Operation - Karl Eugel Fischer

KARL EUGEN FISCHER GmbH ⋅ MASCHINENFABRIK
Postfach 12 65 - 96220 Burgkunstadt/Germany
Operating Manual Order no.: CA101351
Cord Cutting Line Page: 5-1
Operation
Function and operation of the components
Component Function Operation

Main control panel To control the whole line. Input of the data.
Let-off station To unwind the cord material and Inserting of the cord material.
to wind-up the liner. Attaching of a new roll on the material
end.
Feeding system To transport the cord material Not operator assisted.
into the cutter.
Cutter To cut the cord material into Not operator assisted.
strips.
Splicer To splice automatically the cut Adjustment and supervision.
material strips together.
Slitter To cut the material strip Adjustment.
lengthwise into two strips.
Gum edge unit To wedge the material strips with Adjustment and supervision. Refilling
gum wedge strips. of gum wedge material.
Wind-up unit To wind-up the material strip. Cutting of material strip.
Change of cartridge.
Safety Instructions
During the operation of the line it is not allowed to touch the conveyors!
It is forbidden to lay anything down on them! Nobody is allowed to climb over the
conveyors, to sit down or to stand on the conveyors!
During the operation of the line, it is forbidden to stay inside the danger areas!
During the operation of the line, it is forbidden to touch the moving cord material,
to take anything away from the conveyor and reach into the cord loops or to
touch the cord loops!
After resetting the light barriers or doors, it is not allowed to stay inside the
respective danger area!
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N:\Cord\Kumho_Vietnam\CA101351_SCM-G_4600-1\QS\Operating_Manual\5-Operation.doc 2007-Jul.-25
Control
Operating elements control panel
The following operating elements are to be found on the control panel for the line:
Designation Function
EMERGENCY STOP The machine is stopped immediately by switching-off the
control voltage.
CONTROL VOLTAGE OFF Switches the control voltage off.
CONTROL VOLTAGE Switches the control voltage on.

ON Push button beams.
AUTOMATIC To stop the automatic function of the splicer.

STOP SPLICER
OPERATION / In operating mode ‘Maintenance’ certain functions can be
MAINTENANCE carried out from the main control panel. The service box on
the cutter can be used.
The key is to be kept by skilled personnel!

Use this mode for maintenance work only!
WITHOUT MEASURING / Without = To switch the width measuring system off.

MEASURING WITHOUT Display continues to function.
CORRECTION /
MEASURING WITH Without correction = Machine is stopped in case of error.
CORRECTION
With correction = If width measuring system determines a
deviation from the set width over a constant distance, a
correction will be done automatically, i e the strips will be
cut smaller or wider.
AUTO STOP To stop the automatic of the basic machine let off/feeding
CUTTER system/cutter.
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Screen
The available pictures of the control are shown in the first line of the screen and can be selected.
The last line of the screen serves for error displaying. If one of the fields becomes red, an error is
occurred at this machine component. Error diagnostic can be called for detailed error description.
FISCHER PICTURE
If this picture appears on screen the control voltage for the line is switched off. By pressing the
illuminated key “PLEASE TURN CONTROL VOLTAGE ON!“ on the control panel, the line is ready
for operation.
Shutdown
By actuating the button “SHUTDOWN“, the computer will close the operating system.
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MANUAL MODE
In this mode some functions on the line can be carried out manually or switched off resp. on. The
respective operating modes are highlighted.
When carrying out the manual functions nobody is allowed to stay inside the
danger areas of the cutter and the feeding system!
An inexpert operation can cause damages on line parts!
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Functions in ´MANUAL MODE´
Key Designation Function

traverse For manual movement of magnet bar located in the down
magnet bar holder.
P1 above / below
down holder For manual movement of the down holder located at the
P2 above / below cutter.
When actuating the ‚Up’-function for a longer time, the down
holder is run completey upwards in maintenance position, e g
to insert the material.
upholder For manual movement of the upholder located in the

P9 above / below conveyor of the cutter.
Precondition:
Safety devices reset.
gripper
P3 open To open and close the gripper manually.
P4 close
P5 forward To move the gripper of feeding system in running direction of

material away from the cutter blade.
P6 reverse To move the gripper of the feeding system backward to the
cutter blade.
Precondition:
Reference run for feeding system is carried out.
conveyor in cutter
P7 to front To jog the conveyor in the cutter.
P8 to rear
Precondition:
cutter
P11 mainmotor on To start the main motor in the cutter.
The remaining run-up time is displayed in seconds.
single stroke To carry out manually a cutter stroke.

Function appears as soon as the mainmotor is run up.
Precondition:
Gripper must be outside the cutter in a safe position.
letoff
P15 forward To manually jog the material in the let-off forward or
P16 reverse backward.
Precondition:
Safety devices at let-off station reset.
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GO HOME MODE
To move the axes, at first a reference run must be carried out for each axis. This can be done in
the ´GO HOME MODE´.
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As soon as the reference run is successfully completed, a „√“ tick is shown before the function
description on the screen.
Reference run is to be done at all axes in order to start the machine.
Axis Execution
Traverse Necessary at each switching-on of the line.
Function key is to be pressed as long as the reference limit switch
is actuated.
Splice head 1 / 2 Necessary at each switching-on of the line.
Function key is to be pressed as long as the reference limit switch
is actuated.
Splice conveyors Reference values are usually available when switching-on.
Reference run is only necessary at a new transmission of the PLC
program. Press function key as long as the minimum adjustments
are set.
Cutting angle Reference value is usually available when switching-on. Reference
run is necessary when changing the absolute encoder or at a new
transmission of PLC program. Press function key as long as the
minimum angle is set.
Further reference runs
This process is possible in each operating mode!

The reference values are usually available when switching-on.
Reference run is necessary when changing the absolute encoder/reference initiator or at a new
transmission of PLC program.
Move the axis on the position to the initiator indicated:
Axis Position
Splice angle Move to minimum angle in creep speed.
Splice width Move to maximum strip width in creep speed.
Slitter blade Move to maximum strip width in creep speed.
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SETUP MODE
In the ´SETUP MODE´, the actual cutting data and the data sent by the recipe capability are
displayed.
Transmission of cutting data
⇒ New data are to be input or called in recipe capability.
⇒ Transmit data to the PLC.
⇒ Call Setup picture. The data are displayed as preset values.
⇒ The data are transmitted to the line via key button „P8“ and are displayed as actual values.
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RECIPE CAPABILITY (Option)
An order data bank can be prepared for the cutting data by means of recipe capability and the data
are retrievable at any time (option). After input of the necessary cutting data like “NUMBER“,
“NAME“, “CUTTING WIDTH“, “WINDUP LENGTH“, the order is stored under the name of the
‘NUMBER’ by selecting the menu point “DATASET Æ SAVE“. Furthermore there is the possibility
to input a cutting program directly without data storage. In the left area of the screen a list of the
stored orders appears which can be changed or viewed according to selection. The input data or
the selected orders are transmitted as sequence order “SEND TO PLC” in SETUP Picture. The
recipe capability can be left via menu point “EXIT RECIPE” or by pressing the function key
“SHIFT+F8“.
Remark:
A detailed description is included in the online-help of the recipe capability.
Call with “?“ in the menu bar.
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AUTOMATIC MODE
There are two pictures available for operating mode Áutomatic´.
In the upper part of the screen it is displayed if width measuring system and cutting width
correction were selected (key-operated switch at operating panel).
During automatic operation nobody is allowed to stay inside the danger areas of
the line!
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AUTOMATIC
Functions

machine
P1 automatic To start automatic operation.
START Feeding system moves the material into the cutter. Then,
the cutter carries out a stroke.
automatic The corresponding function key located below on the

STOP operating panel is to be pressed to interrupt automatic
operation.
The feeding system and the cutter close their cycle and
return into starting position.
P2 automatic splicer To start automatic operation of the splicer.

START
P3 RESET breaker on To reset a strip after a manual cutter stroke or after

conveyor removal of a strip from the conveyor.
A new cut could only be carried if it is input in the control
that no strip is on the conveyor.
splice angle To display actual angle position of the splicer.
jog conveyors
direction To display the transport direction of the conveyors.
forward / reverse
P6 runin and runout To jog the conveyors together or separately.
P7 runin
P8 runout
position runin
P9 position + For exact positioning of incoming strip on the splice line.
P10 position -
position runout
P17 position + For exact positioning of outgoing strip on the splice line.
P18 position -
material guiding To readjust the material guiding on the run-in conveyor of
P13 position - the splicer.
P14 position +
splicing
splice shoe For operation of the splicer with/without splice shoe.
P15 with / without
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AUTOMATIC - DATA
In the upper part of the screen the current cutting data and the preconditions are displayed for
automatic operation.
Preconditions
The necessary preconditions for automatic mode are shown on the screen (at the top on the right):
letoff / traverse / cutter The protective devices at these components must be closed
safety not OK and reset.
cutting angle adjustment The let-off station is outside the desired position for cutting
out of position angle. The cutting angle is activated newly in the setup
picture.
let-off loop - not filled There is no material in the material loop of the let-off station.
The let-off station transports no material into the loop.
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let-off - end of cord End of cord material is reached. A new material roll is to be
inserted.
please start mainmotor Main motor was not started or it is not yet completely run-up.
cutter not in uppermost The blade beam is not in upper dead center. A cutter stroke
position is to be carried out in manual mode picture.
breaker on conveyor 1 There is a cut strip on feeding conveyor in the cutter. It is
possible to jog the strip out of the cutter or to start the
automatic. It is not possible to carry out a new cut until the
strip passes through the light barrier at cutter end.
If a strip was removed manually from the cutter, it is to be
confirmed with “RESET BREAKER ON CONVEYOR”.
traverse: not referenced The feeding system has lost its reference value. A reference
run is to be carried out.
traverse not in rear position Key button “P1“ for „AUTOMATIC START“ is to be actuated.
traverse is disabled – make Splice angle does not correspond to cutting angle. A set-up is
setup at splicer to be carried at the splicer.
order done, make new setup The order input in the recipe is completed.
let-off preguiding error Stockroll adjustment in the letoff-station is out of range.
KEFuser - no permission for No operator is logged on the machine. It is not possible to

automatic mode start the automatic. An operator is to be logged on.
let-off No station in auto There is no station in auto position. Turn the letoff station A
position or B into auto position by pressing the respective push
buttons at the letoff. The material ends are to be spliced
together, so that the let-off is ready for automatic operation.
calander splice at the cutter After splicing-on of a new calander roll, the splicer is
table automatically switched over to off line mode when the splice
arrives the cutter. The splice has to be cut out.
Functions
The following functions are possible additionally to the usual automatic picture:

let-off
P16 center control To activate or disable the center control of the material in
with / without the let-off station.
In principle the center control is activated after switching-
on the line. Switching-off is necessary, e g at bad material
edge.
shift chunter To reset the shift counter after shift change.

P22 RESET shift counters
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SELECTION OF SERVICE PICTURES
The selection picture can be called via key button ´DIAGNOSTIC´ and by pushing the key button
"EXIT".
Online-Dokumentation
To call the documentation stored on the hard disk.
Update: To load a new documentation. Input of abbreviation and password is necessary to log-in.
The selection picture can be left by pressing the key "EXIT".
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F2 – ANALOG VALUES
The picture “ANALOG VALUES” shows the current set values of speed for drives and the set
values for braking torque of drives and of analog braking units.
By pressing the function key “F2 = PART 2“ the monitor displays further ÁNALOG VALUES´.
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F3 – NETWARE DIAGNOSTIC
The picture shows the status of the ControlNet modules.

By pressing the function key “F3= RETURN“ the monitor displays the „SERVICE”-picture again.
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F4 = GRAFCET DIAGNOSTIC
In picture ´GRAFCET DIAGNOSTIC´ the course steps of single program modules and the function
of the respective modules are shown.
The previous selection picture returns via key “F4 = RETURN“.
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F5 - ERROR MESSAGES
The picture ERROR MESSAGES can be called as follows:
Automatic call-in
By loss of control voltage (e.g. emergency-stop).
Call-in with "DIAGNOSTIC"

At each operating mode via the respective function key.
Big errors (priority 1, e.g. want of air, oil pressure) must be reset by means of blue reset button at
the control panel after failure corrective action was made.
Small errors (priority 2 and 3) are automatically reset after failure corrective action was made.
Picture error messages can be left by pressing the key EXIT.
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The errors messages consist of following:
89 Continuous error number acc. to programming in the control.

=4-18B2 The device designation number of the respective switchgear:
Number 4 means group 4 of the electrical diagram.
Number 18 means page 18 in group 4.
Letter B means the short name of the switchgear.
Number 2 means the current circuit path 2 on page 18.
”support sheet 1(big) Error description with indication of switchgear.
is in rear position”
9:22:00 AM Time of the error occurrence.
LO Short name of the line component e g
LO = let-off station; FED = feeding system;
CU = cutter; WUA = wind-up unit A.
The errors are listed according to the component.

The errors can be filtered according to component and priority by actuation of the switching
surfaces located in the lower screen area.
Error messages occurred in the past can be seen in “special” – “archiv” located at the menu. Archiv
can be left via ESC-key button.
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F6 - SYNOPTIC
For graphical display of the error position in the layout.
The display can be chosen by means of the standard error diagnostics (error message) if there is
an error. The graphical display of the whole line is shown on the screen.
The errors are indicated in the error list of this display, and these errors are marked by a red circle
in the display. If an error appears, it can be selected from the list by clicking the mouse. By this, the
circle assigned to this error becomes red filled (in the corresponding error position). If no error list
appears in the display, the error can be found out by moving the mouse over the layout; the mouse
pointer changes to a green or red circle. The green circle indicates that there is no error in the
respective component. The red circle indicates that there are errors in that component. A new view
of a component only can be shown (e g the let-off station) by means of a click on the respective
component with the left mouse button. All errors for this component are indicated, too.
Complete line
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Let-off station
Wind-up unit
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F7 – AXIS DIAGNOSTIC
The service picture ÁXIS DIAGNOSTIC´ shows the status and the position of the axis positioning
module.
By pressing the function key “F7 = RETURN“ the monitor displays the ´SERVICE´-picture again.
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F8 – COUNTER AXIS
The picture ĆOUNTER AXIS´ shows the current positions of the counter axes and the reference
values.
The previous selection picture returns via key “F8 = RETURN“.
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F9 - USER MANAGEMENT PROGRAMM
General information about user management
The job of the user management software is to set the permissions of all users in a central
software module. For this, you can create as many user and user groups as necessary. The
permissions can be set for each user group separate. The permissions of the user can be set by
assigning them to the user groups they belong to.
As additional option, one user can log on as machine operator. This active operator is displayed in
the visualization by name. In the archive a protocol is written, who has operated the machine at
which time interval.
If required by the customer, the PLC can be programmed to allow automatic mode only if a user
with the required permission is logged on.
If a protected function is called up in an external program like the recipe management software, the
machine runtime protocol or maintenance service program the user management is asked about
the permissions. If the currently logged on machine operator has the permission for this function,
no further password entry is required. If the machine operator has not sufficient rights, there will
appear a logon screen and prompt the user for name and password. In that case, the user has to
enter name and password to get the permission for this function. The active machine operator will
not change by this. This means logging on as machine operator is different to logging on for a
specific function.
The main screen
After start up of the software the main screen will appear.
Here the user can log on, who has to operate the cutting machine (Option). The button [log off]
becomes active only if a operator is logged on.
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By pressing the button [Exit] you can switch back to the machine visualization.
By the menu entry [Edit / User manager] or [Edit / Group manager] you come to the user
management described in an own chapter later.
By selecting the menu item [Language] you can select from the activated languages. By this, the
complete software will be translated to the selected language.
If the central language switching is active, this menu items are disabled. In that case, the language
can be selected in the start up screen of the machine visualization or in the error diagnostic screen.
There the active language can be selected and all the Fischer programs installed will switch to this
language automatically.
The menu item [Info / archive] will lead to the archive of machine operators, described in the next
chapter.
The archive (Option)
Here you can find out who was operator of the machine at a selected time. The duration how long
this information is stored can be adjusted for the requirements of the customer.
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By the menu item [File / Print] the list can be printed on the default printer. The font and page setup
can also be defined.
By selecting the menu item [File / Export] you can export the list as coma separated file. This is
useful to bring the data to other software like Excel or Word. If one or more lines are selected, only
the selected lines will be exported. If no lines are selected, the complete list will be exported. As
the user management and the machine runtime protocol software work hand in hand, you can view
this list of machine operator also in the machine runtime protocol if this one is installed on the
machine computer.
Manage operators
In this screen you can manage the operators of the machine.
After selecting the menu item [User / Create new user] you will be asked for the name of the new
user. This name can contain up to 30 characters.
Then you have to enter and confirm the password containing up to 20 characters.
The information field [Created] is filled automatically when creating a new user.
The information in [Last modified] is also filled automatically each time someone changes the
group relations of this user.
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The permissions of the user can not be adjusted directly. You have to edit the relationship to the
existing groups in the right side of the screen. By this the permissions of the user are influenced.
By selecting the menu item [User / Duplicate current user] also a new user is created. However, by
this the current user is taken to make a copy. This means the same group relations are created for
the new user as existing for the current user.
The menu item [User / Delete current user] will delete the currently selected user.
By the menu item [Group / Group manager] you can switch directly to the group management. This
screen is described in the next chapter.
After selecting the menu item [Change Password] you are asked to enter the current password for
the selected user. Then you can define and confirm the new password.
By the menu item [Reset Password] the password for the selected user is deleted. This is useful if
an operator has forgotten his password. The administrator can reset the password and there is no
need to create a new user account. After that the password can be changed to a new one like
described above. The old password is blank in that case.
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Manage user groups
Here you can manage the properties of the user groups.
Normal user groups
After selecting the menu item [Group / Create new group] you will be asked for the name of the
new group in every language which is activated in your software.
The info field [Created] is filled automatically at creation of a new group. The data in [Last modified]
will be filled every time the permissions of a group are changed.
In the middle of the screen you can adjust the permissions of the group by toggling the checkboxes
of the desired permissions.
In the right side of the screen you can select the persons who are member of the actual group or
not.
By selecting the menu item [Group / Duplicate current group] also a new group is created.
However, in this way the current group is used as pattern and the permissions of the new group
will be set to the same permissions as the current group.
By the menu item [Group / Delete current group] the selected group is deleted.
The menu item [User / User manager] will switch directly to the user manager. This function was
described in the last chapter.
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System groups
After selecting the menu item [View / System groups] you have to enter a password. This system
groups should not be modified in the normal machine operation. If you need to change this
settings, please contact K. E. Fischer company to get the password. The settings can be adjusted
together with Fischer company to meet the requirements of the customer.
This system groups are for some basically program settings.
By the group [Default permissions] is defined, which permissions are granted when NO user is
logged on as machine operator. After a machine operator has logged on, this settings have no
longer any meaning.
Example:
You can set here the permission [BDE: View protocol data]. By this, the function can be used also
no user is logged on who has this permission.
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By the group [Always ask for password] you can set, which permissions are so critical that you
always have to enter name and password at the logon screen.
By default, external programs like recipe management software, machine runtime protocol or
Maintenance service program ask the user management software first for the permissions of the
currently logged on machine operator. If this operator has the required permission (for example
acknowledge a maintenance job as done) the function is executed without further dialog boxes and
the name of the current machine operator is written to the protocol if required. If the current
machine operator has not enough permissions for the chosen function, a logon screen will appear.
Then you can log on with name and password of a authorized user.
If the required permission is marked in the system group [Always ask for password] the name and
password of the user is always asked, no mater of the permissions of the current machine
operator.
Example:
The operator User1 is logged on as machine operator and has the permission to acknowledge
maintenance jobs of priority 9. If in the maintenance service program a maintenance job of priority
9 has to be acknowledged, by default no logon box would appear because the machine operator
has the required permission.
If this permission [Maintenance: Prio. 9 acknowledge] is marked in the system group [Always ask
for password] there will appear a logon screen asking the operator to authorize with name and
password to acknowledge the maintenance job. In this case any user with the required permission
can log on, also the current machine operator User1.
By use of the system group [Visible Permissions] you can specify which permissions should be
visible for the normal user or user groups. By this, the permissions not necessary for this machine
can be hidden.
Example:
If a machine is running without the optional maintenance service program you can hide all
permissions associated with this program. By this, the number of permissions decreases. In the
user management only such permissions will appear which influence the machine operation.
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F10 - MAINTENANCE CYCLES
General
The software for showing the maintenance service intervals is an additional module for a FISCHER
Cord Cutting Line.
With this module cyclical maintenance jobs will be shown on screen of control panel.
The actual jobs are shown in a list. Every job (message) is linked with a position in a picture as
well. With this the maintenance crew can locate the position and execute the job at the machine
very fast and correctly.
The shown jobs have to be marked as finished by the maintenance crew. For that purpose a code
and a name have to be entered.
A printout of the cyclical maintenance jobs is available in the electrical documentation.
How to use
When a job becomes due, a little window pops up:
Here are 99 maintenance jobs

to do (acute)
1 job in the near future

(preview-) parameter)
Press this button for a list of Press this button and this window
all acute maintenance jobs. pops up in nearly 3 hours.
With a task-change (ALT + TAB -key) this window can be set to the foreground every time.
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Key treat now
After pressing the key ‚treat now’ the following picture appears at screen:
Menu
Table of acute maintenance jobs General information

(red = acute, yellow = simple jobs (no password
available), white = preview, green = done)
Here all actual jobs can be seen in a list. They are sorted by machine component and cycle.
Legend to the columns:
no id of cycle (e.g. 5th cycle since the plant was put into operation)
component machine component
time after this time value (hours) the job have to be leaded
cut after this cuts the job have to be leaded
pos position of the job at the component (see ‘View’ and printout of
maintenance jobs)
look at element of component
what to do job to do at the component
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The cursor in the table is controlled by the cursor keys at keyboard.
When a message is selected (↵-key or double click or menu view) the following picture appears:
Here you get all the actual jobs to do at this component. For that, all available pictures with cross
references to the locations of the job are listed. The highlighted name is the actual picture name.
The columns are equal to the table definition above.
Here the jobs will be marked when they are done (‘ok’). Do this with double click at ok-column (first
of columns). The box is then marked (x). After return, all the marked jobs will be green labelled in
main-picture. Jobs that can be done by every operator (without password) are labelled yellow.
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When you want to store them as ‘done’ jobs (!), click the button ‘confirm’.
Now you have to enter a name and a code:
When the code and the name match (see user management) all the marked jobs will be listed
again. Now you can check again if all these jobs are really done. If necessary the jobs can be
unmarked.
Save as confirmed jobs Back without saving
The confirmed jobs are stored in a database.

You can look at this table with the button ‚protocol’.
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After the login as shown above (rights for login see user management) a new table sorted by
components and cycles appears:
2nd cycle at linear guide
17th cycle at linear guide
In the time- and cuts-column you see two values.

The first value shows the moment of finishing the job and the second value shows the right
moment of doing the job (according to the documentation).
You can export all these data to a:
a) text file:
b) Microsoft Access database with table “cycles”:
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When all jobs are done (table empty), you get back to the machine program.
But not all jobs have to be confirmed at once. In this case a little message window pops up again
after 3 hours.
If there are jobs marked and not confirmed and the exit-button is pressed, a new info-window will
pop up:
Yes: a login is necessary to confirm the marked jobs (see above).

No: back to the machine control and after 3 hours you get a reminder that there are jobs to do!
If you want to finish the program totally press the x in the upper right edge of the little window (s.
picture 1). For this you need the master code and name.
Test mode with showing all possible cycles
When you activate this option you will see all the cycle-messages in the main list. The cycle
number is 1, the time is the cycle time and the cuts are the cycle cuts between the cycles.
In this mode you can do all the things you can do in the normal run except the saving of
acknowledged jobs into archive.
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Adding a new maintenance cycle
After the login as shown above (rights for login see user management) a new window with ability to
enter a new maintenance cycle appears:
For a new cycle you need to set the belonging component, the cycle time, the position in the
loadable picture (if available), the necessary user rights, an information for the position in the
machine (look at) and what is to do.
If there is a new component (after basic installation of the machine) installed, for that is no name in
the component drop down list, you can enter the name of the component into the belonging text-
field.
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When pressing the button “yes” you can choose if you want to add the new component to the
system database or not.
Every job needs a group for the rights. Only personal of this group can confirm the job.
There are 10 groups available (see user management).
After pressing the button text, you can change the name of the group.
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F11 - PRODUCT DATA MANAGEMENT
General information
The first job of the BDE-Program is to log the downtimes of the machine. The operator has to
select the reason of the downtime.
The second job is to log the shifts operated on the machine. This means, if the PC runs, every shift
recognized by means of the shift plan is logged to a shift protocol. The operator can enter a
comment and special shift data like the waste amount.
The third job is the logging of the production amount. The customer can chose to log the length
and production time of each single roll, the data of the total job or both. For this the recipe code
and the length of produced material is read out continuously for each production line. If the length
decreases down to zero, a new job or roll is recognized.
The main screen
After start of program the following screen appears:
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In this state the program continuously reads the status of the machine and displays it in the bottom
of the screen. If the machine is not down, the program can be exited. Then the program works
invisible in the background.
In the menu item LANGUAGE all available languages can be chosen. By this, the complete screen
is switched to the selected language.
If the central language switching is activated, the menu item will be disabled. In this case the
desired language in the startup screen and the error diagnostic screen of the visualization can be
selected. This will change the active language in all Fischer programs to the requested language.
Selecting a fault reason
As soon as the PLC indicates a fault, the BDE software comes to the foreground and the operator
has to enter a reason for the fault.
The start time of the fault and the duration in hours and minutes appears in the screen. The reason
is set to „--„ by default.
Now the operator has to enter the reason for the fault by clicking one fault button with the mouse or
entering a fault with the keyboard.
The list of available fault reasons can be edited in a separate window which is explained later. This
is usually done before machine startup together with the customer.
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Up to four cards each with up to 16 fault reasons can be displayed.
The operator can leave this window, but as long as no fault reason is selected, the BDE software
will continuously pop up to the foreground to prompt the operator for a fault reason.
After the operator has selected a fault reason, the button will be highlighted and the reason is
displayed in the text field. If the fault ends, this fault reason will be stored automatically in the
database.
If the operator changes the fault reason within 30 seconds, the old fault reason is ignored and the
new reason is active for all the down time. If the operator changes the fault reason after 30
seconds, he will be asked what to do with the time up to now. It can be decided to book the whole
down time to the new fault reason or to book the time up to now to the old fault reason and start
the time new beginning from now with the new fault reason. In this case the down time is split into
two parts. The time for the new reason starts from 0.
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Entering the shift data
In the folder shift data the operator can see the current shift time automatically detected by the
software.
Additionally, a comment to the actual shift can be entered by the operator as well as up to 5
numeric values. The meaning of this values can be individually defined in accordance with the
customer. This fields can be used for example to enter the waste amount per shift.
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The data evaluation
In the menu item View different views of the data stored in the database can be displayed. All
these data views can be displayed in the page preview, printed and exported to a CSV-file. The
separation character for the CSV-file can be set in the program parameters. In Germany this is
usually the ';' and in USA this is usually the ','.
View - internal data
In the submenu internal data the internal tables of the database can be viewed. These data are not
prepared for the customer, it is just the raw data to check the correct function of the software.
For example here is a screenshot of the table 'Production' containing the production data.
To explain the structure of the data all entries related with the recipe 196b are marked and
described with a comment. The side LA indicates entries for start / stop of a production job. The
side L1 indicates entries for each single roll.
LA: production start
L1: roll 1 start
L1: roll 1 end / 131m of

recipe 196b on this roll
L1: roll 2 start
L1: roll 2 end / 129m of

recipe 196b on this roll
L1: roll 3 start
LA: production end / 390m of recipe 196b
L1: roll 3 end / 130m of recipe

196b on this roll
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View - internal queries
In the menu item internal queries you can select SQL-queries stored in the database. All queries
beginning with 'REPORT_' are displayed in the submenu automatically. By this special queries can
be defined to meet the special requirements of the customer. Such special queries can be added
with MS Access without changing the source code of the software.
For example here is a screenshot of the query 'Errors and Production'.

All start and stop entries for the production jobs and the down times of the machine are listed
chronologically here.
Recipe 172b /Start
Two downtimes
happened during
this production
Recipe 172b /End

261m produced
System fault 0:
Computer was down
for about 14 hours
Status log entry

caused by computer
Status log entry

caused by shift
change
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View - Reports
In the sub menu Reports there are reports designed for customer’s requirements. These reports
are too specific and complex to implement as query. They are part of the software and can be
modified only by changing the source code of the program.
These reports can be designed according to customer’s requirements (this is an additional

OPTION).
A typical report for the availability of the machine can lock like the following, for example:
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Automatically export of roll data
If the customer needs the roll data for automatic data processing (for example to print a material
card with barcode for each roll produced), the parameters of the software can be set to create a
text file with the main production data of each roll.
The path and filename is freely adjustable, so that this file can be put on a computer in the
network. For this the destination computer must be connected to the network and must have a
folder shared on the network. This path must be specified in the corresponding parameter.
The ID for the side will be appended automatically to the path. (for example L1, L2, LA, LB, ...)
If the path ends with a underscore '_' the date and time will be appended as well to create unique
files which do not overwrite each other.
Example 1:
Path: \\HOST_PC\Share1\Folder1\RollProtocol
If the BDE software runs on a one leg line to the left with slitter, the following files are written:
\\HOST_PC\Share1\Folder1\RollProtocol_L1.TXT
\\HOST_PC\Share1\Folder1\RollProtocol_L2.TXT
These filenames are always the same. This means after the next change of the roll this files will be
overwritten.
Example 2:
Path: \\HOST_PC\Share1\Folder1\RollProtocol_
If the BDE software runs on a one leg line to the left with slitter, the following files are written for
example at 12 November 2002, 13:46:
\\HOST_PC\Share1\Folder1\RollProtocol_2002_11_12_13_46_L1.TXT
\\HOST_PC\Share1\Folder1\RollProtocol_2002_11_12_13_46_L2.TXT
In this case the date and time are included in the filename and the files will not be overwritten. For
each produced roll a new file is created. The customer is responsible for deleting the files after
data processing is done (for example after printing of the material card).
The files contain the following data:
"Recipe: TypA"
"Length: 125"
"Start: 2002-11-13 11:02:39"
"End: 2002-11-13 13:42:20"
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Definition of the possible fault reasons
Via menu item [Edit / Fault] the following list appears where the fault reasons can be defined as
requested by the customer.
If a password was defined in the menu item [Edit / Password] it has to be entered to come to the
screen with the fault definition.
The field Error is the ID of the fault and must not be modified.
The field Group can be used to assign some faults together to a similar group, for example:
mechanical faults / electrical faults / general faults or faults caused by operator / faults not caused
by operator.
If the field Manual_Start is activated the fault can be activated even though the machine is running.
This makes only sense in some special cases, for example when test-run of the machine should be
recorded (the machine works, but the material is not used in production).
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Via field Visible the fault buttons not used can be hidden.
The last field contains the fault reason as text and is linked with the language table.
In the protocol of the database the fault ID's (for example 1A) are stored only.
By this, the list of faults should only be extended with new fault reasons. Mistakes in spelling can
be corrected or text modifications can be made. But the meaning of an existing fault reason should
never be changed.
ATTENTION:
If the meaning of a fault reason is changed, this will result in wrong reports.
For example if you change the fault reason 1A from the current meaning 'shift start / -stop' to the
new meaning 'no material', the new fault reason 'no material' will appear in all reports.
If such a change is necessary the protocol data should be deleted so that the protocol starts new
and to avoid wrong reports.
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Definition of the shift plan
Via menu item [Edit / Shift plan] following screen appears:

If a password was defined in the menu item [Edit / Password] it has to be entered to come to the
editor of the shift plan.
Here the shift plan can be entered, which is used by the software to write the protocol of the shifts
where the machine was on. Up to 9 shifts per day can be defined. If the end time is before the start
time, the software expects the shift to end the next day.
A modified shift plan becomes valid after the current shift is over. The currently active shift will not
be changed once it has started and is logged to the database.
Example:
The shift Monday-1 (6:00 -- 14:00) has started and becomes active.
Monday morning at 8:00 the operator changes the shift plan as follows:
Mo1 (4:00 -- 10:00)
Mo2 (10:00 -- 16:00)
In this case the active shift will continue until 14:00.
At 14:00 the shift plan is evaluated to get the next shift.
Because only one shift can be active at a time, the start of the next shift is set to 14:00. The shift
written to the protocol is Monday-2 (14:00 -- 16:00).
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F12 = WIDTH MEASURING
A description of width measuring system can be found in the electrical documentation of

subsuppliers section letter B for BST.
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Starting
Before each start, the operator must ensure that nobody is working in/at the line!
Normal start
⇒ Master switch on at control cabinet.
⇒ Air supply on.
⇒ Control voltage on at the main control panel.
⇒ Reset safety devices.
⇒ Main motor on in manual mode.
⇒ Carry out reference run.
⇒ Input of the cutting data in setup mode..
⇒ Call automatic mode and start automatic.
Start after EMERGENCY STOP
If the machine/line has been taken out of operation by an emergency stop, the
operator must find out the reasons for the stoppage before switching back on
again!
⇒ Pay attention to the error advice of the control.
⇒ Unlock the EMERGENCY STOP key button.
⇒ Control voltage on at the main control panel.
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Abwickler / Let-off station
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Abschneidevorrichtung
Cutting device Abzugsrolle
Wickelrichtung gedreht
Draw-off roll
Cord Cutting Line
Let-off station
Winding direction turned Parkstellung Andrückrolle

Parking position Druckrolle Contact
pressure roll
Operating Manual
Materialrolle Pressure roll

Material roll
Vorbereitungsleiste
Preparing bar
Tänzerrolle arretiert
Dancer roll locked
Steuerrolle
Steering roll
Page: 5-52
Order no.: CA101351
N:\Cord\Kumho_Vietnam\CA101351_SCM-G_4600-1\QS\Operating_Manual\5-Operation.doc
Materialstreifen Transportrolle
Mitläuferaufwicklung Material strip Feeding roll
Liner winder Spleißleiste
Wickelrichtung normal Splicing bar Tänzerrolle abgesenkt
Winding direction normal Dancer roll let down
Optic “Kante suchen”
Optic searching edge
2007-Jul.-25
Date:
Operator panels
Operating elements let-off rear:
EMERGENCY STOP To stop the machine immediately in case of emergency.
RESET To reset safety barrier at prepareposition.

SAFETY LIGHT BARRIER
STOCKROLL LOADED To select the direction of which the stockroll material will be
NORMAL FROM BELOW / coming off of the material roll in automatic position.
TURNED FROM ABOVE
STOCKROLL ADJUSTMENT To manually adjust the stockroll position laterally.
TO LEFT / TO RIGHT
STOCKROLL To jog forward or reverse the direction of the stockroll in the
PREPAREPOSITION prepare position.
REVERSE / FORWARD
JOG LINERROLL To jog the liner roll in prepare position.
PREPAREPOSITION
TURNING STATION To manually turn the station A/B to the auto position.
A / B TO AUTO POSITION
PREPAREBAR TO To swivel the preparing bar.
AUTOPOS. / PREPAREPOS.
PREPARE To align automatically the material at the preparing bar in
START prepareposition und to release for automatic turning and
splicing.
When actuating once more, the release will be switched off.
MAGNET ROLL To jog the magnet roll forward or reverse manually.
REVERSE / FORWARD
MATERIAL SPOOL Initiation of this push button puts the let-off section in
PREPARED automatic for automatic turn and rewinding of the liner. This
button is pushed after preparation of the stockrolll is
complete.
Operating elements let-off lateral:
RESET SAFETY To reset safety door at the let-off.
DOORS
AUTOMATIC STOP Stops the automatic function of the basic machine.
AUTOMATIC START Starts the automatic function of the basic machine.
STOCKROLL To jog forward or reverse the direction of the stockroll in the
REVERSE / FORWARD automatic position.
STOCKROLL ADJUSTMENT To manually adjust the master roll position laterally.
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TO LEFT / TO RIGHT
DRAW OFF ROLL Jogs the draw off roll forward or backwards.
REVERSE / FORWARD
ADJUSTMENT OPTICS To readjust the optic “EDGE SEARCH” manually.
"EDGE SEARCH"
WIDE / SMALL
EDGE SEARCH Light if the optic “EDGE SEARCH“ moves.
SPLICING In manual mode: To move manually out the splicing bar.

In automatic mode: To carry out a splice cycle with automatic
alignment of material.
TURNING STATION To manually turn the station A / B to the auto position.
A / B TO AUTO POSITION
PREPARING BAR To swivel the preparing bar.
TO AUTOPOSITION /
PREPARING POSITION
CUT OFF DEVICE To manually move the blade of the cutting device to left or
<--- ---> right.
CUT OFF To start the cutting device.
SUPPORT SHEET To shift manually the support sheet on the cutter table.
ANGLE ADJUSTMENT
REVERSE / FORWARD
Operating elements let-off inside:
FEEDING ROLL To select the jog direction.
REVERSE / FORWARD
PRESSURE ROLL To move the pressure roll at the feeding roll up or down
FEEDING ROLL manually.
UP / DOWN
FEEDING ROLL JOG To jog the feeding roll resp. the material forwards or
(at helix cable) backwards depending on the position of the selector switch.
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Inserting of the material in the prepare position
⇒ Choose direction of rotation of the preparation position with selector switch „STOCKROLL
LOADED TURNED FROM ABOVE / NORMAL FROM BELOW“.
⇒ Enter danger area open bearings and insert material roll into the bearing with suitable lifting
device. Close tilting bearing.
The spool must be handled with care otherwise there is the danger of
crushing e.g. at the columns of the light barriers, fence or let off!
Take care of other persons and cause no damage on the machine!
⇒ Leave danger area and reset safety light barrier.
⇒ Unwind liner by means of jack button „STOCKROLL PREPARE POSITION FORWARD“ and
guide it around the rolls according to the sketch.
⇒ Open tilting bearing, insert empty winding core for line with suitable lifting device and close
tilting bearing.
⇒ Fix liner on empty spool.
⇒ Leave danger area and reset safety light barrier.
⇒ Wind liner on by push button “MITLÄUFER VORBREITUNGSPOS. TIPPEN“.
⇒ Swivel preparing bar in prepare position by jack button “PREPARING BAR TO

PREPAREPOSITION”.
⇒ Enter danger area and fix begin of material on the preparing bar. Without any tension after
positioning of the material in the roll.
It is a must that the material covers the total height of the preparing bar.
Otherwise, the area for splicing-on is too small and therefore, the splice does
not stick!
⇒ Leave danger area and reset light barrier. The cycle for material alignment is started by means
of push button „PREPARE START“ and the prepareposition for automatic turning and splicing
is released.
First threading-up of material through let off and cutter to the splicer
⇒ Lift down holder up (control - picture manual mode).
⇒ Turn let-off station means of jack switch „TURNING STATION A / B TO AUTOPOS.“

(operating console at the side of let-off).
⇒ Align material roll by means of jack button „STOCKROLL ADJUSTMENT TO LEFT / TO

RIGHT” to let-off station.
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⇒ Jog begin of material by means of jack button “STOCKROLL AUTOPOS. FORWARD” as far
as it is possible to put the material strip through the draw-off roll and the pressure roll.
⇒ Enter the safety area and lead the begin of the material between the draw-off roll and the
pressure roll.
⇒ Lift dancer roll and lock it.
⇒ Leave danger area and reset door.
⇒ Jog the begin of the material forward by means of jack button “DRAW OFF ROLL FORWARD“
to the ground grid. The material can only be jogged until the light barrier of the loop is
interrupted. This function can be bridged by pressing the jog button and the key button Auto-
Stop at the same time.
⇒ Enter danger area: Feed the begin of the material through under the metal roller and dancer
roll. Lift the pressure roll by actuating the jack button „PRESSURE ROLL FEEDING ROLL
UP“. Guide the begin of the material under the pressure roll and and clamp the material with
“PRESSURE ROLL FEEDING ROLL DOWN”.
Danger of crushing at the pressure roll!
⇒ Release dancer roll, leave danger area and reset door.
⇒ Start automatic at let-off.
⇒ Enter danger area in front of the cutter. Guide begin of material over the cutter table as far as
over the blade edge by means of push button „ FEEDING ROLL JOG” located at helix cable.
⇒ Close safety door and reset.
⇒ Lower the down holder and carry out a single stroke in ´MANUAL´-picture.
⇒ Move scrap out of the cutter by jogging the conveyors.
⇒ Start automatic.
Manual splicing on of a new material roll
⇒ At the end of material the let-off station stops automatically. Turn prepared winding station to
automatic position with jack switch “TURN STATION A/B TO AUTOPOS.”.
⇒ Align new material roll by means of jack switch “STOCKROLL ADJUSTMENT TO LEFT / TO
RIGHT” to material end.
⇒ Position the end of material by means of the jack button „DRAW OFF ROLL REVERSE“ at the
splicing bar.
⇒ Actuate push button “SPLICING”.
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⇒ After splicing-on of a new material roll, the material is automatically stopped when the splice
arrives the shear/cutter.
Automatic splicing on of a new material roll
⇒ The prepared roll is spliced on fully automatic after stop of the let-off at the end of material:
- The turntable swivels by 180°.
- Edge of material beginning is detected.
- Edge of material end is detected.
- The new roll is aligned to material end.
- End of material is transported back to the splice bar by the draw off roll.
- The splice bar moves out and splices the new roll on.
⇒ Then check if splicing has been carried out correctly and start automatic.
⇒ After splicing-on of a new material roll, the material is automatically stopped when the splice
arrives the cutter.
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Main control panel
Angle regulation
Precondition: Protective devices must be closed and safety light barrier at the let-off station must
be reset.
⇒ The desired angle is to be input at the main control panel or is to be selected in the program
menu (option).
⇒ The regulation of cutting angle is carried out by permanent pressing of the key button in the
Setup picture at the control panel:
- Dancer loop is filled.
- Gripper moves the material forward. At the same time the support sheet moves into the front
position in the cutter.
- Gripper opens and runs back from the cutter.
- Let-off station runs to the new angle, at the same time the material is withdrawn by contact
pressure roll.
- The support sheet moves back.
- Cutter cuts the scrap.
- The scrap is transported out of the cutter to the pallet for scrap.
- If swivelling movement exceeds a certain angle, the process will be repeated.
It is absolutely forbidden to stay in the swivelling range during the angle

regulation! Special attention must be paid to the area behind the let-off
station!
The operator must ensure that there are no obstacles or any pieces on the
ground in the swivelling range!
⇒ Then the angle must be set at the other line components (see description of line components).
Width adjustment
⇒ The required width is to be input at the main operating console or is to be selected in the
program menu (option).
⇒ The data are delivered to the line by pressing the function key „SETUP DATA“ in the Setup
picture.
⇒ Then all components of the line after the cutter must be adjusted to the changed material width
(see description of the line components).
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Splicer
Following operating elements are to be found in the control for the splicer:

machine
P1 automatic To start automatic operation.
start Feeding system moves the material into the cutter. Then,
the cutter carries out a cut.
automatic The corresponding function key located below on the

stop operating panel is to be pressed to interrupt automatic
operation.
The feeding system and the cutter close their cycle and
return into starting position.
P2 automatic splicer To start automatic operation of the splicer.

start
P3 RESET breaker on To reset a strip after a manual cutter stroke or after
conveyor removal of a strip from the conveyor.
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jog conveyors
forward / reverse To display the transport direction of the conveyors.
P6 runin and runout To jog the conveyors together or separately.
P7 runin
P8 runout
splice heads
P9 1:up For manual movement of the splice heads 1 or 2 to the
P10 1: down left or to the right or of the splice heads 1 or 2 up and
P17 1: to left down.
P18 1: to right
P11 2:up
P12 2: down
P19 2: to left
P20 2: to right
material guiding
P13 position - To readjust the material guiding on the run-in conveyor of
P14 position + the splicer.
splicing
P15 splice shoe For operation of the splicer with/without splice shoe.
with / without
splice head start
position
P21 position - To readjust the starting position of splice wheels.
P22 position +
Operating elements control panel splicer:
SETUP SPLICER At first the splicer runs to the angle input at the main control
panel. Then, the conveyor are adjusted to the angle.
RESET SAFETY OPTIC To reset the light curtain at the splicer.
SPLICE ANGLE To readjust the splice angle. If the correction exceeds 0,5°,
-/+ the conveyors will have to be readjusted too.
SPLICE POSITION To readjust the starting position of splice wheels.
SPLICE HEADS For manual movement of the splice heads to outside.
TO OUTSIDE
JOG To jog the conveyors located in front of and behind the
REVERSE / FORWARD splicer.
To select transport direction.
MATERIAL GUIDING To readjust the material guiding on the run-in conveyor of the
SLIDING BAR -/ + splicer.
JOG RUNIN To jog the runin conveyor manually.
JOG To jog the conveyors together.

RUNIN / RUNOUT
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JOG RUNOUT To jog the runout conveyor manually.
AUTO STOP SPLICER To stop automatic operation of the splicer.

CYCLE STOP SPLICER To stop automatic function of the splicer.
Cutting and splice cycle is finished first.
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Functioning of the splicer
The splicer works in automatic operation without control. Essentially adjustments are to be done.
Spleißer / Splicer
Spleißlinie Startposition Spleißwinkel

Materialführung Splice line Start position Splice angle
Sliding bar
Aus-/Einlauf-Lichtschranke
Run-out/-in light barrier Spleißkopf 1
Splice head 1 Spleißkopf 2 Spleißschuh
Einstellung nicht verändern
Splice head 2 Splice shoe
Do not change the adjustment
Einlauflineal Lichtschranke Hochhalter Auslauflineal Magnetplatte

Run-in ruler Light barrier Lifting device Run-out ruler Magnet plate
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For understanding of the functioning of the splicer and to show the adjustment possibilities of the
splicer, the functioning course of a splice is described step by step as detailed below:
⇒ A strip is cut by the cutter in automatic mode and the strip is transported to the splicer with fast
speed.
⇒ The light barrier for the run-in and run-out recognizes the strip. The conveyors decelerate.
Attention! The position of the light barrier is fixed at start-up and must not be changed.
⇒ The strip is guided between run-in ruler and material guiding.
Adjustment: The correction of material guiding can be made via “MATERIAL GUIDING-/+“
(splicer picture). The strip should be guided through the magnets when running-in, but it
should not get in contact with the conveyor. The material guiding is not run to the edge at
small strips (smaller than approx. 200 – 250 mm).
⇒ The light barrier in front of the splice line recognizes the strip.
⇒ The begin of the strip is exactly positioned at the end of the previous strip on the splice line.
Adjustment: The stop position of the incoming strip can be exactly adjusted via
“POSITION RUNIN” (picture automatic). After the positioning there must not hardly be a
gap between the strips and the strips must not go wavy.
Adjustment: The splice shoe can additionally be used if the strips overlap at the point
(selection via “SPLICE SHOE WITH“ in splicer picture).
⇒ The lifting devices located between the conveyors lower the end of strip.
⇒ Run-out ruler moves down.
⇒ The splice wheels run down. The starting position which brings optimal output is automatically
calculated by the control.
Adjustment: Readjustment of the starting position can be made via “SPLICE HEAD
START POSITION +/-” (splicer picture), e g at turned-up material point or thicker material.
The automatic calculation of the starting position will be deactivated. The manual shifting
of the splice position will be cancelled by actuation of the push button “SETUP SPLICER“
at the control. The automatic calculation of the starting positions becomes again active.
⇒ The splice wheels press upon both material edges.
Adjustment: The contact pressure of the splice wheels can be changed. The pressure is
adjustable by means of pressure regulator valve and manometer. Higher pressure is
required for thicker material.
⇒ The splice wheels move to the splice line and splice both strips together.
Adjustment: Angle correction of the splice line can be made by means of push buttons
“SPLICE ANGLE +/-“. The print of the splice wheels must be symmetrical to the splice
seam. The splice line is displayed by a laser line to make it easier.
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⇒ The splice wheels run up and return in their starting position.
⇒ The strip is transported away.
⇒ The light barrier for the run-in and run-out recognizes the end of strip. The conveyors
decelerate.
⇒ The run-out ruler moves up and guides the end of strip.
Adjustment: The run-out ruler can be adjusted with hand wheel at splice-offset.
⇒ Light barrier in front of the splice line becomes free.
⇒ The lifting devices between the conveyors lift the end of strip.
⇒ The end of strip is exactly positioned on the splice line.
Adjustment: The stop position of the running-out strip can be exactly adjusted via
“POSITION RUNOUT” (automatic picture).
Adjustment of angle and width
⇒ The required angle and the width are to be input at the main control panel or are to be selected
in the program menu (option).
⇒ Actuate push button “SETUP“ permanently (operating panel splicer):

- First the splicer runs to the set angle.
- Then run-in and run-out conveyors run to the set angle.
-Material guiding runs to the set width at wide strips.
It is absolutely forbidden to stay in the swivelling range during the
regulation!
It is not allowed to reach into the adjustment mechanism under the splicer or
under the protecting cap!
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Failure corrective action at the splicer
Fault Remedial measures

Open splice Gap between the strips.
Adjust value for run-out in this way that the end of the strip
stops on the splice line.
Increase value for run-in.
Splice wheels do not symmetrically run to the splice seam.
Correct splice angle.
Increase contact pressure of the splice wheels.
Overlap splice Strips run on each other.

Adjust value for run-out in this way that the end of the strip
stops on the splice line.
Reduce value for run-in.
Operate with splice shoe.
Material goes upwards Reduce contact pressure of the splice wheels.
Splice offset Adjust run-out ruler.
Incoming strip does not run Adjust value for run-out in this way that the end of the strip
near enough to the running-out stops on the splice line.
strip Increase value for run-in.
Incoming strip runs too far on Adjust value for run-out in this way that the end of the strip
running-out strip stops on the splice line.
Reduce value for run-in.
Strips do not stop at all Check, if light barrier located in front of the splice line still
works.
Splice is overlapped at the top Operate with splice shoe.

Increase the splice angle a little so that the splice shoe is
located at the edge of the running-out strip.
Shift the starting point of the splice heads to the outside.
Splice is open at the top Reduce the splice angle a little so that the splice shoe is
located at the edge of the running-out strip.
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Repair conveyor
Splice overlap detection
Splice offset detection Open splice detection
Following operating elements are to be found on the operator panel:
Label Function
AUTOMATIC STOP To stop the automatic function of the control conveyor.
AUTOMATIC START To start the automatic function of the control conveyor.
SETUP To setup the run-in guide to material width input at the control.
ERROR SPLICE OPEN To show if an error is occurred at the open splice detection.
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RUN IN GUIDER To readjust the run-in guide.

+/-
JOG To jog the repair conveyor reverse.
REVERSE
JOG To jog the repair conveyor forward.
FORWARD
ERROR SPLICE To show if an error is occurred at the splice overlap detection.
OVERLAP
SETUP To setup the splice overlap detection.
SPLICE OVERLAP The push button will flash if the material thickness is changed in
the recipe.
When the new material is in the viewing range of the optic, make
sure that there is no overlapping. With pushing the button the
new thickness will be recognized.
ERROR SPLICE OFFSET To show if an error is occurred at the splice offset detection.
Splice overlap detection

On the control conveyor a laser light barrier irradiates across the material strip and determines the
material thickness. In case of the deviation of the theoretical thickness, the automatic is switched
off and the error is displayed on the operator panel via signal lamp. The material thickness is taken
over as theoretical value by means of pressing the key button „SETUP SPLICE OVERLAP“. The
tolerance is stored in the control. The light barrier can be calibrated to zero in maintenance picture
(height of transport conveyor).
Splice offset detection

Two laser light barriers, which measure the material edges, are attached in the run-in guide of
repair conveyor. If a deviation at an edge is detected, the automatic is switched off and the error is
displayed on the operator panel via signal lamp.
Maximum tolerance is to be input in recipe under ‚Edit’ and ‚Tolerance editor’.
Splice open detection

Three light barriers, which sense the material strip at the edges and in the middle, are attached at
the run-in guide of repair conveyor. At open splice one or more light barriers are not interrupted by
the material strip. The automatic is switched off and the error is displayed on the operator panel via
signal lamp.
Filename: Date:
Slitter
The slitter works in automatic operation without control. Essentially adjustments are to be done.
Danger of crushing!
The turning frame on the slitter follows the material edges
or if an impulse is released in the measuring device e.g. through reaching-into!
Slitter / Slitter
Mit Slittern Ohne Slittern (Option)

With slitting Without slitting (option)
Drehrahmen
Turning frame
Messer
Blades
Materialstreifen Vorderer Streifen Einstellung Messerüberlappung

Material strip Strip front Adjustment blades overlapp
Hinterer Streifen
Strip behind
Filename: Date:
Operating panel
Operating elements:
AUTOMATIC STOP To stop the automatic function of the slitter.
AUTOMATIC START To start the automatic function of the slitter.
MIDDLE CONTROL To switch off the center control at the slitter (push button
WITHOUT / WITH lights!). Repeated actuation switches on the center control
(push button does not light!).
This function is required to allow an easier change of width
and angle of material strip.
SLITTERING This selector switch sets the component for use with slitting
WITHOUT / WITH or for use without.
JOG REVERSE To jog the strip backward.
JOG FORWARD To jog the strip forward.
SETUP RUN IN GUIDER The runin guider moves to strip width input at the main
operator panel.
RUN IN GUIDER To readjust the run-in guide.
+/-
SETUP The blade moves to strip width input at the main operator
BLADE ADJUSTMENT panel.
BLADE ADJUSTMENT To readjust the blade.
+/- Adjustment to “+” means, the cutter assembly is moved to
the back, thus making the first strip on the operator side
wider.
There is a scale on the blade carriage.
Without Slitting
⇒ Input data at the main operator panel for one strip.
⇒ When required: Remove backward the material out of the range of the blade by actuating the
push button “JOG FORWARD”.
⇒ Set selector switch to “SLITTERING WITHOUT”.
⇒ Move the blade out of the range of material by actuation of push button „SETUP BLADE
ADJUSTMENT“.
⇒ Actuate push button „SETUP RUNIN GUIDER“. The run-in guide runs automatically to the
width input.
⇒ Open sliding door. Guide the strip over the turning frame, thread it between the brush roller
and the guiding roller (see drawing).
⇒ Close sliding door and start automatic.
Filename: Date:
With Slitting
⇒ Input the data at the main operator panel for two strips.
⇒ Set selector switch to “SLITTERING WITH”.
⇒ Actuate push buttons „SETUP BLADE ADJUSTMENT” and „SETUP RUNIN GUIDER”. The
run-in guide and the blade run automatically to the dimensions input.
⇒ Switch off slitter center control by means of push button “MIDDLE CONTROL WITHOUT”,
push button lights.
⇒ Open sliding door, guide the strip manually over the turning frame, thread it between the brush
roller and the guiding roller and insert it in the blade (see drawing).
⇒ Close the sliding door and move the strip forward by push button “JOG FORWARD”.
⇒ Switch on slitter center control by means of push button “MIDDLE CONTROL WITH”.
⇒ When required, adjust run-in guide and blade during the operation.
Adjustment possibilities
• Blade edge overlap: Open sliding door and adjust the overlap according to the material
thickness on metering clockwork. Adjust overlapping in that way that the driving discs press the
strip, but do not clamp it.
• Contact pressure of the blades: Open sliding door and adjust pressure regulator valve (approx.
3 – 4 bar depending on material thickness).
• Change driving discs: The scope of supply includes an additional pair of driving discs for the
adjustment to different material thickness (see chapter maintenance).
Filename: Date:
Failure corrective action at the slitter
Fault Remedial measures

Width 1 too small and Run the blade backward by “+”, thus the strip at operating
Width 2 too wide side becomes wider and the second strip becomes
smaller.
Width 1 too wide and Run the blade forward by “-”, thus the strip at operating
Width 2 too small side becomes smaller and the second strip becomes
wider.
Both strips too small New data input is necessary. Enlarge both strip widths in
the recipe.
Both strips too wide New data input is necessary. Reduce both strip widths in
the recipe.
Blade does not convey the Are the correct driving plates (with regard to the material)
material mounted?
Are the blades clamped?
Blade overlap is too small? Enlarge the overlap by spindle
regulation to allow the driving plates to take the strips in a
better way.
Blade always releases Check if overlap is too big.

protective motor switch If YES, reduce overlap with the hand wheel at the blade.
If NO, check current consumption at the motor (stiffness of
the mechanism).
Automatic fails Check, if the protective grating is closed (defective

contact).
Are the blades clamped?
Is the material strip positioned in the control range of the
center control?
Filename: Date:
Gum wedge unit
It is forbidden to reach into the gum wedge unit during the operation! There is
the danger of crushing and pulling in on rollers, bars and units.
The material can only be transported by means of jog button if there is material into the loop in
order to prevent stretching or breaking off. This function can be bridged, e g for emptying or fault
clearing, by pressing the jog button and the key button Auto-Stop at the same time.
Operator panels
Operating elements gum wedge unit:
AUTOMATIC STOP To stop the automatic function of the gum wedge unit
mechanism.
AUTOMATIC START To start the automatic function of the gum wedge unit
mechanism.
SETUP To setup the runin guide and the gum wedge strip guides to
the width input from the program at the main operator panel.
LOOP FILLING Gum wedge strip is called and fills the loop of the gum wedge
unit.
RUN IN GUIDER To manually readjust the runin guides to the width of the
-/+ material strip.
STRIP GUIDER To manually readjust the gum strip guider.
-+
EXTRUDER External signal for extruder.
AUTO / SET-UP
JOG SELECTION To select the jog direction of the conveyors.
REVERSE / FORWARD
0= WITHOUT To select wedging and edging or without wedging.
1= WITH WEDGING
2= WITH WEDGING +
EDGING
JOG To jog the gum wedge strip.
STRIP SLITTER
STRIP TENSION To change the speed of slitter blade.
+/- Speed data are taken from recipe by means of actuation of
setup key button.
+ means: Speed will be increased in steps of 0.5 % at each
actuation of the key button, thus gum wedge strip becomes
faster.
Filename: Date:
- means: Speed will be reduced in steps of 0.5 % at each

actuation of the key button, thus gum wedge strip becomes
slower.
If required adjustment can be saved in recipe (see automatic
picture).
JOG GUM WEDGE To jog gum wedge unit forward or backward depending on
(Helix cable) the position of the selector switch.
Operating panel bypass conveyor:
AUTOMATIC To stop the automatic function of the bypass conveyor.
STOP
AUTOMATIC To start the automatic function of the bypass conveyor.
START
SET UP To setup the runin guide to the width input from the program
at the main operator panel.
RUN IN To manually readjust the runin guides to the width of the
GUIDER - / + material strip.
JOG To jog the bypass conveyor manually.
BYPASS CONVEYOR
Filename: Date:
Belegevorrichtung / Gum wedge unit

Umlenkrolle justierbar
Deflection pulley adjustable
Längsteilvorrichtung Belegestreifen vom Extruder

Slitter Gum strip out of the extruder
Einfassbürsten
Edging brushes
Einlaufführung Belegestreifenführungen Andrückrolle Andrückrolle

Run-in guide Gum wedge strip guides Contact pressure roll Contact pressure roll
Filename: Date:
Belegevorrichtung / Gum wedge unit
Längsteilvorrichtung
Slitter
Gummi oben - Folie unten
Gum above - foil below
Umlenkrolle mit Führungen

Deflection pulley with guides
Drehgriff für
Belegestreifenführung
Turn grip for gum wedge strip guide
Führungsring Streifenpositonierrolle Anlagebund

Rändelmutter für Streifenpositionierung Collar
Knurled nut for strip positioning Guiding ring Strip positioning roll
Rändelschraube für Streifenbreite
Knurled screw for strip width
Filename: Date:
First adjustment
⇒ Guide the gum wedge strip from the Extruder around the deflection pulleys according to the
sketch to the slitter of gum wedge unit.
⇒ Adjust deflection pulleys with guides to the width of gum wedge strip via turning handle and
pass the strip through the blade.
⇒ Guide the wedge strip via push button “JOG STRIP SLITTER” around the rolls to the gum
wedge strip guide according to the sketch.
⇒ Activate push button „LOOP FILLING“. The loop is filled.
Without wedging
⇒ Set function selectors to ,,WITHOUT”.
⇒ By actuation of the push button „SETUP“ the runin guide runs to the strip width input at the
main operating console.
⇒ Transport strip by means of push button „JOG GUM WEDGE“ through the whole unit (see
drawing), when doing this possibly reset gum wedge strip guide including wedging and edging
units.
Danger of pulling in!

Don’t touch the material or the conveyor!
With wedging
⇒ Set function selector to ,,WITH WEDGING”.
⇒ By actuation of the push button „SETUP“ the runin guide runs to the strip width input at the
main operating console.
⇒ Set function selector to „EXTRUDER AUTO“ or „EXTRUDER SETUP“.
⇒ Insert material strip into the unit.
⇒ When there is a change in width of the gum wedge material, adjust guiding ring at the strip
positioning roll and adjust the gum wedge strip guide with turn grip to enable exact strip
running on the strip positioning roll between collar and guiding ring.
When wedging a small material strip with a gum wedge strip, a strip positioning roll is to be
removed when required. Turn the knurled nut as long as it is possible to remove the roll from
the guidings.
Filename: Date:
⇒ Put gum wedge material on and convey it by means of push button ,,JOG GUM WEDGE”
behind the foil draw-off ruler, at the same time check if the gum wedge material is on the
required position of the material strip, if need be rectify it by adjusting the corresponding
guiding devices.
Danger of crushing!
Don’t reach into the clamping roll!
With wedging and edging
In order to avoid formation of wrinkles when edging, it is possible to exchange supporting tables
which can be inserted.
For thicker gum wedge material: supporting tables with metal rollers.
For thinner gum wedge material: supporting tables without metal roll.
The supporting tables are kept in a holding device at the edging device.
The movable supporting table is to be shifted under the strip when using wider cords.
⇒ Set function selector to ,, WITH WEDGING + EDGING”.
⇒ Adjust the required edging width at the scale by means of knurled nuts at the strip positioning
rolls.
⇒ When there is a change in width of the gum wedge material, adjust guiding ring at the strip
positioning roll and adjust the gum wedge strip guide with the turn grip to enable exact strip
running on the strip positioning roll between collar and guiding ring.
⇒ Jog forward by actuating push button ,,JOG GUM WEDGE”.
⇒ Put edging brushes by means of hand wheels to the material strip edge.
⇒ Jog forward by actuating push button ,,JOG GUM WEDGE” and check if required edging
quality is attained.
Adjustment possibilities at the slitting device
• Rough ordering of the gum wedge material is made with help of the adjustable deflection pulley
located above the blade.
• Precise ordering of the gum wedge material with help of the adjustable guiding rings on the
deflection pulley located below the blade.
• Adjust the first deflection pulley after the blade to exact strip guiding.
Filename: Date:
• Adaptation of the speed from the gum wedge material to material strips via jack button.
Adjustment possibilities at the gum wedge unit
• Correction of the run-in guide by jack button to the material width.
• Correction of the gum wedge strip guide by jack button to material width.
• Adjust guiding ring with knurled screw on the strip positioning roll to width of the gum wedge
material.
• Correction of the wedging position to the material edge with knurled nut according to the scale
at the strip positioning roll.
• Correction of the gum wedge strip guide by means of turn grip to enable exact strip running on
the strip positioning roll.
• Adjust contact pressure of the rubberised foil pressing rolls by means of pressure regulator
valve.
• Set edging brushes by hand wheel to material edge.
• Knurled nuts for height adjustment of the edging rolls according to thickness of the material.
Filename: Date:
Wind-up unit
Entering the front of the wind-up section (without stopping the back section) is only possible if the
back station is in the wind-up position. If the light barrier is interrupted during the adjustments of
the conveyors, the movements are automatically stopped.
Entering the front of the wind-up the material/laize transport keeps moving to the
rear wind-up station. Stay clear of this area. Do not touch the, lean on, or crawl
underneath the conveyor belts while they are running!
During operation of the wind-up nobody is allowed to stay inside the fenced-in
danger area of the wind-up unit!
Aufwickler / Wind-up unit
Transportband in Anwickelposition Einlaufführung

Materialstreifen conveyor in wind-on position run-in guide
material strip
Einlaufführung
run-in guide Mitläufer Aufwickelrolle Klemmvorrichtung
liner roll wind-up spool clamping device
Band in Transportposition Transportband in Anwickelposition

conveyor in transport position conveyor in wind-on position
Kassette Transportband in Wickelposition Mitläufer Aufwickelrolle

cassette conveyor in winding position liner roll wind-up spool
Filename: Date:
Operator panels
Operating panel run in:
AUTOMATIC To stop the automatic function of the elevating conveyor.
STOP
AUTOMATIC To stop the automatic function of the elevating conveyor.
START
SETUP To set up the run-in guiders of elevating conveyor and
winding positions to the width input from the program at the
main operator panel.
START RESTWINDING To start the finish winding function of the winding position.
STOP FOR CUTTING To stop the material strip manually for cutting.
RUN IN GUIDER To readjust the run in guider manually.
+/-
JOG CONVEYOR RUN IN To jog the conveyors forward.
Operating panel at the winding position:
AUTOMATIC To stop the automatic windup function of the winding station.
STOP
AUTOMATIC To start the automatic windup function of the winding station.
START
CASSETTE LOOSEN To loose the cassette.
RESET SAFETY To reset safety barrier.

STATION 1
JOG WINDER To jog manually the winding position.
LOOP STATION 1 To manually move the swivel belt up or down.
OPEN / CLOSE
JOG CONVEYOR To jog the windup conveyors manually.
STATION 1
RUN IN GUIDER To manually adjust the product guides to the width of the
+/- material strip.
Filename: Date:
Operating panel bypass conveyor:
AUTOMATIC To stop the automatic windup function of the bypass
STOP conveyor.
AUTOMATIC To start the automatic windup function of the bypass
START conveyor.
SET UP To set up the run-in guider of the bypass conveyor to the
width input from the program at the main operator panel.
RUN IN GUIDER To manually adjust the product guides to the width of the
+/- material strip.
JOG To jog the bypass conveyor manually.
BYPASS CONVEYOR
Adjustment of the wind-up unit
⇒ Loose the clamping device by actuating the push button „CASSETTE LOOSEN”.
⇒ When actuating the push button „SETUP“ (operating console run-in guide) the run-in guides of
the wind-up stations run to the width input at the main operating console.
Insert new cartridge
⇒ Put in the prepared cartridge to the limit stop (pneumatic cylinder arrests automatically)
The cartridges are to be handled with care otherwise there is

the danger of crushing e.g. at the columns of the light barriers
or at the wind-up!
Pay attention to other persons and cause no damage at the machine!
⇒ Loosen the locking device for rolls on the cartridge.
The locking device for roll must be loosened of the cartridge!
⇒ Leave danger area and reset light barrier.
Nobody is allowed to stay any longer in the secured area of the wind-up!
⇒ When required: Wind the liner on by actuation of the push button “JOG WINDER“.
Filename: Date:
⇒ Start automatic at the winding position and at elevating conveyor (operating panel run-in guide)
of both double wind-up units.
Change of material
⇒ Normally the wind-up function stops if the input winding length is attained and the luminous
push button „START RESTWINDING“ is blinking (operating console run-in guide).
When required: Material is stopped by push button „STOP FOR CUTTING“ in the automatic
mode.
⇒ Cut the material strip on the transport conveyor. Lifting the begin of the material strip, return
into the loop and lay down again, so that approx. 20 mm broad gap at the point of separation
develops.
⇒ Wind the rest of material in by actuating the push button „START RESTWINDING“.
Removal of the cartridge
The wind-up function stops if the input winding length is attained and the luminous push button „
START RESTWINDING“ is blinking (operating console run-in guide).
⇒ The remaining material and the remaining liner is automatically wound in by actuating the push
button “START RESTWINDING”.
⇒ The full cartridge must be released by push button ,,CASSETTE LOOSEN” at the winding
position.
⇒ Enter danger area and pull the cartridge out.
The cartridges are to be handled with care otherwise there is

the danger of crushing e.g. at the columns of the light barriers
or at the wind-up!
Pay attention to other persons and cause no damage at the machine!
⇒ Clamping the looking device for rolls on the cartridge manually.
Filename: Date:
Putting out of service
Emergency stop
There are emergency key buttons on the machine/line at all operating panels, working places and
many other places.
By actuation of a key button in case of danger, the control voltage is interrupted and the machine is
immediately stopped.
The fly wheel at the gear inside the cutter still coasts approx. 3 min. after
switching off!
Putting out of service at the end of work
⇒ The control voltage is to be switched of.
⇒ Close the operating system.
⇒ By switching off the master switch at the switch cabinet the machine/line is to be disconnected
from the network.
⇒ Air supply is to be disconnected.
The fly wheel at the gear inside the cutter still coasts approx. 3 min. after
switching off!
Putting out of service for maintenance and repair purposes
⇒ The control voltage is to be switched off.
⇒ Close the operating system.
⇒ The master switch at the control cabinet is to be thrown over and is to be protected against
erroneous and unauthorized reclosing. Attach warning label.
⇒ Check if there is no current between the terminals L1-L2, L2-L3 and L1-L3 after the main
switch.
⇒ Air supply is to be disconnected.
Putting out of service for a longer time
⇒ The batteries for the program memory are to be checked.
Filename: Date:

Operation - Karl Eugel Fischer

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KARL EUGEN FISCHER GmbH ⋅ MASCHINENFABRIK

Postfach 12 65 - 96220 Burgkunstadt/Germany

Operating Manual Order no.: CA101351

Cord Cutting Line Page: 5-1

Function and operation of the components

Component Function Operation

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Operating elements control panel

CONTROL VOLTAGE Switches the control voltage on.

AUTOMATIC To stop the automatic function of the splicer.

The key is to be kept by skilled personnel!

WITHOUT MEASURING / Without = To switch the width measuring system off.

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Operating Manual Order no.: CA101351

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An inexpert operation can cause damages on line parts!

Operating Manual Order no.: CA101351

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Functions in ´MANUAL MODE´

Key Designation Function

upholder For manual movement of the upholder located in the

P5 forward To move the gripper of feeding system in running direction of

single stroke To carry out manually a cutter stroke.

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Operating Manual Order no.: CA101351

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Further reference runs

This process is possible in each operating mode!

Move the axis on the position to the initiator indicated:

Splice width Move to maximum strip width in creep speed.

Slitter blade Move to maximum strip width in creep speed.

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Transmission of cutting data

⇒ New data are to be input or called in recipe capability.

⇒ Transmit data to the PLC.

⇒ Call Setup picture. The data are displayed as preset values.

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RECIPE CAPABILITY (Option)

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There are two pictures available for operating mode ´Automatic´.

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Key Designation Function

automatic The corresponding function key located below on the

P2 automatic splicer To start automatic operation of the splicer.

P3 RESET breaker on To reset a strip after a manual cutter stroke or after

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Operating Manual Order no.: CA101351

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let-off preguiding error Stockroll adjustment in the letoff-station is out of range.

KEFuser - no permission for No operator is logged on the machine. It is not possible to

Key Designation Function

shift chunter To reset the shift counter after shift change.

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SELECTION OF SERVICE PICTURES