the unwind arms apart so that the unwind core can be removed.
5. Remove the unwind core.
6. Center the unwind core with a new parent roll axially and radially between
the chucking heads.
NOTE! If the unwind core is not centered axially and radially between
the chucking heads, the web control system may be damaged.
7. Move the unwind arms together.
ð The chucking heads are now inserted correctly in the core.
8. Clamp the clamping heads (not applicable when equipped with clamping
cones).
9. Raise the unwind arms until the parent roll is in the unwind position.
10. Set the operating mode of the web control to [Manual mode].
11. Align the scanning head for the web control to the edge of the material.
12. Pull in the beginning of the material web in line with the material web
guide
13. Align the material web to the end of the existing material web in the ma-
chine.
14. Tape the start of the material web and the end of the material web to-
gether along a straight edge.
15. Set the operating mode of the web control to [Automatic].
16. Apply the brake in the unwinder.
17. Open the Main Menu page at the visualization.
18. Adjust the visualization screen to the material being processed, e. g.
- length and diameter preselections for the unwinder
- parent roll width
- material thickness
- brake tension
- material density
- starting diameter of the new parent roll
- direction of rotation of the parent roll
ð Changing of the parent roll is complete.

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7.4 Base machine

7.4.1 Setting up the edge trim suction unit

Setting up the edge trim suction unit consists of manually moving the two
suction nozzles to the corresponding position and fastening them in place with
the clamping screw.
ü The material web is drawn in, and the individual webs are wound in at the
winding cores.
1. Release the suction nozzles.
2. Align the suction nozzle according to the slitting pattern.
3. Fasten the suction nozzles in position.
4. Switch on the suction unit or set [Auto] operating mode for the suction
unit, if available.
5. Insert the edge trim into the respective suction nozzle.
ð The edge trim suction unit is now set up.

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7.4.2 Threading the material

CAUTION
Cut hazard at the cutting tool of the longitudinal slitting unit
When threading the material web there is a cut hazard at the cutting tool of the
longitudinal slitting unit.
1. Wear suitable protective gloves.
2. Avoid contact with the cutting tool.

ü The knife holders are withdrawn.

ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü The material web to be threaded must exhibit no material tangles.
1. Swing out the pendulum roll.
2. Jog the threading chain until the driving dog in the material threading
device is in the load position.
3. Release the unwinder brake.
4. Feed the material web by hand over the material web guides as far as the
driving dog of the material threading device.
5. Attach the material to the driving dog of the material threading device.
6. Apply the brake in the unwinder.
7. Jog the threading chain, at the same time driving the transport rolls and
the unwinder, until the material is fed as far as the bottom knife shaft.
8. Detach the material from the driving dog of the material threading device.
9. Jog the machine and the material web over the material web guides as
far as the winding side 2.
10. Move all knives into slitting position.
11. Jog the machine forward once again and transport the material to the
point where the cut webs emerge from the winding side 2.
12. Manually cut off the material that had not been slit.
13. Guide the cut off material webs according to the material guides to wind-
ing side 1 and winding side 2, adhesively bond them to the respective
winding cores and wind on until the material is taut.
14. Guide any edge trim to the suction nozzles of the edge trim suction unit.
15. Switch on edge trim suction unit.
16. Align the scanning head for the web control to the edge of the material.
17. Set the operating mode of the web control to [Automatic].
18. Switch on the ionization.
19. Switch on the rewinders.
ð Move the winding crossbars towards the base machine until the wind-
ing cores lie against the contact rolls and these apply pressure at the
correct point. The winding position has now been reached.
ð The winding drives are switched on and the material wound on until it
is taut.
ð The material has now been fully threaded.

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7.5 Longitudinal slitting unit

7.5.1 Removal and installation of the bottom knife shaft

The machine can be equipped with different bottom knife shafts depending on
the type of cutting. For example, a grooved knife shaft for blade cuts in grooves
or burst cuts, a radially clamping and air-expanding knife shaft for shear cuts, a
transport roll for blade cuts in air and others.

1
3

3
5

Figure 240: Bottom knife shaft can be rolled out

1 Bottom knife shaft 2 Coupling
3 Exit rail 4 Bearing shell
5 Nut
Depending on the desired type of cutting, the appropriate bottom knife shaft is
installed, if necessary equipped with the appropriate cutting tool:

NOTE
The nuts must only be loosened after the exit rails have been
mounted on both sides.
Consequences

ü The machine drives must be set to zero speed and be switched off.
ü All knives moved out.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Switch off the control voltage and remove the key.
NOTE! Secure the unit against being switched on again. That means
the key must not be accessible to unauthorized individuals.
2. Mount the exit rails.
3. Loosen both nuts and open the bearing shells.
4. Push the bottom knife shaft in the direction of the non driven side until the
coupling is released.
ð The drive connection to the bottom knife shaft is interrupted.

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7 | Operation

5. Carefully roll out the bottom knife shaft on the exit rails until the limit stop.
6. Lift the bottom knife shaft with the crane and a suitable hoist with the ne-
cessary care and place it on a suitable surface.
ð The bottom knife shaft is removed.
7. Mount the bottom knife shaft or transport roll corresponding to the desired
type of cutting in reverse order.
NOTE! Note the tightening torque of the nuts, 18 Nm!
8. Dismantle the exit rails.
9. Switch on the control voltage.
ð The removal and installation of the bottom knife is completed.

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7.5.2 Position the knife holders

The positioning of the knife holders according to the desired slitting pattern is
done manually. Knife holders that are not used in the slitting pattern are marked
as parked and are positioned in their respective parking positions.

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

7 8
1

2
5

6
9

4 3

Figure 241: Knife holders

1 Knife holders 2 Blade holder
3 Blade 4 Locking pin
5 Screw 6 Locking bar
7 Measuring rod or measuring 8 Star handle
scale
9 Connecting rod tighteners
ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü The surface of the locking bar is free of oil and grease.
ü The holding force of the connecting rod tighteners is at least 30 kg.
1. Open the slitting pattern screen in the visualization.
2. Set and accept a slitting pattern.
3. Loosen the locking pins of the blade holders, swing the blade holder to
the home position and let the locking pins engage again.
ð The blade holders are fixed in the home position.
4. Release the connecting rod tighteners of the knife holders.
5. Roughly align the knife holders according to the slitting pattern.
6. Turn the star handle for fine adjustment to move the knife holder.
7. Move the knife holder until the position indicator for the knife holder
shows 0.00 or the pointer of the measuring scale points to the correct di-
mension.

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7 | Operation

8. Lock the connecting rod tighteners of the knife holders.

ð The knife holders have been aligned according to the slitting pattern.

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7.5.3 Setting up the knife holders for blade cut

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

8
1 7

9
6

2 3 4 5
Figure 242: Blade holder
1 Knife holder 2 Blade holder
3 Fastening screw for blade holder 4 Hole for clamping pin (for the
or burst knife holder blade mirror cut slitting principle)
5 Hole for clamping pin (for the 6 Centering pins for blade (for the
blade groove cut slitting prin- blade mirror cut slitting principle)
ciple)
7 Centering pins for blade (for the 8 Lug
blade groove cut slitting prin-
ciple)
9 Clamping pin
ü The machine drives must be set to zero speed and be switched off.
1. Mount the blade holder on the knife holder with the fastening screw.
2. Release the clamping pin.
3. Remove the lugs.
4. Center the blade on the centering pins according to the type of cutting.
5. Attach the lug according to the type of cutting.
6. Tighten the clamping pin.
7. Set the cutting depth.
ð The knife holders are designed for blade cutting.

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7 | Operation

7.5.4 Check that there is no collision between the blade

and bottom knife shaft

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

Figure 243: Blade holder

(1) Locking pin
1. Release the locking pin.
2. Swing in the blade holder carefully and slowly, checking that the blade
penetrates into the bottom knife shaft without a collision.
In the event of collision, realign the blade holder and check again.

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7.5.5 Swinging the blade holders in/out

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

A B

1
3

Figure 244: Pivot positions

A Swung in B Swung out
1 Hole for locking pin (blade holder 2 Hole for locking pin (blade holder
is swung out) is swung in)
3 Locking pin
1. Release the locking pin.
2. Swing the blade holders.
3. Lock the blade holders with the locking pins.

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7 | Operation

7.5.6 Adjusting the slitting depth of the knife holders

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

Figure 245: Blade holder

1 Screw 2 Lug
3 Scale
1. Loosen the screw.
2. Adjust the lug.
ð The slitting depth changes. The setting can be read off the scale.
3. Tighten the screw.

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7.5.7 Changing the slitting angle

CAUTION
Sharp knife
Risk of being cut by sharp edges!
1. Do not touch cutting edge.
2. Wear protective gloves.

Figure 246: Blade holder

1 Screw 2 Lug
3 Scale
1. Loosen the screw.
2. Change the slitting angle.
ð The setting can be read off the scale.
3. Tighten the screw.

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7 | Operation

7.6 Rewinder

7.6.1 Contact roll unit

7.6.1.1 Changing the control circuit

The load pressure needed for winding is controlled by computer.
Every control circuit of the contact roll unit is associated with a proportional
pressure control valve (I/P converter). The I/P converter generates a pneumatic
pressure on the basis of the electrical value provided by the computer. The
pneumatic pressure is transmitted to the pneumatic cylinder of a contact roll
unit. Accordingly, the contact roll unit of every active winding station must be
associated with a corresponding control circuit. For example: Winding station
1.4 - Control circuit 4 or Winding station 2.3 - Control circuit 3.

7.6.1.2 Setting up the contact rolls

CAUTION
Laser radiation, laser class 2
Looking into a laser beam can injure the eye.
1. Never look into the laser beam.

NOTE
Possible malfunction due to absence of limit switch
The contact roll unit with the limit switch that monitors the moving away of the
rewind crossbar must be used. Operation is not possible without it.

The number of contact roll units used and the length of the contact roll depend
on the number of winding stations used and the web width. Unneeded contact
levers are moved into the parking space during setup and secured.

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2
2
1 3
3

Figure 247: Contact roll unit

1 Contact roll 2 Bearing cap
3 Contact lever 4 Pneumatic cylinder
5 Star handle

ü The machine drives are set to zero speed and switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Release the star handles.
2. Align the contact lever symmetrically to the material web being slit ac-
cording to the specified contact roll length.
3. Connect the limit switch using the plug connector and pneumatic connec-
tion according to the slitting pattern.
NOTE! If one contact lever needs to be moved, release the pneumatic
connection as required.
4. Open the bearing cap.
5. Place the contact roll into the open bearing cap according to the web
width.
6. Close the bearing cap
7. Check the position of the contact roll unit relative to the web width, cor-
rect it if necessary and lock the contact lever using star handles.
ð The contact roll is now set up.

7.6.1.3 Coupling the contact lever

CAUTION
Laser radiation, laser class 2
Looking into a laser beam can injure the eye.
1. Never look into the laser beam.

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7 | Operation

If the calculated contact pressure for the desired slitting width, the desired
finished roll diameter or the desired winding tension cannot be achieved, the
contact pressure must be increased. The operator is notified of this on the
screen.
The contact pressure is increased by connecting the contact lever to an
unneeded, adjoining contact lever via a pin. The pneumatic connections must
then be made accordingly. In this way, the contact pressure is generated by
three or four cylinders (option).

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7.6.2 Installing/removing a winding head with central

screw
Depending on the winding cores to be clamped and the drive motors used, the
winding levers must be equipped with the suitable winding heads (mechanically
expanding winding heads, take-up disks or idle heads).
On the driven lever, the winding core is held by a mechanically expanding
winding head which clamps the winding core radially if the direction of rotation is
in the material movement direction.
A take-up disk is fitted on the non-driven lever.
In special cases, idle heads are placed on one of the driven levers of a winding
station in order to achieve low winding tension. The operator is notified of this
on the screen.

NOTE
Only use winding heads with the same outside diameter on one
winding side.
Consequences

The following tools are needed:

– Torque wrench (30 – 70 Nm, not included with delivery of the machine)
– Locking tool (included with delivery of the machine)

Figure 248: Winding head with central screw

1 Central screw/cylinder head 2 Winding head
screw

ü The machine drives must be set to zero speed, and switched off.
ü No winding cores are fitted.
ü All required safety precautions must have been taken, e.g. cordoning off, in-
formation given to operating personnel, etc.
1. Switch off the control voltage and remove the key.
NOTE! Secure the unit against being switched on again. That means
the key must not be accessible to unauthorized individuals.

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7 | Operation

2. Loosen the cylinder head screw.

3. Pull the winding head to be removed off the drive shaft.
4. Remove any winding residue and remove any dirt from the removed
winding head, then store it.
5. Inspect the winding head to be installed for the following prior to installa-
tion:
- Expansion and retraction of the clamping segments.
- Clamping segment wear.
- Visible inspection for any damage present.
6. Clean and lubricate the winding head fitting surfaces.
7. Slide the winding head to be installed onto the drive shaft.
8. Using the torque wrench, tighten the cylinder head screw to the specified
tightening torque (see below).
9. Following installation, remove excess grease with a cloth.
10. Switch on the control voltage.

NOTE
Observe the tightening torque for the screws!
Failure to comply will impair operation and result in the premature wear or fail-
ure of components.

Tightening torques and strength classes for cylinder head

screw in winding head
Winding lever Cylinder head Tightening torque Strength class
type screw
1000 kg (1) 50 Nm 12.9
2000 kg (1) 50 Nm 12.9
3000 kg (1) 70 Nm 12.9
5000 kg (1) 70 Nm 12.9
Winding head in- (1) 30 Nm 12.9
sertion depth ≤ 20
mm
Cylinder head (3) 30 Nm 12.9
screw C

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7.6.3 Positioning the winding lever

The positioning of the winding levers according to the desired slitting pattern is
done manually. Winding levers that are not used in the slitting pattern are
marked as parked and positioned in their respective parking positions.

NOTE
Deformation of the winding sleeve by excessively long winding
sleeves
If the core length exceeds the web width by more than the permitted value
(maximum 5 mm with an insertion depth of the winding head up to 40 mm and
maximum 10 mm with an insertion depth of the winding head equal to or greater
than 40 mm), this can lead to deformation of the winding core in the area of the
core projection during tensioning.
This can impair the stability of the winding core so severely that correct clamp-
ing is no longer assured and the risk of the finished roll dropping out of the
winding station cannot be ruled out.

ü The machine drives must be set to zero speed and be switched off.
ü The winding sleeve length corresponds to the particular web width of the
winding station.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü A slitting pattern is preselected
1. Set the hand lever on the winding lever 1.11 to the left.
ð The parking brake of the winding lever is released.
2. Move the winding lever by hand until the position indicator for the winding
lever shows 0.00 or the pointer of the measuring scale points to the cor-
rect dimension.
3. Set the hand lever on the winding lever 1.11 to the right.
ð The parking brake of the winding lever is closed and the winding lever
is fixed.
4. Position all other required winding levers in the same way.
ð The winding levers have been positioned automatically.

Drive with several motors

If the finished rolls at the winding stations are driven by two or three AC servo
motors, the parking brake in the connected winding lever remains released.
1. Move the hand lever of the winding lever attached to the winding station
to the left.
2. Set the hand levers of the actual winding station to the right.
ð The parking brakes of the winding station are applied.
ð The coupled winding lever is not fixed. The winding station is fixed.

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7 | Operation

7.6.4 Coupling a winding lever

If the drive of the winding station is not sufficient for winding finished rolls, the
winding levers of this winding station can be connected to the adjacent driven
winding lever of a winding station not currently required, using a coupling and a
lug. In this way, the winding sleeve can be driven by up to four AC servo
motors.

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 Operation | 7

Figure 249: Winding lever coupled

Figure 250: Winding station driven by two motors

Figure 251: Winding station driven by three motors

Figure 252: Winding station driven by three motors

111101_en-US_2022-02-22_v1 275
7 | Operation

Figure 253: Winding station driven by four motors

Coupling the winding levers:

2 1 1 2

Figure 254: Winding lever master/slave

(1) “Master” winding lever
(2) “Slave” winding lever

Figure 255: Winding lever coupling

ü The winding levers have been positioned and the parking brakes are ap-
plied.
ü The (Master) winding station is in the “open” position.
1. Release the parking brake of the winding lever "Slave" to be coupled.
2. Move the “Slave” winding lever far enough away from the “Master” to al-
low the coupling to be inserted by hand.
3. Insert the coupling by hand into the profiled socket of the (Master) wind-
ing lever.

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 Operation | 7

4. Move the “Slave” towards the “Master” until the profiled pin of the coup-
ling is inserted into the profiled socket of the winding lever that is in use.
WARNING! Crush hazard!
5. Screw both winding levers, "Master" and "Slave", together with the sup-
plied lug.
ð The parking brake of the "Master" remains applied (lever of the parking
brake points to the right) and the parking brake of the "Slave" remains
released (lever of the parking brake points to the left).
ð The winding station is coupled and can be fitted with a core.

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7 | Operation

7.6.5 Equipping the winding levers with cores

WARNING
Deformation of the winding cores due to excess length
Cores that are too long can be deformed. If cores are used that are too long, the
finished rolls to be wound could fall out of the winding station.
1. Only use cores with the maximum permissible excess length.
2. Only use cores with sufficient core strength according to the finished roll
weight.

ü The machine drives must be set to zero speed and be switched off.
ü The winding sleeve length corresponds to the particular web width of the
winding station.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü The winding levers are positioned.
1. Open the winding station.
Hold the core centrally between the winding heads.
NOTE! The difference in outside diameters of the winding sleeves must not
exceed max. ±1.5 mm on a winding side.
1. Close the winding station.
2. Load all winding stations that are to be used according to the slitting pat-
tern.
ð The winding stations are fitted with cores.

7.6.6 Changing the finished roll in the rewinder

DANGER
Moving machine parts
Various components, including rollers, move during operation. Contact with
moving components can result in crushing or other injuries.
1. Never stand in the hazard zones while the machine is running. Do not
reach into the machine while it is running.
2. Do not touch moving parts.

ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Switch off the machine.
2. Switch off the rewinder.
3. Swing out the winding crossbars and pull the finished rolls away from the
contact rolls. Continue swinging out until the material can be cut.
4. Separate the material on the finished rolls.
5. Tape the finished rolls.
6. Move the finished roll removal cart into the removal position.
7. Swing out the winding crossbars further until the finished rolls rest on the
pallets.

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8. Press the operating elements WS.1 Release All and WS.2 Release All.
ð All winding stations selected for the slitting pattern are disengaged and
have released the finished rolls.
9. Check that all finished rolls are released. If not, move the finished rolls by
hand until the winding heads are free.
10. Ensure that there is no contact between the finished roll and the winding
station.
11. Swing in the winding crossbars until the winding stations are in the load-
ing position.
12. Use the finished roll removal cart to move the finished rolls out of the ma-
chine area.
13. Load the winding stations with empty cores, see corresponding chapter.
14. Attach the cut material webs to the corresponding winding sleeves with
edges flush and wind in until the material is taut.
15. Adjust the machine parameters in the visualization:
- Rewinder linear pressure
- Rewinder linear tension
- Rewinder stop length
- Rewinder stop diameter
16. Ensure that no one is in the danger zone of the machine.
WARNING! Moving machine parts.
17. Switch on the rewinders.
ð The rewinder drives are switched on.
ð The winding crossbars swing in until the winding sleeves reach the
contact rolls and the material is wound until it is kept taut.
ð Changing the finished rolls is completed.

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7 | Operation

7.7 Starting the machine

CAUTION
Moving machine parts
Moving parts can cause crushing and cutting injuries.
1. Do not reach into the work area.
2. Do not open or remove protective devices while the machine is operating.

ü The material web is pulled in as described.

ü All required safety precautions must have been taken, e.g. cordoning off, in-
formation given to operating personnel, etc.
ü There is no one in the danger zone of the machine.
ü All protective devices are functioning properly.
1. Select a low machine speed.
2. Press the Machine On control element.
ð The buzzer installed in the machine emits a warning and the signal
lamp attached on each winding side lights up.
3. Ensure that no one remains in the danger zone of the machine after the
warning sound ends and the signal lamps go out.
4. Set a low machine speed.
5. Press the Machine On control element again.
ð The machine starts to run and accelerates to the set speed. The set
speed and actual speed are displayed on the screen.
6. Check the following settings at a low machine speed and readjust them if
necessary:
- Alignment of the parent roll
- Brake tension: Correction via the visualization
- Setting the spreader roll position
7. Accelerate the machine to the operating speed.
ð The machine is now in operation.

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7.8 Shutting down the machine

There are several options for shutting down the machine, see the following
chapters.

7.8.1 Shutting down using length selection and diameter

selection for the unwinder
The machine can be shut down using the running length calculation or the
diameter length calculation integrated into the PLC. When the setpoint is
reached, the specified program steps are executed and the corresponding
machine drives are reduced to zero speed and then switched off.

Shutting down with the length selection

ü Machine is switched off.
ü Production has not yet begun.
1. Enter the desired setpoint value for the unwinding length in the visualiza-
tion.
2. Enter a minimum setpoint value for the unwinding diameter in the visual-
ization.
ð The machine stops automatically at the preset value reached first.

Shutting down with the diameter selection

ü Machine is switched off.
ü Production has not yet begun.
ü The desired minimum set diameter must be larger than the outside diameter
of the unwinder core.
1. Enter the desired setpoint value for the unwinding diameter in the visual-
ization.
2. Enter a maximum setpoint value for the unwinding length in the visualiza-
tion.
ð The machine stops automatically at the preset value reached first.

7.8.2 Shutting down using length selection and diameter

selection for the rewinder
The machine can be shut down using the running length calculation or the
diameter length calculation integrated into the PLC. When the setpoint is
reached, the specified program steps are executed and the corresponding
machine drives are reduced to zero speed and then switched off.

Shutting down with the length selection

ü Machine is switched off.
ü Production has not yet begun.
1. Enter the desired setpoint value for the rewinding length in the visualiza-
tion.

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7 | Operation

2. Enter a minimum setpoint value for the rewinding diameter in the visualiz-
ation
ð The machine stops automatically at the preset value reached first.

Shutting down with the diameter selection

ü Machine is switched off.
ü Production has not yet begun.
1. Enter the desired setpoint value for the rewinding diameter in the visualiz-
ation.
2. Enter a maximum setpoint value for the rewinding length in the visualiza-
tion.
ð The machine stops automatically at the preset value reached first.

7.8.3 Shutting down using the pushbutton

If during operation a Machine Off pushbutton is pressed, the machine speed is
reduced to zero and the main drive is switched off.
If one of these pushbuttons is then pressed once again, the rewinde drive is
reduced to zero speed and all drives are switched off.
1. Press the pushbutton.
ð All drives are reduced to zero speed.

7.8.4 Shutting down using the emergency stop function

NOTE
The material tears on triggering of the emergency stop function
Triggering machine shutdown by means of the emergency stop function can
cause the material web to tear.

Shut down the machine as quickly as possible if there is a risk to people or the
machine. For this reason, the machine is equipped with several readily
accessible to emergency stop control devices.
The following actions are triggered on actuation:
– The machine stops immediately; this means that all motion is brought to a
stop as quickly as possible.
– All drive motors are switched off.
Under certain circumstances, use of an emergency stop control device can
result in an undefined shutdown state.
To maintain safe conditions, energy may still be stored in the machine in the
form of pneumatic pressure.
Before the machine is started again, all moving components must be checked
and, if necessary, returned to their home position. It may also be necessary to
remove wrong products and/or products that have fallen out of position.
Before the machine can be put into operation again, emergency stop control
device must be released and the fault reset.

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7.9 Switching off the machine

1. Set the machine drives to zero speed and switch them off.
ð All drives are at a standstill and are switched off.
2. Lower lifted loads, move system components into the home position.
3. Switch off the control voltage and remove the key.
Keep the key out of reach of unauthorized persons.
ð After a confirmation prompt, the computer shuts down and the control
voltage is switched off.
4. Lock the maintenance switches (pneumatic maintenance switches and
main switch) and secure them with a personal padlock.
5. Wait three minutes until the machine is completely voltage-free.
6. Pay attention to any residual energy (e.g. springs, condensers, com-
pressed air including existing pressure accumulators) and discharge
them if necessary.
7. Take any other required safety precautions, for example inform operating
personnel.
8. Secure the machine against being switched back on by following the in-
ternal operating instructions for protection against being switched back
on.
ð The machine is switched off.

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7 | Operation

7.10 Fixing a web break

If the web breaks, the material can wrap around rolls. The following procedure
explains how to remove a broken web from the machine.

CAUTION
Machine in unsafe condition
If the material web breaks, the machine is in an unsafe condition. There may be
residual energies in the material or assemblies that discharge spontaneously,
for example in springs or pneumatic cylinders.
1. Operate an emergency stop control device.
2. Only trained personnel familiar with the situation may remove the material
web.
3. Inform all personnel of this unsafe condition and prohibit any work on the
machine.
4. Secure components with potential residual energies so that sudden
movement of the components cannot cause damage.

NOTE
Damage to rolls due to sharp objects
If the material has wrapped around the rolls, the use of sharp objects to remove
the material web may cause damage to the rolls or the roll surface.
1. Carefully remove the material.
2. Do not use sharp objects.

1. Switch off the machine.

2. Operate an emergency stop control device.
3. Ensure that the emergency stop command has been executed.
4. Wait until all rolls, drives and other moving components have come to a
standstill.
5. Remove the material web and the material residues from the machine
and dispose of them according to local regulations.
6. As required, thread the material web again, remove finished rolls or insert
a new original roll.
7. Unlock all emergency stop control devices.
8. Reset safety areas and safety elements.
9. If necessary, readjust the machine and its parameters.
ð The break in the material web was repaired.

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7.11 Putting the machine out of operation

DANGER
Improper fastening of loads and damaged load handling equipment
Serious or fatal injuries from falling loads
1. Do not step under or in front of moving loads.
2. Only use suitable, undamaged and correctly dimensioned load handling
equipment.

WARNING
Danger due to electrical voltage
Severe or fatal injuries due to electric shock
1. Before dismantling, check that the machine is free of voltage.
2. After switching off the power supply, check the machine for residual elec-
trical energy, for example in capacitors.
3. Electrical components may only be removed by a qualified electrician.

CAUTION
Danger due to hot system components
Burns when touching the system components.
1. The moving parts of the machine heat up during operation. Even after the
power is switched off, system components, especially those of dynamic-
ally operating drives (e.g. motor), may still have hot surfaces.
2. Allow heated system components to cool down for a correspondingly long
time before touching them or wear heat-resistant protective gloves.

CAUTION
Danger due to pressurized system components
Crushing injuries and shear injuries caused by unexpected movement.
1. Pneumatic cylinders pose a potential crushing hazard. Depending on the
operating pressure and speed of the cylinders, there is a higher or less
high risk of crushing.
2. Special caution is recommended in the vicinity of pneumatically driven
systems.
3. During dismantling, extreme caution is required due to suddenly released
residual energy.

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7 | Operation

CAUTION
Danger from pressurized liquids
Crushing injuries and shear injuries caused by unexpected movement.
1. Any liquids under pressure (e.g. hydraulic power unit) pose a danger.
2. Caution is required during dismantling due to suddenly released residual
energy.

Dismantling work is always carried out by qualified personnel with

relevant vocational training, qualifications and experience in the
mechanical and electrical dismantling/mounting of automated
industrial systems.

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 Operation | 7

Notes To avoid injuries and material damage, proceed as follows:

1. Observe the locally applicable laws, ordinances and regulations and the
safety instructions in this operating manual.
2. Prevent hazards from adjacent systems (e.g. switch off upstream sys-
tems and secure them against being switched on again).
3. Switch off the machine.
See Switching off the machine [} 283]
4. Disconnect the machine from the supply lines.
5. When handling operating fluids and auxiliary materials, observe the
safety regulations that apply to the product. Observe the safety data
sheets for operating fluids and auxiliary materials.
6. When picking up, transporting and loading loads, pay attention to stabil-
ity, correct traffic routes and the load capacity of the hoists
(example: Machine's own weight + payload (tools) = total weight).
7. Refer to the respective manufacturer's documentation for information on
dismantling of the individual components.
See Separate documentation [} 385]

111101_en-US_2022-02-22_v1 287
8 | Maintenance

8 Maintenance

8.1 General information

Regular machine care and maintenance is essential for smooth operation.
The individual lubrication points are listed in the following chapters. The
lubrication intervals are given in operating hours.
Operating the machine 24 hours per day, 365 days per year results in 8,760
operating hours per year.
9000
24
8000
7000

Operating hours per day

Total operating hours

6000
16
5000
4000
3000 8
2000
1000
0
0 4 8 12 16 20 24 28 32 36 40 44 48 52
Machine runtime in weeks
Figure 256: Operating hours

NOTE
Mixing lubricants destroys their lubricating effect
Mixing different lubricating greases with each other can result in them no longer
lubricating properly and damaging the components concerned. The same ap-
plies to lubricating oils..
1. Do not mix different lubricants.
2. Only use identical lubricants or otherwise completely remove the old lub-
ricant before changing to a new one.

NOTE
Increased material wear due to inadequate lubrication
Moving components are subject to increased wear without lubrication.
1. If not already full, fill the units with the necessary lubricant before initial
start-up.

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 Maintenance | 8

NOTE
Product contamination in the food industry due to incorrect lubric-
ant
If lubricants are used in the machine which have been certified for the food in-
dustry or feed industry, they must be relubricated with a lubricant which has
also been certified accordingly. The use of non-certified lubricant may lead to
contamination or destruction of the product in case of contact with it.
1. If necessary, ensure that the lubricant is appropriately certified when re-
lubricating.

NOTE
Lubrication intervals and consumption quantities may vary
The lubrication intervals and consumption quantities specified in this document
are recommendations. Exact lubrication intervals and consumption quantities of
lubricants may deviate under the operating conditions on site.
1. Determine the exact lubrication intervals and consumption quantities of
lubricants by testing under operating conditions.
2. If the lubricant is in a poor condition after the first lubrication intervals
(contamination), the interval must be shortened and/or the lubrication
quantity increased.

111101_en-US_2022-02-22_v1 289
8 | Maintenance

8.2 Prerequisites for maintenance work

KAMPF accepts no responsibility for damage or consequential damage caused
by the malfunction or failure of assemblies/components due to inadequate or
belated cleaning, maintenance or function checks.
To rule out any unexpected movements of machine parts during maintenance
work, bring the machine into a safe state.
Unless otherwise specified in the relevant chapter, the following prerequisites
apply to all maintenance work:
– Interval according to manufacturer's specifications and prevailing operating
conditions
– Inspection and maintenance work according to the manufacturer's specifica-
tions
– Maintenance and repair work by qualified personnel only.
– Carry out maintenance and repair work in accordance with the relevant
chapter
– Observe routine action before and after maintenance work
The following necessary conditions apply for safe and hazard-free work:
– Training in operation and maintenance by the manufacturer or by trained
and experienced operators or maintenance personnel.
– free access to the operating instructions
– the exact knowledge of the contents relevant for the respective activity

See
2 Intended audience [} 34]
2 Separate documentation [} 385]
2 General safety instructions [} 24]
2 Routine action before maintenance work [} 292]
2 Routine action after maintenance work [} 293]

290 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.3 Maintenance switch

For maintenance and repair work it is necessary to disconnect pneumatic and
electrical drive components from the power supply.
The compressed air supply is disconnected via maintenance units. These
maintenance units have a lockable shut-off valve.
The electric drives are switched off using isolating switches. These isolating
switches are secured by a lock against being switched back on again.

1 2

Figure 257: Maintenance switch

1 Pneumatic maintenance unit 2 Isolating switch (main switch)

111101_en-US_2022-02-22_v1 291
8 | Maintenance

8.4 Routine action before maintenance work

CAUTION
Danger from residual energy in the system
When the machine is switched off, there may still be residual energy in the sys-
tem, for example pneumatic energy or spring force.
1. Secure all components that may contain residual energy against sudden
movements, e.g. pneumatically lifted assemblies or components clamped
by spring force.

NOTE
Operation of key switches and key buttons by qualified personnel
only
Keys left behind in key switches or key buttons can lead to incorrect operation
of the machine and thus to critical machine states.
ü Only qualified personnel are in possession of the keys.
ü Qualified personnel are familiar with the actions associated with the key
switch or key button.
ü Qualified personnel are authorized to perform actions with the key switch or
key button.
1. Keep keys inaccessible to unauthorized persons after completing the ac-
tion.

1. Check whether there is any damage that could put persons within the
safety area at risk during maintenance work (visual inspection).
2. Switch off the machine.
See Switching off the machine [} 283]
ð Maintenance work can be carried out.

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 Maintenance | 8

8.5 Routine action after maintenance work

DANGER
Danger due to disabled protective devices and safety units
Severe or fatal injuries when operating the system.
1. Before starting the machine, reinstall any protective devices or safety
units that have been removed, bypassed or disabled during maintenance
or servicing work.
2. Before starting the machine, check that all protective devices and safety
units are in full working order.

1. Make sure that no persons are in the danger zone.

2. Close the safety gates.
3. Remove the fuses on the maintenance switches.
4. Open the shut-off valve of the pneumatic pipe.
5. Check the system pressure at the pressure reducing valve and adjust it if
necessary.
6. Switch on the main power supply.
ð The computer boots, and the main menu appears on the screen.
ð No hardware control elements are functional yet.
7. Switch on the control voltage.
ð The Fault indicator lamp lights up.
ð All hardware control elements are functional.
8. Unlock all Emergency Stop command devices.
9. Check that all safety units (Emergency Stop, safety light barriers, safety
light curtains etc.) are installed and in full working order.
10. Operate the machine or system components at reduced speed at the be-
ginning to detect malfunctions at an early stage and to avoid damage to
property.

111101_en-US_2022-02-22_v1 293
8 | Maintenance

8.6 Lubricants
All roller bearings used in the machine that are not covered or sealed on both
sides and not lubricated by a central or independent lubrication system must be
cleaned and have 30% to 50% of their free space filled with grease after
approx. 5,000 operating hours or one year, at the latest.
No. Lubricants DIN 51502 lub- ISO 6743 lubric- Viscosity at 40
ricant code ant code °C mm²/s (cSt)
1 Gear oil CLP 150 L-CKC 150 150
2 Gear oil CLP 220 L-CKC 220 220
3 Hydraulic fluid HLP 46 L-HM 46 46
DIN ISO 2137 DIN 51825 oper-
DIN 51825 lub-
walk penetra- ating temperat-
ricant code
tion ure range
Grease for roller -20 °C
265 – 295
4 bearings and K 2 K-20
(NLGI-2) 120 °C
sliding bearings
Grease for roller -20 °C
220 – 250
5 bearings and K 3 K-20
(NLGI-3) 120 °C
sliding bearings

294 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.7 Standard lubricants

Lubricant code
DIN 51502
or DIN CLP 150 CLP 220 HLP 46 K 2 K-20 K 3 K-20
51825
ISO 6743/6 ISO 6743/6 ISO 6743/4 ISO 6743/9 ISO 6743/9
ISO 6743
L-CKC 150 L-CKC 220 L-HM 46 L-XBCCA 2 L-XBCCA 3

Manufac- Manufacturer's designation

turer
Degol BG
Aralub HL 2
Degol BG 220 Vitam GF
150 46 Aralub HLP Aralub HL 3
Degol BG
2
220 Plus

Energrease Energrease
Energol
Energol GR- Energol GR- HLP-HM 46 LS 2 LS 3
XP 150 XP 220 Energrease Energrease
Bartran 46
LS-EP 2 LS EP 3

Spheerol
Alpha SP Alpha SP Spheerol
AP 2
150 220 Hyspin AP 3
AWS 46 Spheerol
Optigear Optigear Spheerol
EPL 2
BM 150 BM 220 Tribol 943 EPL 3
AW 46 Castrol Tri-
Tribol Tribol Olista
bol GR
1100/150 1100/220 Longtime 3
100-2 PD
Mobil DTE
Mobilux EP Mobilux EP
Mobilgear Mobilgear 25 Ultra
2 3
600 XP 150 600 XP 220 Mobil DTE
Unirex N 2 Unirex N 3
10 Excel 46

CEN-
CEN-
Klüberoil Klüberoil TOPLEX 2
LAMORA TOPLEX 3
GEM 1-150 GEM 1-220 Klüberplex
HLP 46 PETAMO
N N BEM
GHY 133 N
41-132
Shell Omala Shell Tellus
Shell Omala F 220 S 46 Shell Al- Shell Al-
150 Shell Omala Shell Tellus vania RL 2 vania RL 3
220 46

Meropa Meropa Rando HD

150 220 46 Multifak EP Multifak
Pinnacle Pinnacle Rando EP 2 Premium 3
EP 150 EP 220 Ashless 46

111101_en-US_2022-02-22_v1 295
8 | Maintenance

8.8 Initial equipment

No lubricants need to be provided by the customer for initial equipment of the
machine.
For the electrical connection, a power supply cable must be provided up to the
power supply terminal on the machine.
The compressed air supply requires a 1/2" compressed air thread.

296 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9 Unwinder

8.9.1 Chucking head

8.9.1.1 Lubricate the 3" chucking head

Figure 258: Chuck

1 Bolt 2 Wedge

1, 2

Maintenance instructions
1. See at the end of this table.

Maintenance
5000 h/annually
interval
Aids Unimoly C 220; ALTEMP X NB 50

ü The chuck is vented.

1. Loosen the screws at the front of the cover.
2. Remove the cover.
3. Remove the clamping jaws together with the springs from the chuck.
NOTE! Tension springs could fall down. Carry out work above a suit-
able collecting container.
ð The bolt and wedges are exposed.
4. Check and clean the sliding surfaces of the bolt and wedges.
5. After cleaning, spray with lubricant spray and then apply lubricant paste.
6. Insert the wedges.
7. Push on the clamping jaws together with the tension springs.
8. Attach the cover. Make sure that the bar of the clamping jaws is located
underneath the lid.
9. Use new screws for the cover. Wet the screws with threadlocker.
10. Tighten the cover with new screws.

111101_en-US_2022-02-22_v1 297
8 | Maintenance

8.9.1.2 Maintaining the chucking head

(1)
Maintenance instruction
1. Service the chucking head according to the in-
structions in separate manufacturer documenta-
tion
See Svecom: Chuck [} 392]

Maintenance
5000 h/annually
interval
Number of
0 1 maintenance Every chucking head
points
Aids ALTEMP X NB 50; Unimoly C 220

8.9.2 Disk brake

8.9.2.1 Cleaning bearings and sliding surfaces

Figure 259: Disk brake

(1)

Maintenance instructions
1. Clean bearings and sliding surfaces.

Maintenance in-
1000 hours
terval
Aids -

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 Maintenance | 8

8.9.2.2 Lubricating bearings and sliding surfaces

Figure 260: Disc brake tappet

1 Tappet

NOTE
Brake failure if pads come into contact with lubricant
Do not allow the brake pads to come into contact with lubricant. Contact with
lubricant will impair the braking effect up to and including total brake failure.
1. When servicing the brakes, protect the pads against lubricant.
2. If brake pads come into contact with lubricant, remove them, clean any
lubricant off the brake and install new, clean pads.

(1)

Lubricating instructions
1. Apply grease to the tappet at the exit point.

Number of lub-
0 1 1 per disc brake
rication points
Lubricant K2K-20

Amount of lub-
As needed
ricant
Lubricating inter-
1000 hours
val

See
2 Separate documentation [} 385]

111101_en-US_2022-02-22_v1 299
8 | Maintenance

8.9.2.3 Checking mobility

Figure 261: Disk brake

(1)
Instructions
1. Check to see if the brake calipers moves slightly.

Interval 1000 hours

Tool(s) -

Criterion Slight mobility

300 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9.2.4 Checking gap

Figure 262: Disk brake gap

(1) Instructions
1. With the brake caliper released, check to see
that the brake pads to not rub against the disk/
there is an even gap on both sides. If necessary,
measure the gap according to the manufacturer's
documentation.
See Separate documentation [} 385]
Interval 1000 hours
Tool(s) -

Criterion Even gap

111101_en-US_2022-02-22_v1 301
8 | Maintenance

8.9.2.5 Adjusting the air gap

1
2

3 4

Figure 263: Disk brake screw

1 Nut 2 Screw
3 Tappet 4 Brake disk
5 Druckzylinder

(1) Maintenance instructions

1. Pressurize the pressure cylinder with 5 to 6 bar air
pressure.
2. Tighten the screw on the tappet until there is still a
slight clearance (of 0.2 to 0.4 mm) between the
friction linings and the brake disk, but the friction
linings are not yet rubbing.
3. Secure the bolt by locking it with the nut.
ð When the spring pressure cylinder is vented, the full
braking torque (holding torque) is now available.
Maintenance
1000 hours
interval
Number of
0 1 maintenance Every disk brake
points
Aids -

See
2 Separate documentation [} 385]

302 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9.2.6 Checking the brake pads and the disc braken

Figure 264: Disk brake

(1) Inspection instruction

1. Check brake pad thickness according to instruc-
tions in separate manufacturer's documentation.
2. If the brake pad thickness is too low, replace the
pads together with the disc brake.
See Separate documentation [} 385]
Inspection inter-
Weekly
val
Aids -

Sufficient pad thickness:

Prüfkriterium at least 4 mm distance to the steel angle support
plates.

111101_en-US_2022-02-22_v1 303
8 | Maintenance

8.9.2.7 Checking the screw connections of the disk brake

Figure 265: Disk brake

(1) Inspection instruction

1. Check the screw connections, this includes:
– Brake caliper at machine part
– Spring pressure cylinder at brake caliper lever arm
– Brake pads at caliper lever arm
– Pressure cylinder flange connection
Inspection inter-
Monthly
val
Aids Allen keys; Open-jaw wrench

Inspection cri-
Tight fit of all screw connections
terion

See
2 Separate documentation [} 385]

304 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9.2.8 Checking leak tightness

Figure 266: Disk brake

(1) Inspection instruction

1. Cover the brake pad so that it does not come into
contact with leak finder spray.
2. Check the hose connections for leaks with leak
finder spray.
Inspection inter-
Monthly
val
Aids Leak Finder Spray

Inspection cri-
No leaks
terion

See
2 Separate documentation [} 385]

111101_en-US_2022-02-22_v1 305
8 | Maintenance

8.9.3 Parent roll clamping device

8.9.3.1 Lubricating the gear motor

Figure 267: Lubricating the gear motor

(1)
Lubrication instructions
1. Service the gear motor according to the instruc-
tions in the separate manufacturer's documenta-
tion.

Number of lub-
0 1 1
ricating points
Lubricant CLP 220

Amount of lub-
0.45 l
ricant
Lubrication inter-
15,000 h/2-3 years
val

306 111101_en-US_2022-02-22_v1
 Maintenance | 8

Figure 268: Lubricating the gear motor

8.9.3.2 Lubricating the roller chain

Figure 269: Lubricating the roller chain

(1)

Lubrication instructions
1. Coat the roller chain evenly with lubricant.

Number of lub-
0 1 1
ricating points
Lubricant HD 30

Amount of lub-
As required
ricant
Lubrication inter-
2000 hours
val

111101_en-US_2022-02-22_v1 307
8 | Maintenance

Figure 270: Lubricating the roller chain

8.9.3.3 Lubricating the ball screw drive

Figure 271: Lubricating the ball screw

(1) Lubrication instructions

1. Lubricate the ball screw drive using the lubrica-
tion nipple of the ball screw nut.
2. Then move the ball screw drive a distance that is
approx. 3 times the length of the ball screw nut
and re-lubricate it as described in 1.
Number of lub-
0 1 2x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
4 g per lubrication nipple
ricant
Lubrication inter-
500 hours
val

308 111101_en-US_2022-02-22_v1
 Maintenance | 8

Figure 272: Lubricating the ball screw drive

8.9.3.4 Lubricating the linear roller guide

Figure 273: Lubricating the linear roller guides

111101_en-US_2022-02-22_v1 309
8 | Maintenance

NOTE
Increased material wear due to inadequate lubrication
Insufficient movement of the guide carriages on the linear roller guides can res-
ult in inadequate lubricant.
1. Ensure the guide carriages travel the maximum distance possible on the
linear roller guide twice per week.

(1) Lubrication instructions

1. Re-lubricate the carriages of the linear roller
guideways via the lubrication nipples.
2. Move the assembly a distance of approx. 5 times
the length of a carriage.
Number of lub-
0 1 2 x 5 items
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
2 g per lubrication nipple
ricant
Lubrication inter-
500 hours
val

Figure 274: Lubricating the linear roller guideway

310 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9.4 Parent roll lift-in unit

8.9.4.1 Lubricating the planetary gear

Figure 275: Planetary gear

(1)

This component is lubricated for life.

111101_en-US_2022-02-22_v1 311
8 | Maintenance

8.9.4.2 Lubricating the toothed chain

Figure 276: Toothed chain

(1)

Lubrication instructions
1. Spray the toothed chain evenly with lubricant.

Number of lub-
0 1 2x
ricating points
Lubricant Castrol Viscogen KL 23

Amount of lub-
As needed
ricant
Lubrication inter-
1000 hours
val

312 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.9.4.3 Lubricating the ball screw

Figure 277: Ball screw

(1) Lubrication instructions

1. Lubricate the ball screw using the lubrication
nipple of the ball screw nut.
2. Then move the ball screw a distance that is ap-
prox. 3 times the length of the ball screw nut and
re-lubricate it as described in 1.
Number of lub-
0 1 2x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
10 g each
ricant
Lubrication inter-
1000 hours
val

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8.9.4.4 Lubricate the bolts of the locking unit

Figure 278: Bolt of the locking unit

(1) Lubrication instructions

ü The unwinding arms are in lowered position.
ü The machine drives are set to zero speed and
switched off.
1. Wet the bolts with lubricant.
Number of lub-
0 1 2
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Schmierstoff-
Nach Bedarf
menge
Amount of lubric-
Monthly
ant

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 Maintenance | 8

8.9.5 Generator brake

8.9.5.1 Checking the belt tension of the electro-dynamic brake

1

Figure 279: Electro-dynamic brake belt tension

(1) Inspection instructions

1. Check the belt tension at setting point (1) for the
test values for poly-V-belts below according to
the separate manufacturer's documentation and
correct it if there is a difference.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Inspection cri-
Belt run frequency f = 77 Hz
terion

Figure 280: Electro-dynamic brake belt tension

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8.9.5.2 Adjusting belt tension

CAUTION
Danger of crushing due to falling motor when screws are loosened
too much
To tension the belt, loosen the screws of the motor plate. If these are all
loosened too much, there is a risk that the motor will fall and cause serious
crushing injuries.
1. Loosen the screws only a few turns, never completely.
2. Loosen the screws only enough to allow the motor plate to move freely.

2
1

Figure 281: Individual parts for adjusting the belt tension

1 Belt 2 Screws for fastening the motor
plate
3 Set screw
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü The machine drives must be set to zero speed and be switched off.
ü Checking the belt tension has revealed that the belt needs to be tightened
or loosened.
1. Release and remove the belt drive cover.
2. Release the screws of the motor plate.
When doing so, unscrew the screws only a few turns, never completely!
ð The motor plate is released and can be moved.
3. Loosen the lock nut of the set screw.
4. Use the set screw to move the motor plate to increase or decrease the
belt tension.
5. Keep checking the belt tension until the correct belt tension is set.
6. Retighten the screws of the motor plate.
7. Tighten the lock nut of the set screw.
8. Move the belt or belt pulley.

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 Maintenance | 8

9. Check the belt tension again.

ð If the belt tension is still correct, the adjustment is complete. If the belt
tension is not correct, adjust the motor plate further with the set screw.
10. Install the belt drive cover.
ð The belt tension has been adjusted.

8.9.5.3 Replacing the belt

CAUTION
Crush hazard due to the motor falling.
When replacing the belt, the screw connections of the motor have to be
loosened. If the load is incorrectly applied, the motor may fall down.
1. Before starting work, secure the motor against falling down with a suitable
hoist.

8 5

2 3 4 5 6 7
Figure 282: Electro-dynamic brake
1 Three-phase motor 2 Screw for fastening the motor
3 V-belt pulley 4 Bracket
5 Screw for fastening the bracket 6 Lock nut
7 Screw to tension the belt 8 Poly V-belt
9 V-belt pulley
ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü The weight of the motor is taken up by a suitable hoist, such as a crane.
ü The belt drive cover is removed.
1. Switch off the control voltage and secure it against being switched on
again.
ð After a confirmation prompt, the computer shuts down and the control
voltage is switched off.
2. Release the screws of the bracket without unscrewing them completely.

111101_en-US_2022-02-22_v1 317
8 | Maintenance

3. Release the lock nuts.

4. Release the tensioning screw and turn it further.
ð The bracket with the three-phase motor moves toward the V-belt pul-
ley. The belt is now relaxed.
5. Release and remove the motor screws.
ð The motor is now suspended by the hoist.
6. Pull the three-phase motor with the V-belt pulley off the bracket.
7. Remove and replace the belt.
8. Fit a new belt.
9. Use a suitable hoist to place the three-phase motor with the V-belt pulley
on the bracket and fasten it with the screws.
10. Check the correct position of the belt.
11. Tighten the belt with the tensioning screw.
12. Lock the tensioning screw with the lock nut.
13. Tighten the screws of the bracket.
14. Install the belt drive cover.
15. Switch on the control voltage.
ð The computer boots up and the main menu appears on the screen.
ð This completes replacement of the belt.

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8.10 Base machine

8.10.1 Lubricating the linear roller guideway for web

control

Figure 283: Linear roller guide for web control

(1) Lubrication instructions

1. Re-lubricate the guide carriages of the linear
roller guideways via the lubrication nipples.
2. Move the assembly a distance of approx.
5 times the length of a guide carriage.
Number of lub-
0 1 1x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
1.5 g per lubrication nipple
ricant
Lubrication inter-
2000 hours
val

8.10.2 Material threading device

111101_en-US_2022-02-22_v1 319
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8.10.2.1 Lubricating the spur wheel gear motor

Figure 284: Spur wheel gear motor material threading device

(1)
Lubrication instructions
1. Service the spur wheel gear motor according to
the instructions in the separate manufacturer's
documentation.
See Bauer: Gear motor [} 385]

Number of lub-
0 1 1x
rication points
Lubricant CLP 220

Amount of lub-
0.9 l
ricant
Lubrication inter-
15,000 h/2-3 years
val

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 Maintenance | 8

8.10.2.2 Lubricating the roller chain

Figure 285: Webbing-up device roller chain

(1)

Lubrication instructions
1. Evenly coat the roller chain with lubricant.

Number of lub-
0 1 1 item
rication points
Lubricant HD 30

Amount of lub-
As needed
ricant
Lubrication inter-
2000 hours
val

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8 | Maintenance

8.10.3 Spreader roll

8.10.3.1 Lubricating worm gear for the adjustment drive

Figure 286: Worm gear

(1)
Lubrication instructions
1. Lubricate the gear unit using the lubrication
nipple.

Number of lub-
0 1 1x
ricating points
Lubricant K2K-20

Amount of lub-
4 g per lubrication nipple
ricant
Lubrication inter-
1000 hours
val

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 Maintenance | 8

8.10.3.2 Lubricating the pivot bearing

Figure 287: Spreader roll pivot bearing

(1)
Lubrication instructions
1. Lubricate the pivot bearing using the lubrication
nipple.

Number of lub-
0 1 1x
ricating points
Lubricant K2K-20

Amount of lub-
4g per lubrication nipple
ricant
Lubrication inter-
1000 hours
val

8.10.3.3 Adjusting the fine adjustment drive

The fine adjustment drive allows the circumferential speed of the spreader roll
to be adjusted. A tension in the material web is generated by a lag.

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8 | Maintenance

Figure 288: Fine adjustment drive

1 Link V-belt 2 Regulating wheel

NOTE
Damage to machine parts due to work not carried out properly
The work described here is complex. Incorrectly performed work can lead to
damage to machine parts.
1. If you have any questions regarding the work, please contact KAMPF.

(1) , (2) Maintenance instructions

The adjustment of the regulating wheels was carried out
at the factory. Only change the setting of the regulating
wheels if the roller diameter has changed due to regrind-
ing, recoating or replacement of the roller or if the posi-
tion of the regulating wheels has changed.
ü The required circumferential speed of the spreader
roll is known.
1. Adjust the regulating wheel so that the desired
peripheral speed is achieved.
Maintenance
If necessary
interval
Number of
0 1 maintenance 1
points
Reference measuring instrument for circumferential
Aids
speed

324 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.10.4 Transport roll

8.10.4.1 Maintaining the spring-loaded multi-disc brake

Figure 289: Spring-loaded multi-disc brake

(1) Lubrication instructions

1. Check for dust, if dust is present dismantle the
brake according to the manufacturer's instruc-
tions and wet the discs with the specified lubric-
ant
See Stromag: Brake KLB [} 392]

Number of lub-
0 1 1
ricating points
Lubricant HLP 46

Amount of lub-
As needed
ricant
Lubrication inter-
2000 hours
val

111101_en-US_2022-02-22_v1 325
8 | Maintenance

8.11 Longitudinal slitting unit

8.11.1 Lubricate the connecting rod tighteners of the knife

holders

Figure 290: Linear roller guideway of the knife holders

(1)
Lubrication instructions
1. Spray the joints on the connecting rod tightener
with lubricant.

Number of lub-
0 1 5
ricating points
Lubricant Unimoly C 220

Amount of lub-
One spray application each
ricant
Lubrication inter-
1000 hours
val

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 Maintenance | 8

8.11.2 Lubricating the take-up mandrel linear roller

guideway

Figure 291: Linear roller guideway of the knife holders

(1)

This component is lubricated for life.

111101_en-US_2022-02-22_v1 327
8 | Maintenance

8.12 Rewinder

8.12.1 Contact roller unit

8.12.1.1 Adjusting the contact lever brake force

Figure 292: Adjusting the contact lever brake force

1 Contact lever 2 Nut
3 Grub screw

Maintenance instruction
See below.

Maintenance in-
If necessary
terval
Auxiliary materi-
-
als

ü The machine drives are at zero speed and switched off.

ü All necessary safety precautions must have been taken, e.g. securing the
area, notifying operating personnel, etc.
ü An external compressed air source with connected manometer is available.
1. Switch off the control voltage and remove the key.
NOTE! Secure the unit against being switched on again, which means
that the key must not be accessible to unauthorized individuals.
2. Loosen all three grub screws in the nut.

328 111101_en-US_2022-02-22_v1
 Maintenance | 8

3. Pressurize the pneumatic cylinder to 0.15-0.2 bar overpressure. To do

this, use an external compressed air source with a connected mano-
meter.
4. Adjust the nut until the contact lever slowly moves toward the rewinding
station.
5. Secure the nut with the grub screws.
ð Adjustment is complete and the machine can be put back into operation.

8.12.2 Winding crossbar

8.12.2.1 Swivel drive

8.12.2.1.1 Greasing the planetary gear

Figure 293: Planetary gear

(1)

This component is lubricated for life.

111101_en-US_2022-02-22_v1 329
8 | Maintenance

8.12.2.1.2 Greasing the toothed chain

Figure 294: Toothed chain

(1)

Lubrication instructions
1. Spray the toothed chain evenly with lubricant.

Number of lub-
0 1 2x
ricating points
Lubricant Castrol Viscogen KL 23

Amount of lub-
As required
ricant
Lubrication inter-
1000 hours
val

Figure 295: Lubricating the toothed chain

330 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.12.2.1.3 Lubricating the ball screw

Figure 296: Ball screw

(1) Lubrication instructions

1. Lubricate the ball screw drive using the lubrica-
tion nipple of the ball screw nut.
2. Then move the ball screw drive a distance that is
approx. 3 times the length of the ball screw nut
and re-lubricate it as described in 1.
Number of lub-
0 1 2x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
10 g each
ricant
Lubrication inter-
1000 hours
val

Figure 297: Lubricating the ball screw

111101_en-US_2022-02-22_v1 331
8 | Maintenance

8.12.2.2 Displacement drive

8.12.2.2.1 Lubricating the gear motor

Figure 298: Lubricating the gear motor

(1) Lubrication instructions

1. Service the component according to the instruc-
tions in the separate manufacturer's documenta-
tion.
See Siemens: Gear motor 1FG1 [} 391]
Number of lub-
0 1 2x
ricating points
Lubricant PGLP 220

Amount of lub-
0.45 l
ricant
First interval:
Lubrication inter-
2 years
val
The following intervals: 4 years

332 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.12.2.2.2 Lubricating the spindle-type lifting gear

1
1

Figure 299: Lubricating the spindle-type lifting gear

(1)

This component is lubricated for life.

111101_en-US_2022-02-22_v1 333
8 | Maintenance

8.12.2.2.3 Lubricating the ball screw

1
1

Figure 300: Lubricating the ball screw

(1) Lubrication instructions

1. Lubricate the ball screw using the lubrication
nipple of the ball screw nut.
2. Then move the ball screw a distance that is ap-
prox. 3 times the length of the ball screw nut and
re-lubricate it as described in 1.
Number of lub-
0 1 2x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
10 g each
ricant
Lubrication inter-
1000 hours
val

334 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.12.2.2.4 Lubricating the anti-rotation device on the spindle-type lifting

gear

1
1

Figure 301: Lubricating the anti-rotation device

(1) Lubrication instructions

1. Move the ball screw until the anti-rotation device
is approximately in the area of the lubrication
nipple.
2. Then lubricate the anti-rotation device via the
lubrication nipple.
Number of lub-
0 1 2x
ricating points
Lubricant Castrol Tribol GR 100-2 PD

Amount of lub-
5 g each
ricant
Lubrication inter-
1000 hours
val

111101_en-US_2022-02-22_v1 335
8 | Maintenance

8.12.2.2.5 Winding traverse displacement belt tension

Adjustment point 1

Figure 302: Winding crossbar displacement belt tightener, adjustment point 1

(1) Inspection instructions

1. Check the belt tension at adjustment point (1) in
accordance with the separate manufacturer's
documentation for the inspection values for
PowerGrip GT3 belts (Flender) and readjust it as
necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

– Belt pretension during initial belt installation:

Fv = 113 N – 125 N
– Belt pretension after running in the machine:
Inspection cri- Fv = 80 N – 90 N
terion – Belt span frequency during initial belt installation:
f = 56 Hz – 59 Hz
– Belt span frequency after running in the machine:
f = 47 Hz – 50 Hz

336 111101_en-US_2022-02-22_v1
 Maintenance | 8

Adjustment point 2

Figure 303: Winding crossbar displacement belt tightener, adjustment point 2

(2) Inspection instructions

1. Check the belt tension at adjustment point (2) in
accordance with the separate manufacturer's
documentation for the inspection values for
PowerGrip GT3 belts (Flender) and readjust it as
necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

– Belt pretension during initial belt installation:

Fv = 128 N – 141 N
– Belt pretension after running in the machine:
Inspection cri- Fv = 90 N – 103 N
terion – Belt span frequency during initial belt installation:
f = 91 Hz – 96 Hz
– Belt span frequency after running in the machine:
f = 76 Hz – 82 Hz

111101_en-US_2022-02-22_v1 337
8 | Maintenance

Figure 304: Checking the belt tension

338 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.12.3 Winding heads

8.12.3.1 Servicing the winding chuck

Figure 305: Winding chuck

(1) Maintenance instruction

1. Clean the winding chucks and check them for
wear the first time they malfunction, however, no
later than every six months.
2. Replace worn parts with new parts.
The user can determine winding chuck malfunctions
through insufficient contracting of the clamping jaws or
through problems releasing the finished rolls from the
winding chucks. Winding chuck malfunctions can be
caused by dust from the winding cores, the web tensions
used and contact pressures.
To remove the winding chucks:
See Installing/removing a winding head with central
screw [} 271]
Maintenance
Half-yearly
interval
Auxiliary materi-
-
als

111101_en-US_2022-02-22_v1 339
8 | Maintenance

8.12.3.2 Maintaining the 3" ET62 winding head

2
1

Figure 306: Winding head

1 Cover 2 Screw

WARNING
Incorrect operation of the winding head in the event of incorrect
maintenance.
The screws and the corresponding internal threads must not come into contact
with lubricating grease. A permanent connection can no longer be ensured in
the event of contact. Parts of the winding head could become loose during oper-
ation and cause serious consequential damage.
1. Make sure the screws and internal threads are free of lubricating grease.
Degrease them in the event of soiling.

ü The winding head is removed from the machine.

ü A clean underlay is ready.
1. Place the winding head on a clean underlay.
2. Loosen the screws of the cover, if necessary heat it up beforehand so
that the screw lock is released.
3. Take off the cover.
4. Remove clamping jaws with supporting rollers.
5. Remove the axle if necessary.
6. Clean components with Shell universal cold cleaner.
7. Dry components with compressed air.
8. Thinly grease internal parts on all sides with AUTOL TOP 2000. Remove
excess grease with a cloth.
9. Reassemble components in reverse order.
When assembling, ensure that the supporting rollers are movably seated
in the clamping jaws.
10. Degrease the threaded holes for the screws in the segments with LOC-
TITE 7061 quick cleaner.

340 111101_en-US_2022-02-22_v1
 Maintenance | 8

11. Apply screw lock LOCTITE 259 to new screws for the cover.
12. Mount the cover with the cylinder screws.
The required torque is 5,5 Nm.
ð The winding head has been maintained and can be mounted again on the
winding lever.
See Installing/removing a winding head with central screw [} 271]

8.12.3.3 Winding head 3" ET62 - Replace friction linings

Figure 307: Friction lining

WARNING
Incorrect operation of the winding head in the event of incorrect
maintenance.
The screws and the corresponding internal threads must not come into contact
with lubricating grease. A permanent connection can no longer be ensured in
the event of contact. Parts of the winding head could become loose during oper-
ation and cause serious consequential damage.
1. Make sure the screws and internal threads are free of lubricating grease.
Degrease them in the event of soiling.

ü The machine drives must be set to zero speed and be switched off.
ü No winding cores are fitted
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Remove the screws from the friction lining.
2. Remove the used friction linings and dispose of it properly.
3. Use LOCTITE 7061 quick cleaner to degrease the tapped holes for the
screws.
4. Apply LOCTITE 259 thread locking to the threads.
5. Put on new friction lining and fix it with the screws.
The required torque is 1 Nm.
ð The replacement of the friction lining is finished.

See
2 Installing/removing a winding head with central screw [} 271]

111101_en-US_2022-02-22_v1 341
8 | Maintenance

8.12.3.4 Maintaining the 3" ET62 winding head

Figure 308: Winding head

1 Cover 2 Screw

WARNING
Incorrect operation of the winding head in the event of incorrect
maintenance.
The screws and the corresponding internal threads must not come into contact
with lubricating grease. A permanent connection can no longer be ensured in
the event of contact. Parts of the winding head could become loose during oper-
ation and cause serious consequential damage.
1. Make sure the screws and internal threads are free of lubricating grease.
Degrease them in the event of soiling.

ü The winding head is removed from the machine.

ü A clean underlay is ready.
1. Place the winding head on a clean underlay.
2. Loosen the screws of the cover, if necessary heat it up beforehand so
that the screw lock is released.
3. Take off the cover.
4. Remove clamping jaws with supporting rollers.
5. Remove the axle if necessary.
6. Clean components with Shell universal cold cleaner.
7. Dry components with compressed air.
8. Thinly grease internal parts on all sides with AUTOL TOP 2000. Remove
excess grease with a cloth.
9. Reassemble components in reverse order.
When assembling, ensure that the supporting rollers are movably seated
in the clamping jaws.
10. Degrease the threaded holes for the screws in the segments with LOC-
TITE 7061 quick cleaner.
11. Apply screw lock LOCTITE 259 to new screws for the cover.

342 111101_en-US_2022-02-22_v1
 Maintenance | 8

12. Mount the cover with the cylinder screws.

The required torque is 5,5 Nm.
ð The winding head has been maintained and can be mounted again on the
winding lever.
See Installing/removing a winding head with central screw [} 271]

8.12.3.5 Winding head 3" ET62 - Replace friction linings

Figure 309: Friction lining

WARNING
Incorrect operation of the winding head in the event of incorrect
maintenance.
The screws and the corresponding internal threads must not come into contact
with lubricating grease. A permanent connection can no longer be ensured in
the event of contact. Parts of the winding head could become loose during oper-
ation and cause serious consequential damage.
1. Make sure the screws and internal threads are free of lubricating grease.
Degrease them in the event of soiling.

ü The machine drives must be set to zero speed and be switched off.
ü No take-up cores are taken up
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
1. Remove the screws of the friction linings.
2. Remove the used friction linings and dispose them properly.
3. Degrease the threaded holes of the screws with LOCTITE 7061 quick
cleaner.
4. Insert screw lock LOCTITE 259 into the threads.
5. Put on new friction linings and fix them with the screws.
The required torque is 2 Nm.
ð The replacement of the friction linings is finished.

See
2 Installing/removing a winding head with central screw [} 271]

111101_en-US_2022-02-22_v1 343
8 | Maintenance

8.12.3.6 Checking for wear on polygonal coupling between winding

head and winding arm

1 2

Figure 310: Winding head polygonal receiver

1 Winding head polygonal receiver 2 Winding lever polygonal receiver

(1) , (2)
Inspection instructions
To ensure the function of the polygonal coupling, check
every winding lever for wear.

Inspection inter-
2000 hours
val
Aids -

– Wear limit of winding lever polygonal receiver:

Up to 0.1 mm smaller than P3G32j6/1.12 as per
Inspection cri- DIN 32711
terion
– Wear limit of winding head polygonal receiver:
Fit tolerance of P3G32H7/1.12 as per DIN 32711

8.12.3.7 Checking polygonal coupling for wear

ü The machine drives are off and stopped.
ü No winding cores are mounted.
ü All necessary safety precautions have been taken, e.g., securing the area,
notifying operating personnel, etc.
1. Shut off the control voltage and remove the key.
NOTE! Secure against reactivation, i.e., the key should not be access-
ible to unauthorized personnel.
2. Remove the winding head.
See Installing/removing a winding head with central screw [} 271]
3. Clean loose dirt and fretting corrosion off the polygonal receiver on the
winding lever and winding head.

344 111101_en-US_2022-02-22_v1
 Maintenance | 8

4. Check the polygonal receiver on the winding lever and winding head for
damage.
5. Check the polygonal receiver on the winding lever and winding head for
wear.
6. Replace worn or defective parts with original spare parts.
NOTE! Do not use winding levers with visibly damaged polygonal
shaft or excessive wear, and winding heads with visibly damaged
polygonal receiver or excessive wear until the affected parts have
been repaired or replaced. Worn or defective parts should only be
replaced with original spare parts supplied by Kampf Schneid- und
Wickeltechnik GmbH & Co. KG.
7. Install the winding head, tightening the bolts to torque.
For the necessary tightening torques:
See Installing/removing a winding head with central screw [} 271]
ð Wear check is complete and the machine can be put back into operation.

8.12.3.8 Checking mounting bolt tightening torque

Figure 311: Winding head with center bolt

(1) Instructions
1. Check the tightening torque for the center bolt on
the winding head.
For tightening torque:
See Installing/removing a winding head with cent-
ral screw [} 271]
Interval 2000 hours
Tool(s) Torque wrench

Criterion Tightening torque for the center bolt.

111101_en-US_2022-02-22_v1 345
8 | Maintenance

8.12.4 Winding lever 2000 kg

1 2

Figure 312: Winding lever 2000 kg

1 Winding lever, left 2 Winding lever, right

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 Maintenance | 8

8.12.4.1 Left winding lever belt tension

Adjustment point 1

Figure 313: Left 2000 kg winding lever adjustment point 1

(1) Inspection instructions

Check the belt tension at setting point (1) for the
check values listed below according to the separate
manufacturer's documentation and adjust it as neces-
sary.
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Inspection cri- – Belt pretension: Fv = 730 N

terion – Belt span frequency: f = 57 Hz

111101_en-US_2022-02-22_v1 347
8 | Maintenance

Adjustment point 2

Figure 314: Left 2000 kg winding lever, adjustment point 2

(2) Inspection instructions

Check the belt tension at setting point (2) for the
check values listed below according to the separate
manufacturer's documentation and adjust it as neces-
sary.
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Inspection cri- – Belt pretension: Fv = 324 N

terion – Belt span frequency: f = 178 Hz

348 111101_en-US_2022-02-22_v1
 Maintenance | 8

8.12.4.2 Right winding lever belt tension

Adjustment point 1

Figure 315: Right 2000 kg winding lever, adjustment point 1

(1) Inspection instructions

Check the belt tension at setting point (1) for the
check values listed below according to the separate
manufacturer's documentation and adjust it as neces-
sary.
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Inspection cri- – Belt pretension: Fv = 730 N

terion – Belt span frequency: f = 57 Hz

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8 | Maintenance

Adjustment point 2

Figure 316: Right 2000 kg winding lever, adjustment point 2

(2) Inspection instructions

Check the belt tension at setting point (2) for the
check values listed below according to the separate
manufacturer's documentation and adjust it as neces-
sary.
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Inspection cri- – Belt pretension: Fv = 324 N

terion – Belt span frequency: f = 104 Hz

8.12.5 Winding lever 5000kg

1 2

Figure 317: Winding lever 5000 kg

1 Winding lever, left 2 Winding lever, right

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8.12.5.1 Lubricating CARB bearings

Figure 318: Lubricating the winding arm CARB bearings

(1)

This component is lubricated for life.

111101_en-US_2022-02-22_v1 351
8 | Maintenance

8.12.5.2 Checking left winding lever belt tension

Adjustment point 1

Figure 319: Left 5000 kg winding lever adjustment point 1

(1) Inspection instructions

1. Check the belt tension at adjustment point (1) in
accordance with the separate manufacturer's
documentation for the test values for PowerGrip
GT3 belts (Flender) and readjust as necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

– Belt span frequency during initial installation:

Inspection cri- f = 145 Hz
terion – Belt span frequency after machine run-in:
f = 121 Hz

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 Maintenance | 8

Adjustment point 2

Figure 320: Left 3000 kg winding lever adjustment point 2

(2) Inspection instructions

1. Check the belt tension at adjustment point (2) in
accordance with the separate manufacturer's
documentation for the test values for PowerGrip
GT3 belts (Flender) and readjust as necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

– Belt pretension:
Inspection cri- Fv = 324 N
terion – Belt span frequency:
f = 246 Hz

111101_en-US_2022-02-22_v1 353
8 | Maintenance

8.12.5.3 Checking right winding lever belt tension

Adjustment point 1

Figure 321: Right 5000 kg winding lever adjustment point 1

(1) Inspection instructions

1. Check the belt tension at adjustment point (1) in
accordance with the separate manufacturer's
documentation for the test values for PowerGrip
GT3 belts (Flender) and readjust as necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

Belt 1
– Belt span frequency during initial installation:
Inspection cri-
f = 150 Hz
terion
– Belt span frequency after machine run-in:
f = 126 Hz

354 111101_en-US_2022-02-22_v1
 Maintenance | 8

Adjustment point 2

Figure 322: Right 5000 kg winding lever adjustment point 2

(2) Inspection instructions

1. Check the belt tension at adjustment point (2) in
accordance with the separate manufacturer's
documentation for the test values for PowerGrip
GT3 belts (Flender) and readjust as necessary.
See Flender: Poly-V-belt / Toothed belt [} 386]
Inspection inter-
Quarterly
val
Aids Belt tension measuring device

– Belt pretension:
Inspection cri- Fv = 324 N
terion – Belt span frequency:
f = 246 Hz

111101_en-US_2022-02-22_v1 355
8 | Maintenance

8.13 Maintenance of edge trim suction unit

Figure 323: Edge trim suction unit

(1)
Maintenance instructions
1. Service the edge trim suction unit according to the
instructions in the separate manufacturer's docu-
mentation.
See Schuh: Suction [} 390]

Maintenance
-
interval
Number of
0 1 maintenance 1
points
Aids -

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 Maintenance | 8

8.14 General maintenance

111101_en-US_2022-02-22_v1 357
8 | Maintenance

8.14.1 Cleaning machine parts

NOTE
Damage to machine parts due to contamination
Contaminants such as dirty air, dust, whirled-up dirt and other environmental in-
fluences can lead to deposits on machine parts. These deposits can lead to de-
fects in components or increased wear.
1. Keep the ambient air clean.
2. Do not raise dust.
3. Regularly clean machine parts from deposits.

For optimum operation, the machine must be cleaned regularly. The machine
must be switched off before cleaning work and secured against unauthorized
restarting. If there is no visual contact with the main switch during cleaning
work, it must be secured against being switched back on by means of a lock. In
addition, information signs are to be attached, which refer to the work on the
system.

Special attention
General machine parts The machine should generally be protected from dust and deposits or freed
from them. Once dust and deposits are on the machine, they can fall on other
components and contaminate them due to slight drafts.
Greased components Guide rails and carriages in particular, as well as bearing points or surfaces with
a deliberate grease film, are especially susceptible to dust and deposits. Dust
and deposits settle in the grease and enter the component when it moves, thus
reducing the lubricating effect and increasing wear.
Replace dirty grease films or grease fillings with new, clean grease films and
grease fillings.
Electronic components Dust and deposits on electronic components can cause them to heat up more,
which reduces their life span.

Guidelines
Unless otherwise specified, observe the following guidelines:
– Only use suitable aids for cleaning the system.
– Clean the machine when it has in cooled down.
– Do not use acidic or strongly alkaline cleaning and wetting agents.
– Do not use scratching, abrasive agents (abrasive cleaning).
– Do not use organic solvents containing esters, ketones, alcohols, aromatics,
glycol ethers or halogenated hydrocarbons.
– Do not use cleaning agents of unknown composition.
– Do not degrease surfaces that have been deliberately provided with a
grease film.
– Do not use compressed air (compressed air) for cleaning.

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 Maintenance | 8

8.14.2 Clean work area

The machine and the working area inside and around the machine must be
cleaned regularly.

Clean work areas daily after each shift.

1. Clean the floor of the work area with a vacuum cleaner.

2. Remove all material residues as well as edge strips from the machine
and the working area.
3. Clean machine parts.
See Cleaning machine parts [} 358]

111101_en-US_2022-02-22_v1 359
8 | Maintenance

8.14.3 Check sensors systems

If there is dirt on the sensor system, it will no longer switch correctly. Incorrect
messages may be displayed which are based on incorrect signals from the
sensor system.
1. Check the sensor system.
2. In case of heavy contamination, remove dust from the sensor system with
a clean brush, then clean with a soft, damp cloth

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 Maintenance | 8

8.14.4 Checking guides for cleanliness

Figure 324: Linear roller guideway

(1) Inspection instruction

1. Check linear roller guideways for cleanliness and
clean if necessary.
2. For cleaning, take a clean cloth and wipe the lin-
ear roller guideways.
3. After wiping, apply a film of grease to the entire
linear roller guideway until no bare spots remain.
Bare spots can corrode.
Inspection inter-
Weekly
val
Aids Dry, lint-free cloth

Inspection cri-
Cleanliness of the linear roller guideways
terion

111101_en-US_2022-02-22_v1 361
8 | Maintenance

8.14.5 Checking pneumatic system

8.14.5.1 Checking pneumatic connections

Figure 325: Pneumatic connection

(1)
Instructions
1. Check the pneumatic connections for leaks and
proper seating.

Interval Weekly
Tool(s) -

Criterion No leaks and proper seating

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 Maintenance | 8

8.14.5.2 Checking and servicing pneumatic maintenance unit

Figure 326: Pneumatic maintenance unit

(1) Inspection instructions

1. Check and service the component according to
the instructions in the separate manufacturer's
documentation.
See Norgren: Maintenance unit [} 389]
Inspection inter-
Weekly
val
Aids -

Inspection cri-
In proper working condition
terion

111101_en-US_2022-02-22_v1 363
8 | Maintenance

8.14.6 Roll maintenance

8.14.6.1 Checking roll surface

Figure 327: Roll

NOTE
Destruction of roller surface by sharp-edged objects
Sharp-edged tools or objects can damage the delicate surface of the roller and
permanently harm the production process.
1. Avoid touching the roller with any sharp-edged tools or objects.

(1)
Instructions
1. Check the roll surface for damage or soiling, and
clean as needed.

Interval Weekly
Tool(s) -

Criterion Rollers in proper working condition

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 Maintenance | 8

8.14.6.2 Cleaning cork-sheathed rolls

Figure 328: Cork-sheathed roll

(1) Maintenance instruction

1. In case of coarse soiling, clean the rolls with a
brush. Collect the dirt with an industrial vacuum
cleaner.
2. If necessary, clean dirty areas with a damp cloth
without detergent.
Maintenance in-
Weekly
terval
Auxiliary materi-
Dry, lint-free cloth; Brush; Industrial vacuum cleaner
als

111101_en-US_2022-02-22_v1 365
8 | Maintenance

8.14.6.3 Cleaning rubber-sheathed rolls

Figure 329: Rubber-coated roll

(1)
Maintenance instructions
1. If the rolls are soiled, clean them with the spe-
cified means.
Immediately wipe off solvent.

Maintenance in-
Weekly
terval
Aids Water, with surface tension reduced by soap; Solvents

8.14.6.4 Cleaning specially coated rolls

Figure 330: Coated roll

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 Maintenance | 8

NOTE
Destruction of surface of coated rollers by solvent
Solvent-based cleaning agents can destroy the special coating on rollers, such
as plasma-coated rollers. This will permanently harm the production process.
1. Do not use solvent-based cleaning agents.

(1)
Maintenance instructions
1. If the rolls are soiled, clean them with the spe-
cified means.

Maintenance in-
Weekly
terval
Aids Water, with surface tension reduced by soap

8.14.6.5 Cleaning of CFRP rolls

Cleaning refers to the rubber surface of CFRP rolls.

NOTE
Destruction of roller surface by sharp-edged objects
Sharp-edged tools or objects can damage the delicate surface of the roller and
permanently harm the production process.
1. Avoid touching the roller with any sharp-edged tools or objects.

Perform cleaning according to the following table. The use of the recommended
cleaning media is classified as follows:
– [+] = The medium is suitable without restrictions
– [0] = Dampen a cloth. Only brief contact with the surface is allowed. Re-
move residues immediately.

111101_en-US_2022-02-22_v1 367
8 | Maintenance

– [--] = The medium is unsuitable. The medium causes swelling.

Type of Water, Alcohol, Gasoline, Ester, Aromatic
rubber soap solu- Glycol turpentine Ketones 1) hydrocar-
tion bons 2)
By + + -- + 0
C + + 0 -- 0
F + 0 + -- 0
H + + 0 0 0
Ha + + + -- 0
K + + -- 0 --
N + + 0 0 0
P + + + -- 0
S + + 0 -- 0
U + 0 + -- 0
V + 0 + -- +
X + + + -- 0
Z + + + -- 0
ZP + + + -- 0
1)
Aceton, MEK, MIBK, Ehtyl acetate and similar
2)
Xylene, toluene and similar, these media should be avoided for environmental
protection and occupational safety reasons
The recommendations are based on information provided by Schäfer KG
Gummiwalzenfabrik, Benzstraße 40, D-71272 Renningen, Germany, and
reference the types of rubber manufactured there.

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 Maintenance | 8

8.14.7 Checking filter pads

Figure 331: Filter pad on fans

(1)
Instructions
1. Check filter pads on fans for dust accumulation
and replace as needed.

Interval Weekly
Tool(s) -

Criterion Cleanliness of filter pad

111101_en-US_2022-02-22_v1 369
8 | Maintenance

8.14.8 Cleaning the cooling unit

NOTE
Damage to the louvers
Sharp objects during cleaning can damage the louvers.
1. Do not use pointed or sharp-edged objects.
2. Do not press in or damage the louvers strongly during cleaning.

NOTE
Missing function due to missing plug connection
If the cover hood is dismantled, the electrical plug connections on the inside
must be disconnected by hand.
1. When mounting the cover hood, plug in the connectors.

NOTE
Damage to the filter mat
Wringing destroys the structure of the filter mat.
1. Do not wring out the filter mat.
2. Do not direct a sharp jet of water at the filter mat.
3. If the filter mat is oily or greasy, replace the filter mat.

The frequency of the cleaning intervals depends on the respective operating

conditions. Observe the following notes in particular:
– The cooling circuit is filled at the factory with the necessary coolant,
checked for leakages and is subjected to a functional check run.
– Clean the heat exchanger regularly
– Clean the heat exchanger with a soft brush or compressed air
– Regularly check the condensate drain
– For cooling units with pre-filters, the filter mat must be cleaned at regular in-
tervals. The time interval for cleaning or replacing the filter mat depends
greatly on the ambient conditions (air pollution).
– The filter mat can be washed with water up to 40 °C and commercially avail-
able mild detergents. In the case of dry soiling, it can also be tapped, vacu-
umed or blown out.
To clean the cooling unit, proceed as follows:
1. Protect electrical components from water penetration.
2. Disconnect the cooling unit from the power supply.
3. Dismantle the cover hood.
4. Clean the heat exchanger, including the pre-filter, the condensate drain
and the filter mat.

See
2 Pfannenberg: Cooling unit [} 389]

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 Maintenance | 8

8.14.9 Lubricating remaining bearings

1 1

1 1

Figure 332: Sample bearings

(1)
Lubricating instructions
1. Lubricate all bearings with grease nipples not
separately listed.

Lubricant Castrol Tribol GR 100-2 PD

Amount of lubric-
As needed
ant
Lubricating inter-
Half-yearly
val

111101_en-US_2022-02-22_v1 371
8 | Maintenance

8.14.10 Check roller chain drives for tension

Figure 333: Roller chain drive

(1) Inspection instructions

1. Check the roller chain drives for adequate tension
according to the manufacturer's documentation
provided separately.
See Rexnord: Roller chain drive [} 389]
Inspection inter-
Weekly
val
Aid -

Inspection cri- Tension in accordance with the manufacturer´s docu-

terion mentation

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 Maintenance | 8

8.14.11 Checking the emergency stop function

The emergency stop function must be checked annually for correct operation.
ü The machine drives must be set to zero speed and be switched off.
ü All required safety precautions have been taken, e.g. cordoning off, informa-
tion given to operating personnel, etc.
ü No persons are present in the danger zone of the machine.
ü All protective fence doors, gates, etc., where present, are closed.
1. Operate an emergency stop command device.
ð The emergency stop function is triggered.
ð The machine parts and system components are put into a safe state.
2. Check if the machine shows an error message related to the operated
emergency stop command device, if necessary follow the instructions of
the error message.
ð If no error message is shown related to the operated emergency stop
command device, the emergency stop function is working correctly.
3. Make sure that no persons are in the danger zone.
4. Unlock all emergency stop command devices.
5. Reset the emergency stop circuit.
6. Repeat the procedure for each emergency stop command device.
ð The emergency stop function has been checked.

8.15 Belt drive maintenance

8.15.1 Replacing flat belts

(1) Maintenance instructions
1. If the belt tension is no longer up to the specified
value, exchange the flat belt according to the sep-
arate manufacturer's documentation and tension it
accordingly.
See Ammeraal Beltech: Flat belt [} 385]
Maintenance
-
interval
Number of
0 1 maintenance -
points
Aids -

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8 | Maintenance

8.15.2 Replacing toothed belts, Poly V belts and V-belts

(1) Maintenance instructions
1. If the belt is damaged or has an unacceptable
wear level, replace the belt according to the separ-
ate manufacturer's documentation and tension it
accordingly.
See Flender: Poly-V-belt / Toothed belt [} 386]
Keep the values for worn belts or correct them to this
value. Do not re-tension to the value for initial installa-
tion.
Maintenance
If necessary
interval
Number of
0 1 maintenance -
points
Aids Belt tension measuring device

To measure the belt tension, we recommend a belt tension measuring

device. This meter can be purchased from Kampf's Spare Parts
department. For the address:
See Spare parts [} 378]

8.15.3 Link V-belt replacement

(1) Maintenance instructions
1. If the required belt tension is no longer present, re-
place the link V-belt according to the separate
manufacturer's documentation and tension ac-
cordingly.
See Optibelt: Link V-belt [} 389]
Maintenance
If necessary
interval
Number of
0 1 maintenance -
points
Aids -

374 111101_en-US_2022-02-22_v1
111101_en-US_2022-02-22_v1

Maintenance table
Maintenance cycle Assembly Further information
- Entire Machine 8.15.1 Replacing flat belts
Edge trimming vacuum 8.13 Maintenance of edge trim suction unit
Daily Entire Machine 8.14.2 Clean work area
Weekly Entire Machine 8.14.4 Checking guides for cleanliness
8.14.5 Checking pneumatic system
8.14.5.1 Checking pneumatic connections
8.14.5.2 Checking and servicing pneumatic maintenance unit
8.14.6.1 Checking roll surface
8.14.6.2 Cleaning cork-sheathed rolls
8.14.6.3 Cleaning rubber-sheathed rolls
8.14.6.4 Cleaning specially coated rolls
8.14.6.5 Cleaning of CFRP rolls
8.14.7 Checking filter pads
8.14.10 Check roller chain drives for tension
Disk brake 8.9.2.6 Checking the brake pads and the disc braken
Linear roller guide 8.14.4 Checking guides for cleanliness
500 hours Parent roll clamping unit 8.9.3.3 Lubricating the ball screw drive
8.9.3.4 Lubricating the linear roller guide
Monthly Entire Machine 8.14.1 Cleaning machine parts
8.14.3 Check sensors systems
Disk brake 8.9.2.7 Checking the screw connections of the disk brake
8.9.2.8 Checking leak tightness
Locking unit 8.9.4.4 Lubricate the bolts of the locking unit

Maintenance table
375
376

Maintenance table
Maintenance cycle Assembly Further information
1000 hours Swivel drive 8.9.4.2 Lubricating the toothed chain
8.9.4.3 Lubricating the ball screw
8.12.2.1.2 Greasing the toothed chain
8.12.2.1.3 Lubricating the ball screw
8.12.2.2.3 Lubricating the ball screw
Displacement drive 8.12.2.2.4 Lubricating the anti-rotation device on the spindle-type lifting
gear
Disk brake 8.9.2.1 Cleaning bearings and sliding surfaces
8.9.2.2 Lubricating bearings and sliding surfaces
8.9.2.3 Checking mobility
8.9.2.4 Checking gap
8.9.2.5 Adjusting the air gap
Knife holders 8.11.1 Lubricate the connecting rod tighteners of the knife holders
Spreader roll 8.10.3.1 Lubricating worm gear for the adjustment drive
8.10.3.2 Lubricating the pivot bearing
2000 hours Web control 8.10.1 Lubricating the linear roller guideway for web control
Spring-applied multi-disc brake 8.10.4.1 Maintaining the spring-loaded multi-disc brake
Material threading device 8.10.2.2 Lubricating the roller chain
Parent roll clamping unit 8.9.3.2 Lubricating the roller chain
Winding head 8.12.3.6 Checking for wear on polygonal coupling between winding
head and winding arm
8.12.3.7 Checking polygonal coupling for wear
8.12.3.8 Checking mounting bolt tightening torque
Quarterly Unwinder 8.9.5.1 Checking the belt tension of the electro-dynamic brake
Displacement drive 8.12.2.2.5 Winding traverse displacement belt tension
111101_en-US_2022-02-22_v1

Winding arm 2t 8.12.4.1 Left winding lever belt tension

8.12.4.2 Right winding lever belt tension
3 t winding arm 8.12.5.3 Checking right winding lever belt tension
5 t winding arm 8.12.5.2 Checking left winding lever belt tension
Cross member 8.12.2.2.5 Winding traverse displacement belt tension
111101_en-US_2022-02-22_v1

Maintenance cycle Assembly Further information

Half-yearly Entire Machine 8.14.8 Cleaning the cooling unit
8.14.9 Lubricating remaining bearings
Winding head 8.12.3.1 Servicing the winding chuck
8.12.3.2 Maintaining the 3" ET62 winding head
8.12.3.3 Winding head 3" ET62 - Replace friction linings
8.12.3.4 Maintaining the 3" ET62 winding head
8.12.3.5 Winding head 3" ET62 - Replace friction linings
5000 h/annually Expansion chuck 8.9.1.1 Lubricate the 3" chucking head
8.9.1.2 Maintaining the chucking head
Annually Entire Machine 8.14.11 Checking the emergency stop function
15,000 h/2-3 years Material threading device 8.10.2.1 Lubricating the spur wheel gear motor
Parent roll clamping unit 8.9.3.1 Lubricating the gear motor
2 years Displacement drive 8.12.2.2.1 Lubricating the gear motor
If necessary Entire Machine 8.15.2 Replacing toothed belts, Poly V belts and V-belts
8.15.3 Link V-belt replacement
Spreader roll 8.10.3.3 Adjusting the fine adjustment drive
Centered contact roll 8.12.1.1 Adjusting the contact lever brake force
Winding head 8.12.3.2 Maintaining the 3" ET62 winding head
8.12.3.3 Winding head 3" ET62 - Replace friction linings
8.12.3.4 Maintaining the 3" ET62 winding head
8.12.3.5 Winding head 3" ET62 - Replace friction linings
Lubricated for life Displacement drive 8.12.2.2.2 Lubricating the spindle-type lifting gear
Maintenance-free Swivel drive 8.9.4.1 Lubricating the planetary gear
8.12.2.1.1 Greasing the planetary gear

Maintenance table
377
9 | Spare parts

9 Spare parts
Stock-keeping of spare and wear parts on site is an important condition to
guarantee continuous operation and availability of the supplied machine. Please
use the spare parts list if you wish to order any spare parts.
We expressly emphasize that spare parts and accessories not supplied by us
have neither been tested and approved by us. Any installation and/or use of
such products may lead to changes of the original machine design and
influence the active and/or passive safety. For damages caused by spare parts
and accessories which have not been supplied by us, any liability and warranty
by
Kampf Schneid- und Wickeltechnik GmbH & Co. KG
will be excluded. This also refers to spare parts which have been made on your
own according to documents we supplied to you. Please consider that special
manufacturing and delivery specifications often exist for our own as well as for
purchased parts.
Please specify the following data in your spare parts order:
Machine type
1. Commission number
2. Identificaton number of spare part
3. Name of spare part
4. Quantity of spare part
Adress The address of our spare parts department is as follows:
Kampf Schneid- und Wickeltechnik
GmbH & Co. KG
Ersatzteilvertrieb
Postfach 1240
51656 Wiehl
Germany
For spare part questions or orders:
Telephone: +49 (0) 2262-81-478
Telefax: +49 (0) 2262-81-356
E-Mail : [email protected]

9.1 Spare parts list

The term 'class' in the spare parts list presents the significance for the
stockkeeping of spare parts. The individual classes (A, B, C, D and E) have
been divided in correspondence to the technical wear and have the following
meaning:
A = Incidentals/wear parts, stockkeeping absolutely necessary
B = Spare parts, which should be kept on stock
C = Spare parts recommended for stockkeeping
D = Rolls, gears and motors
E = Components with spare part(s)

Documents added (STRG+ ):

2 111101_102_Spare_parts_recommendation_oP.pdf (Resources/
pdf/2574959755.pdf)

378 111101_en-US_2022-02-22_v1
 Spare parts | 9

9.2 Identification of spare parts with ESPAC

Explanation The term ESPAC stands for Electronic Spare PArts Catalog.
ESPAC is for identifying spare parts of the machine.
The electronic spare parts catalog provides the option of finding spare parts
throughout the entire machine structure. At the same time, machine
components or assemblies can be requested from KAMPF by mail using the
integrated shopping cart function.
Functionality The electronic spare parts catalog displays the machine using 3D models and
the corresponding parts lists.
The 3D models and parts lists allow assemblies to be opened in an interactive
manner, turned, components to be displayed and hidden and individual parts of
the system to be selected or displayed.
Circuit diagrams can also be opened.
It is thus possible to search circuit diagrams, to access further circuit diagram
pages via connections and thus easily identify components.
Ordering/queries All machine components requested using the shopping cart function are
handled as queries. An official offer is created as a response. No automatic jobs
or orders are triggered, even if the function in the software has Order as the
name.
If you have any questions An operating manual with the most important ESPAC functions can be selected

in the program using the button.

111101_en-US_2022-02-22_v1 379
9 | Spare parts

Figure 334: ESPAC start page

Figure 335: ESPAC assembly level

380 111101_en-US_2022-02-22_v1
 Spare parts | 9

Figure 336: ESPAC part level (1/2)

Figure 337: ESPAC part level (2/2)

Figure 338: ESPAC circuit diagram (1/2)

111101_en-US_2022-02-22_v1 381
9 | Spare parts

Figure 339: ESPAC circuit diagram (2/2)

Figure 340: ESPAC shopping cart

382 111101_en-US_2022-02-22_v1
 Spare parts | 9

9.3 Opening ESPAC

Depending on the scope of delivery, the electronic spare parts catalog can be
opened as follows:
– Opening ESPAC via the machine visualization screen
– Opening ESPAC via the CD-ROM/DVD provided on any computer with CD-
ROM drive or DVD drive
– Opening ESPAC from a USB flash drive
Opening ESPAC via the machine ü The machine visualization is switched on.
visualization
1. Open the User Administration page at the visualization.
2. Log in as a user of the [Administrator] user group.
3. Open the Navigation page at the visualization.
4. In the Help and Documentation line click the K spare parts button
or
click the Documents page.
5. Click the KAMPF ESPAC button at the bottom of the screen.
ð The electronic spare parts catalog is opened.
Opening ESPAC via CD-ROM/ ü The computer has a CD-ROM drive or a DVD drive.
DVD
1. Insert the ESPAC CD-ROM/DVD in the drive and close the drive.
2. Wait a few seconds.
ð Installation of the electronic spare parts catalog starts automatically.
If the installation does not start:
Open the folder structure of the CD-ROM/DVD and double-click the
Autostart.exe file.
3. Follow the instructions on the screen.
ð The electronic spare parts catalog starts.
Opening ESPAC from a USB ü The computer has a USB port.
flash drive
1. Insert the USB flash drive in the computer's USB port.
2. Open the folder structure of the USB flash drive.
3. Double-click the Autostart.exe file.
4. Wait a few seconds.
ð Installation of the electronic spare parts catalog starts.
5. Follow the instructions on the screen.
ð The electronic spare parts catalog starts.

111101_en-US_2022-02-22_v1 383
10 | Drawings

10 Drawings

10.1 Installation and foundation plan

Documents added (STRG+ ):

2 882125163.pdf (Resources/pdf/2558855307.pdf)
2 882129763.pdf (Resources/pdf/2558856971.pdf)
2 882170560.pdf (Resources/pdf/2558897035.pdf)

10.2 Safety devices

Documents added (STRG+ ):

2 882175291.pdf (Resources/pdf/2558900491.pdf)

10.3 Maintenance drawings

Documents added (STRG+ ):
2 871064765.pdf (Resources/pdf/2558738571.pdf)

10.4 Pneumatic plan

Documents added (STRG+ ):

2 Pneumatikplan_111101_2021_09_16.pdf (Resources/pdf/2558852491.pdf)

384 111101_en-US_2022-02-22_v1
 Separate documentation | 11

11 Separate documentation

11.1 ACE: Shock absorber

Documents added (STRG+ ):
2 MC_SC_MA.pdf (Resources/pdf/9007199362201355.pdf)

11.2 ACE: Profile damper

Documents added (STRG+ ):
2 BA_TUBUS_1-2004.pdf (Resources/pdf/27021597871686027.pdf)

11.3 Ammeraal Beltech: Flat belt

Documents added (STRG+ ):
2 Belt_Type_GG.pdf (Resources/pdf/9007199362235659.pdf)

11.4 Bauer: Gear motor

Documents added (STRG+ ):
2 BA_200.pdf (Resources/pdf/36028797142573579.pdf)

11.5 Block: Power supply

Documents added (STRG+ ):
2 PC-3AC_DC24.pdf (Resources/pdf/18014399786244619.pdf)

11.6 Boettcher: Grinding instructions

Documents added (STRG+ ):
2 Grinding_instructions.pdf (Resources/pdf/27021597871825035.pdf)

11.7 Bosch-Rexroth: Tooth chain drive

Documents added (STRG+ ):
2 Zahnkette.pdf (Resources/pdf/107656075.pdf)

111101_en-US_2022-02-22_v1 385
11 | Separate documentation

11.8 Clouth: Roller maintenance

Documents added (STRG+ ):
2 Roller_maintenance.pdf (Resources/pdf/27021597872656267.pdf)

11.9 Elero: Linear drive

Documents added (STRG+ ):
2 Junior_1_ 1S_ 2.pdf (Resources/pdf/9007199363294987.pdf)

11.10 Erhardt + Leimer: Web controller

Documents added (STRG+ ):
2 ADS--556066.PDF (Resources/pdf/2566931211.pdf)
2 DO_3311.pdf (Resources/pdf/2495611403.pdf)
2 README.PDF (Resources/pdf/668329995.pdf)

11.11 Festo: Pressure switch

Documents added (STRG+ ):
2 SPAU.pdf (Resources/pdf/18014399949284619.pdf)

11.12 Flender: Coupling

Documents added (STRG+ ):
2 AN4200.pdf (Resources/pdf/27021597873694603.pdf)
2 BA8704.pdf (Resources/pdf/27021597873696523.pdf)

11.13 Flender: Poly-V-belt / Toothed belt

Documents added (STRG+ ):
2 GTMR.pdf (Resources/pdf/135107988930591371.pdf)

11.14 Joucomatic: Pressure regulating valve

Documents added (STRG+ ):
2 IM14120-MSP302-1-R9.pdf (Resources/pdf/9007199365613963.pdf)

386 111101_en-US_2022-02-22_v1
 Separate documentation | 11

11.15 Kammerer: Ball screw

Documents added (STRG+ ):
2 Ball_screws.pdf (Resources/pdf/90071992658983947.pdf)

11.16 Kampf: Chuck

Documents added (STRG+ ):
2 870010405.pdf (Resources/pdf/18014398633741835.pdf)

11.17 Keyence: Digital laser sensor

Documents added (STRG+ ):
2 LV-N10_IM.pdf (Resources/pdf/112089867.pdf)
2 LV-N10_UM.pdf (Resources/pdf/112091787.pdf)

11.18 Kickert: Spreader roll

Documents added (STRG+ ):
2 Operation.pdf (Resources/pdf/180143985206513803.pdf)

11.19 KTR: Coupling BOWEX AS

Documents added (STRG+ ):
2 BOWEX_004_005.pdf (Resources/pdf/9007199366466827.pdf)

11.20 KTR: Coupling BOWEX SD

Documents added (STRG+ ):
2 BOWEX_SD.pdf (Resources/pdf/9007199366469515.pdf)

11.21 KTR: Torque limiter RUFLEX

Documents added (STRG+ ):
2 RUFLEX.pdf (Resources/pdf/18014398621226891.pdf)

111101_en-US_2022-02-22_v1 387
11 | Separate documentation

11.22 Microsyst: Display

Documents added (STRG+ ):
2 Mipan_PN.pdf (Resources/pdf/1267115915.pdf)

11.23 Moeller: Foot switch

Documents added (STRG+ ):
2 FAK.pdf (Resources/pdf/9007199367581963.pdf)
2 FAK-S-KC11-I_TD.pdf (Resources/pdf/9007199367586571.pdf)

11.24 Mönninghoff: Coupling SecMatic

Documents added (STRG+ ):
2 SecMatic_587.pdf (Resources/pdf/9007199367606923.pdf)

11.25 Mönninghoff: Coupling ServoFlex

Documents added (STRG+ ):
2 ServoFlex_318.pdf (Resources/pdf/9007199368099979.pdf)

11.26 MTS: Position sensor

Documents added (STRG+ ):
2 RPRH_Profinet.pdf (Resources/pdf/126100789679268363.pdf)
2 R-Serie_Profinet.pdf (Resources/pdf/126100789679270283.pdf)

11.27 Norgren: Pneumatic valve

Documents added (STRG+ ):
2 V40-V45_OM.pdf (Resources/pdf/1023915531.pdf)
2 V44_V45.pdf (Resources/pdf/9007199367710987.pdf)

11.28 Norgren: Clamping cylinder unit

Documents added (STRG+ ):
2 GA_SPC_050316.pdf (Resources/pdf/18014398622461451.pdf)
2 RA_192000.pdf (Resources/pdf/18014398622463371.pdf)
2 SPC_050316.pdf (Resources/pdf/18014398622468619.pdf)

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 Separate documentation | 11

2 Safety.pdf (Resources/pdf/9007199381010699.pdf)

11.29 Norgren: Maintenance unit

Documents added (STRG+ ):
2 N_IM_8_240_100_F64G.pdf (Resources/pdf/18014398622479883.pdf)
2 N_IM_8_240_300_B64G.pdf (Resources/pdf/18014398622481803.pdf)

11.30 Optibelt: Link V-belt

Documents added (STRG+ ):
2 A13-Z10.pdf (Resources/pdf/112267915.pdf)

11.31 Pfannenberg: Cooling unit

Documents added (STRG+ ):
2 DTS_DTI.pdf (Resources/pdf/63050394895602571.pdf)
2 DTS_DTI_6401_6501.pdf (Resources/pdf/1061804683.pdf)
2 DTS_DTI_94_9541_400v.pdf (Resources/pdf/112413451.pdf)

11.32 Phoenix Contact: Isolation Amplifier

Documents added (STRG+ ):
2 Mini_MCR.pdf (Resources/pdf/18014398747793419.pdf)
2 Mini_MCR_TD.pdf (Resources/pdf/18014398747796875.pdf)

11.33 Rexnord: Roller chain drive

Documents added (STRG+ ):
2 Roller_chain_drive.pdf (Resources/pdf/9007199368847371.pdf)

11.34 Riegler: Safety valve

Documents added (STRG+ ):
2 226_01-03.pdf (Resources/pdf/1176171275.pdf)
2 226_01-03_TD.pdf (Resources/pdf/1176173451.pdf)

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11 | Separate documentation

11.35 Ringspann: Brake calliper DV 20 FPM

Documents added (STRG+ ):
2 DV-DH-020-FPM.pdf (Resources/pdf/9007199368885899.pdf)

11.36 Ringspann: Shrink disc RLK 608

Documents added (STRG+ ):
2 RLK-608.pdf (Resources/pdf/9007199368913931.pdf)

11.37 Schmersal: Safety-monitoring module

Documents added (STRG+ ):
2 mrl_srb_301mc.pdf (Resources/pdf/9007199503497099.pdf)

11.38 Schneider Electric: Signal tower XVB

Documents added (STRG+ ):
2 XVB.pdf (Resources/pdf/9007199369755787.pdf)
2 XVB_L_C.pdf (Resources/pdf/18014398624498699.pdf)

11.39 Schuh: Suction

Documents added (STRG+ ):
2 00.pdf (Resources/pdf/2566978827.pdf)
2 01.pdf (Resources/pdf/2566981003.pdf)
2 02.pdf (Resources/pdf/2566983179.pdf)
2 03.pdf (Resources/pdf/2567062155.pdf)
2 04.pdf (Resources/pdf/2567064331.pdf)
2 05_00.pdf (Resources/pdf/2567066507.pdf)
2 05_01.pdf (Resources/pdf/2567068683.pdf)
2 06.pdf (Resources/pdf/2567070859.pdf)
2 07.pdf (Resources/pdf/2567073035.pdf)
2 08.pdf (Resources/pdf/2567088011.pdf)

11.40 Siemens: AC motor 1PH8

Documents added (STRG+ ):
2 1PH813_1PH816.pdf (Resources/pdf/18014398625390987.pdf)

390 111101_en-US_2022-02-22_v1
 Separate documentation | 11

11.41 Siemens: AC servomotor 1FK7

Documents added (STRG+ ):
2 1FK7.pdf (Resources/pdf/135107988937041931.pdf)
2 Safety_instructions.pdf (Resources/pdf/45035996389642123.pdf)

11.42 Siemens: Foot switch

Documents added (STRG+ ):
2 3SE29.pdf (Resources/pdf/18014398625444619.pdf)

11.43 Siemens: Gear motor 1FG1

Documents added (STRG+ ):
2 1FG1_0321.pdf (Resources/pdf/108086391172858507.pdf)

11.44 Simco: Ionisation

Documents added (STRG+ ):
2 EasION.PDF (Resources/pdf/81064793584249227.pdf)
2 EasION_UM.pdf (Resources/pdf/81064793611778315.pdf)
2 EasION-R_PD_XF.pdf (Resources/pdf/81064793611781003.pdf)

11.45 SMC: Pressure amplifier

Documents added (STRG+ ):
2 vba.pdf (Resources/pdf/9007199370785803.pdf)
2 VBA-OM-D002.pdf (Resources/pdf/116048395.pdf)
2 VBA_Operation_manual.pdf (Resources/pdf/9007199371151883.pdf)

11.46 SMC: Precision regulator

Documents added (STRG+ ):
2 IR2000-2020.pdf (Resources/pdf/9007200443320843.pdf)

11.47 SPN: Planetary gear E2

Documents added (STRG+ ):
2 AA-0192-EK-0-E2.pdf (Resources/pdf/9007199370818699.pdf)

111101_en-US_2022-02-22_v1 391
11 | Separate documentation

2 Motor.pdf (Resources/pdf/9007199370820619.pdf)
2 SPN-ECO_E2.pdf (Resources/pdf/18014398625563531.pdf)

11.48 Stromag: Brake KLB

Documents added (STRG+ ):
2 KLB.pdf (Resources/pdf/18014398626168587.pdf)

11.49 Svecom: Chuck

Documents added (STRG+ ):
2 714_MZ.pdf (Resources/pdf/1559680907.pdf)
2 870018106.pdf (Resources/pdf/116715787.pdf)

11.50 Thomson Neff: Ball srew

Documents added (STRG+ ):
2 KGT_TGT.pdf (Resources/pdf/9007199371468939.pdf)

11.51 Valeo Auto Electric: Worm gear

Documents added (STRG+ ):
2 403_540.pdf (Resources/pdf/9007199371492619.pdf)

11.52 Zimm: Spindle lifting gear Z

Documents added (STRG+ ):
2 KGT-S.pdf (Resources/pdf/18014398747940235.pdf)
2 Z-25-S-R.pdf (Resources/pdf/9007199696850827.pdf)
2 Z_GSZ_2015.pdf (Resources/pdf/81064793409538699.pdf)

392 111101_en-US_2022-02-22_v1
 Electrical documentation | 12

12 Electrical documentation

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12 | Electrical documentation

12.1 Circuit diagram

The circuit diagram will be sent to you separately after successful

putting into operation of the machine.

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 Kampf Service Portal | 13

13 Kampf Service Portal

13.1 Log in to the KAMPF Service Portal

ü You are in the main menu.
1. Select File and then 'Login'.

Figure 341: Login menu

ð The Login window opens.

Figure 342: Login

2. In the Server names field, select the [Login@MachineHMI] server name.
3. Enter your personal user name in the Login name name field.
4. Enter your password in the Password field.
5. Confirm with OK.
6. After the first login you will need to enter your new personal password.
See Changing the login password [} 397]

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13 | Kampf Service Portal

ð You have logged in.

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 Kampf Service Portal | 13

13.2 Changing the login password

After the first login you will need to enter your new personal password.
ü You are in the main menu.
1. Select File and then 'Settings / New password' .

Figure 343: "New password" menu

ð The Change passwordwindow opens.

111101_en-US_2022-02-22_v1 397
13 | Kampf Service Portal

Figure 344: Change password

2. Enter the old password in the 'Old password' field.
3. Enter the new password in the 'New password' field.
4. Confirm the new password in the 'Confirm password' field.
5. Click Change to change the password.
ð The password has now been changed.

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 Kampf Service Portal | 13

13.3 Structure of the KAMPF Service Portal

After logging into the KAMPF Service Portal, you will see a similar screen:

3 4

Figure 345: Structure of the KAMPF Service Portal

1 Main menu 2 Facility tree
3 Functions 4 Central window
The KAMPF Service Portal is divided into four areas. The main menu at the top
of the screen, the facility tree at the top left, the functions at the bottom left and
the central window with the corresponding function you have selected.
Area Meaning
Main menu From the main menu you can change
the password and language, access
the conference center, data transfer
and VNC conference areas.
Facility tree The facility tree shows you the com-
pany name with the configured ma-
chines and if applicable the accessible
Ethernet nodes.
Functions The functions show all options associ-
ated with the active component in the
facility tree, e.g.:
– Connection Request,
– Service Request,
– Service Manager or
– Machine record.
Central window The central window shows you the ac-
tual matching functions.

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13.4 Sending a service request

To reach KAMPF Service Experts, you must submit a Service Request . You
can reach the Service Request window via the facility tree by clicking on the
respective machine and then selecting Service Request under Functions.

Figure 346: Service Request

All basic information, such as customer name, machine type, and commission
number are automatically sent with a request.
Please add your contact information. This way we can also contact you by
phone or e-mail.
1. Select the reason for your request, for example machine downtime.
2. Select the error location.
3. Provide a description of the error and the actions taken so far.
4. Optionally add files or screenshots and send the request to the KAMPF
service department.
ð The service department will be informed about your request by e-mail and
will be connected to the machine after your approval.

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 Kampf Service Portal | 13

13.5 Conference Center

After KAMPF service experts have connected to your machine, the conference
center offers the possibility of direct communication.
ü You are in the main menu.
1. Select the speech bubble and then 'Conference Center'.

Figure 347: "Conference Center" Menu

ð The Conference Center window opens.

Figure 348: Conference Center

The + symbol allows you to place the desired window enlarged in the center.
1. Wait for the KAMPF Service Expert to dial in.
ð You can communicate directly with the KAMPF service expert.

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13 | Kampf Service Portal

13.5.1 Participants
ü You will see a list of currently connected participants.

1 2

Figure 349: Participants

1 Chat checkbox 2 Voice conference or video con-
ference checkbox
1. Select the checkbox under the speech bubble next to the participant if
you want to chat with a participant.
2. Select the checkbox under the camera next to the participant if you want
to start a voice conference or video conference.

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 Kampf Service Portal | 13

13.5.2 Text conference

Use the text conference to exchange text messages with one or more
participants.

Figure 350: Chatboard

1. Write your message in the chat window provided.
2. Press Enter to send this message to all subscribers you have previously
selected.

13.5.3 Whiteboard
Use the whiteboard to share drawings or pictures to better describe the
situation.

2 1

Figure 351: Whiteboard

1 Open drawing tools 2 Load image
3 Drawing tools
1. Open the drawing tools.
2. If necessary, open an image from your hard drive.
3. Use the drawing tools to describe the situation.

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13 | Kampf Service Portal

13.6 Service Manager

The Service Manager provides you with information about the currently pending
service request.

13.6.1 Information
The Service Manager provides you with information about the currently pending
service request.
ü You are in the main menu.
1. Select the company in the facility tree.
2. Select the Service Manager in the functions.
ð The Service Manager window opens.

1 2 3 4 5

Figure 352: Info

1 Status 2 Data
3 Date 4 Machine ID
5 Offline since

404 111101_en-US_2022-02-22_v1
 Kampf Service Portal | 13

Here you can see a table with the following information:

Column Meaning
Status Display indicating whether a technician
is currently connected to the machine.
Data Display indicating whether file attach-
ments were sent with this request.
Date Display showing the date and time of
the service request.
Machine ID Display of the commission number of
the machine to identify it.
Offline since If a date is displayed here, the machine
is not connected to the Internet. This
will result in connection problems.
You can find more information under the [Info] tab.

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13 | Kampf Service Portal

13.6.2 Technician logins

Under the [Technician Logins] tab you can see the history of logins of a service
technician.

1 2 3

Figure 353: Technician Logins

1 Technician 2 From
3 To

Column Meaning
Technician Name of the service technician.
From Time and date of logging into your ma-
chine.
To Time and date of logging out of your
machine. If there is no entry, the ser-
vice technician is currently logged into
your machine.

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 Kampf Service Portal | 13

13.6.3 Comments
Under the [Comments] tab you can add additional information to the request.
This information is stored permanently and can be read at any time by Kampf
technicians.

Figure 354: Comments

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13 | Kampf Service Portal

13.7 Machine record

The machine record contains the service history of the machine. All requests
and entries are stored here.

Figure 355: Machine record

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 Kampf Service Portal | 13

13.8 Administration

13.8.1 Log in as administrator

Use this administrator access only to add or remove users.

ü You are in the main menu.

1. Select File and then 'Login'

Figure 356: Login menu

ð The Login window opens.

111101_en-US_2022-02-22_v1 409
13 | Kampf Service Portal

Figure 357: Login

2. In the Server names field, select the [Login@MachineHMI] server name.
3. In the Login name field, typeadmin .
4. In the Password field, typeadmin.
5. Confirm with OK.
6. After the first login you will need to enter your new personal password.
See Changing the login password [} 397]
ð You have logged in as an administrator.

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 Kampf Service Portal | 13

13.8.2 User administration

ü You are in the main menu.
1. Select File and then 'Settings / User Administration'.

Figure 358: User Administration Menu

ð The User Administration - Administrator window opens.

Figure 359: User Administration

With the + icon you can add a new user.
1. Enter the first name and last name in the User name name field (e.g.:
Sebastian Voss).
2. Enter the login name in the Login name field (e.g.: SVoss).

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13 | Kampf Service Portal

3. Enter a personal user password in the Password field.

4. Enter the personal user password for confirmation in the Confirm field.
5. Enter the user's e-mail address in the Email field.
6. Enter the user's phone number in the Telephone field.
7. Enter the duration for access authorization in months in the
Duration in month field.
8. Select the Operator entry in the [Available groups] field and use the ar-
row to move it to the Assigned groups field.
9. Click on the disk icon to save the user.
ð The user is saved.
Repeat this process for each operator of the machine so that each has his/her
own account.

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