CAB WICON SQUIX User manual

Service Manual
MADE IN GERMANY
WICON
Wrap-around applicator

2 2
Service Manual
for the following products
Type
Wrap-around
applicator WICON
Edition: 09/2022 - Part No. 9003822
Copyright
This documentation as well as translation hereof are property of cab Produkttechnik GmbH & Co. KG.
The replication, conversion, duplication or divulgement of the whole manual or parts of it for other intentions than its original
intended purpose demand the previous written authorization by cab.
Trademark
Windows is a registered trademark of the Microsoft Corporation.
Editor
Regarding questions or comments please contact cab Produkttechnik GmbH & Co. KG.
Topicality
Due to the constant further development of our products discrepancies between documentation and product can occur.
Please check www.cab.de for the latest update.
Terms and conditions
Deliveries and performances are e󰀨ected under the General conditions of sale of cab.
Germany
cab Produkttechnik GmbH & Co KG
Karlsruhe
Phone [phone]
www.cab.de
USA
cab Technology, Inc.
Chelmsford, MA
Phone [phone]
www.cab.de/us
Taiwan
cab Technology Co., Ltd.
Taipei
Phone [phone]
www.cab.de/tw
Singapore
cab Singapore Pte. Ltd.
Singapore
Phone [phone]
www.cab.de/en
France
cab Technologies S.à.r.l.
Niedermodern
Phone [phone]
www.cab.de/fr
Mexico
cab Technology, Inc.
Juárez
Phone [phone]
www.cab.de/es
China
cab (Shanghai) Trading Co., Ltd.
Shanghai
Phone [phone]
www.cab.de/cn
South Africa
cab Technology (Pty) Ltd.
Randburg
Phone [phone]
www.cab.de/za

3
Table of Contents
1 Introduction............................................................................................................................................4
1.1 Instructions...............................................................................................................................................4
1.2 General Safety Instructions......................................................................................................................4
1.3 Protective Devices ...................................................................................................................................5
1.4 Handling Electricity ..................................................................................................................................5
1.5 Procedure in Case of Accidents ..............................................................................................................5
1.6 Environment.............................................................................................................................................5
2 Preparation.............................................................................................................................................6
2.1 Tools.........................................................................................................................................................6
2.2 Removing the Applicator from the Printer ................................................................................................6
2.3 Removing the Covers...............................................................................................................................7
2.3.1 Removing the Side Covers.................................................................................................................7
2.3.2 Removing the Service Door................................................................................................................7
3 Replacing Assembly Units....................................................................................................................8
3.1 Replacing the Transport Module..............................................................................................................8
3.2 Replacing the PCB Sensor Labels...........................................................................................................8
3.3 Replacing the Centering Panels...............................................................................................................9
3.4 Replacing the Guard Plate.....................................................................................................................10
3.5 Replacing the Belt...................................................................................................................................11
3.6 Replacing the Cam Plate and the Locking Lever...................................................................................12
3.7 Replacing the PCB Control....................................................................................................................13
4 Adjustments .........................................................................................................................................14
4.1 Adjusting the Centering Panels..............................................................................................................14
4.2 Calibrating the Diameter Recognition ....................................................................................................15
5 Error Treatment ....................................................................................................................................16
6 Block Diagram......................................................................................................................................17
7 Index......................................................................................................................................................18

4 4
1 Introduction
1.1 Instructions
Important information and instructions in this documentation are designated as follows:
Danger!
Draws attention to an exceptionally great, imminent danger to your health or life due to hazardous
voltages.
!
Danger!
Draws attention to a danger with high risk which, if not avoided, may result in death or serious injury.
!
Warning!
Draws attention to a danger with medium risk which, if not avoided, may result in death or serious injury.
!
Caution!
Draws attention to a danger with low risk which, if not avoided, may result in minor or moderate injury.
!
Attention!
Draws attention to potential risks of property damage or loss of quality.
i
Note!
Advices to make work routine easier or on important steps to be carried out.



Environment!
Gives you tips on protecting the environment.
Handling instruction
Reference to section, position, illustration number or document.
Option (accessories, peripheral equipment, special ttings).
Time Information in the display.
1.2 General Safety Instructions
This service manual is intended for use by qualied service and maintenance personnel. For more operation and
conguration information, refer to the user or conguration manual.
Follow the general safety rules below:
• Keep the area around the device clean at all times!
• Work with safety in mind.
• Parts of device that are removed during the maintenance work must be put in a safe place.
• Avoid risks of tripping over.
Danger!
Danger to life and limb from increased current ow through metal parts in contact with the device.
Do not wear clothing with metal parts.
Do not wear jewelry.
Do not wear spectacles with metal frames.
!
Warning!
Items of clothing drawn into the device by moving parts can lead to injuries.
Do not wear any items of clothing which could get caught by moving parts.

5
1 Introduction
1.3 Protective Devices
!
Warning!
There is a risk of injury if protective devices are missing or defective.
Replace all protective devices (covers, safety notices, grounding cables etc) after maintenance work
has been completed.
Replace parts that have become defective or unusable.
Wear protective goggles for:
• Knocking pins or similar parts in or out with a hammer.
• Using spring hooks.
• Inserting or removing springs, retaining rings or grip rings.
• Using solvents, cleansers or other chemicals.
1.4 Handling Electricity
The following work may only be done by trained and qualied electricians:
• Work on electrical components.
• Work on an open device still connected to the mains supply.
General precautions before starting maintenance work:
• Find out where the emergency and power switches are so that they can be quickly thrown in an emergency.
• Disconnect the current supply before carrying out the following work:
- Installing or removing power units.
- Working in the immediate vicinity of open power supply components.
- Mechanical check of power supply components.
- Modifying circuits in the device.
• Test the zero potential of the device parts.
• Check the working area for possible sources of danger, such as wet oors, defective extension cables, defective
protective conductor connections.
Additional precautions in the case of exposed voltages:
• Ask a second person to remain near the working site. This person must know where the emergency and power
switches are, and how to switch the current o󰀨 if danger arises.
• Only use one hand to work on electric circuits of devices that are switched on. Keep the other hand behind your
back or in your pocket.
This prevents electricity from owing through your own body.
1.5 Procedure in Case of Accidents
• Act calmly and with great care.
• Avoid danger to yourself.
• Switch o󰀨 power.
• Request medical assistance.
• Give rst aid, if necessary.
1.6 Environment



Obsolete assemblies contain valuable recyclable materials that should be sent for recycling.
Send to suitable collection points, separately from residual waste.
Send the parts for recycling.

6 6
2 Preparation
2.1 Tools
Do not use any worn of damaged tools.
Only use tools and testing devices that are suitable for the task at hand.
Standard tools:
• Screw driver TX 10
• Screw driver TX 20
• Screw driver TX 25
• Screw driver TX 30
• Socket wrench 9
• Allen key 2 mm
• Allen key 2.5 mm
• Open-end wrench 5
• Snap ring pliers ZGG 0
• Pointed pliers straight
• Belt tension measuring device
cab special tools:
• Calibration rod 10 mm (Part No. 5988543)
2.2 Removing the Applicator from the Printer
12 3
Fig. 1 Removing the applicator from the printer
Switch o󰀨 the printer.
Loosen screw (2).
Remove the applicator from the printer. The plug of the applicator will be disconnected from the connector (1).

7
2 Preparation
2.3 Removing the Covers
For a couple of maintenance operations it is necessary the remove the covers from the winding assembly.
2.3.1 Removing the Side Covers
35 12 4
1
Fig. 2 Removing the side covers
Loosen the screw (5) and remove the stopper (4).
On both sides loosen each ve screws (1) and remove the side covers (2,3).
Re-mounting will be carried-out in opposite order.
2.3.2 Removing the Service Door
i
Note!
It is not absolutely necessary the remove the service door. But with the side covers removed the service
door cannot be xed anymore. Therefore the removing of the door can facilitate the service work.
31 2 4
Fig. 3 Removing the service door
Loosen the screws (1) and remove bracket (2) and service door (3).
For mounting push the bracket (2) over the pins (4) and x it with the screws (1).

8 8
3 Replacing Assembly Units
3.1 Replacing the Transport Module
31 2 1 4 5 4 6
Fig. 4 Replacing the transport module
Remove the covers
Turn the winder plate (3) to the position shown in the gure.
Loosen the screw (2) and remove the transport module (6).
The screw (2) is secured and remains in the winding plate.
Guide the pins (4) of the new transport module into the holes (1) and x the transport module by tightening the
screw (2).
Mount the covers.
3.2 Replacing the PCB Sensor Labels
21 2 3
Fig. 5 Replacing the PCB Sensor Labels
Remove covers an transport module.
Pull out the motor cable (3) from the PCB.
Loosen two screws (2) and remove the PCB (1) upward.
Mount the new PCB in the opposite order.

9
3 Replacing Assembly Units
3.3 Replacing the Centering Panels
Centering panel gear side Centering panel winder side
321
421 5
3 2 1
5 4 2 1
Fig. 6 Replacing the centering panels
Remove the covers.
Loosen two screws (1) and washers (2) and remove the centering panel (3).
Disconnect the cable (5) from the PCB (4).
Mount the new centering panel (3) in the opposite order.
Adjust the centering panels.
Mount the covers.

10 103 Replacing Assembly Units
3.4 Replacing the Guard Plate
42 31a 2 1b 2 2
Fig. 7 Replacing the guard plate
Remove the covers and the centering panel at the gear side.
Loosen two screws (3).
Loosen two shoulder screws (1a,1b) and remove the guard plate (4).
Mount the new guard plate and if necessary new washers (2) as shown in the gure.
Tighten the shoulder screws (1a,1b) slightly.
Mount the centering panel.
1a 1b5
Fig. 8 Tighten the shoulder screws
i
Note!
The applicator must be operated with the printer to adjust the shoulder screws.
!
Caution!
Risk of hand injuries
Do not grasp in the area of the turning winder plate!
Insert a product (5) to close the centering panels. That way the shoulder screw (1a) is reachable.
Press repeatedly the single-step button and tighten the shoulder screw (1a) until the movement of the
touch guard will be hindered.
Press again repeatedly the single-step button and loosen slightly the shoulder screw (1a) until the touch
guard can move without hindering.
Adjust the shoulder screw (1b) in the same way.
Mount the covers.

113 Replacing Assembly Units
3.5 Replacing the Belt
431 2 65
Fig. 9 Replacing the belt
Remove side cover, centering panel and guard plate at the gear side
Pull the belt (1) from the gear wheels (2-6).
Push the new belt onto the gear wheels.
71 75 8
Fig. 10 Tensioning the belt
Check the tension of the belt.
Pluck the belt at the marked point (1) and measure the frequency of the oscillation withe a belt tension measuring
device.
Set value: f = 200...250 Hz
If the result is out of the set value range, loosen for screws (7), tension the belt by pressing against the gear wheel
(5) on the motor (8) and re-tighten the screws (7).
Repeat the measurement.
Mount guard plate, centering panel and cover.

12 123 Replacing Assembly Units
3.6 Replacing the Cam Plate and the Locking Lever
4
1
53 6 7 8
2
Fig. 11 Replacing the cam plate
Remove covers and centering panels.
Loosen two screws (8) and remove the plate (7).
Loosen two screws (1) and pull the winder plate (4) with the cam plate (3) and the transport module (6) out of the
housing.
Pull the cam plate (3) from the pins (5).
Set the new cam plate onto the pins (5).
9 10
Fig. 12 Replacing the locking lever
Pull the locking lever (10) from the pin (9).
Mount the new locking lever.
Push the winder plate (4) with the cam plate (3) and the transport module (4) into the housing and mount the
winder plate with two screws to the gear wheel (2).
Mount the plate (7).
Mount the centering panels and the covers.

133 Replacing Assembly Units
3.7 Replacing the PCB Control
1 2 1 1 1
Fig. 13 Replacing PCB Control
Loosen four screws (1).
Pull-out all cables from the connectors of the PCB Control (2).
Pull the PCB Control out of the housing.
Mount the new PCB in the opposite order.
1098
74 5 63
131211
Fig. 14 PCB Control - connectors
Pos. Connector Lettering
3 Periphery Periphery
4 LP Sensor Centering gear side Centering L
5 LP Sensors Reference+Diameter Ref+Dia
6 LP Spring Contact Spring contact
7LP Sensor Touchguard Touchguard
8 Service Button Service1
9Sensor Applicator Locked Swingo󰀨
10 Ventilator Fan
11 Motor Touchguard Touch-Motor
12 LP Sensor Centering winder side Centering R
13 Motor Winding Drum-Motor
Table 1 PCB Control - connectors

14 14
4 Adjustments
4.1 Adjusting the Centering Panels
i
Note!
The applicator must be operated with the printer to adjust the centering panels.
Checking
Switch on the system
Insert the calibration rod 10 mm (1 / Part No. 5988543).
Turn the winder plate by pressing the single-step key and observe the hunting of the rod.
If the rod hunting seems to be excessive the centering panels (7) may be adjusted individually.
1 2 3
2
Fig. 15 Adjusting the centering panels
Adjusting
Remove the side covers.
!
Caution!
Risk of hand injuries
Do not grasp in the area of the turning winder plate!
Loosen two screws (2) and slightly pivot the centering panel (3).
Tighten the screws and repeat the check.
If necessary repeat the adjustment.
Mont the side covers.

15
4 Adjustments
4.2 Calibrating the Diameter Recognition
Switch on the system.
Start menu.
Select Setup > Labelling > Calibrate device.

Insert the calibration rod 10 mm (Part No. 5988543).
Select Continue.
The wrapping unit will be turned ten times with closing and opening the jaws and measuring the diameter of the
test pipe.
The display shows the success of the calibration, the determined o󰀨set and the tolerances of the o󰀨set value.
Select Continue.
The determined o󰀨set will automatically be stored and considered for future measurements.

16 16
5 Error Treatment
i
Note!
The following table describes the reasons for error messages which occur repeatedly or permanently.
Message Error/Reasons Remedy
Touch guard error Failure of the touch guard movement
• Shoulder screws at the guard plate
tightened to hard Adjust the shoulder screws
• Washers worn Replace the washers
• Guard plate worn Replace the guide plate
• Drive defective Replace the motor touchguard
• Sensor touchguard defective Replace the sensor touchguard
• Cable sensor defective Replace the cable sensor
• PCB Control defective Replace the PCB Control
No label on belt
detected After a labeling cycle is started no label is detected on the transport belt
• Label transfer from the printer failed Check the peel-o󰀨 behavior
Adjust the peel positions in the printer setup
and the software
• Transport module defective Replace the transport module
• PCB Spring Contact soiled Clean the contacts
• PCB Spring Contact defective Replace the PCB Spring Contact
• Contacts at the PCB Sensor Labels
worn Replace the PCB Sensor Labels
• Sensor labels defective Replace the PCB Sensor Labels
• PCB Control defective Replace the PCB Control
Product release
failed/
Wrapping failed
Failure of the wrapping unit movement
• Belt tension not correct Adjust the belt tension
• Chuck jaws hard-steering Removing the winder plate and pulling-o󰀨 the
cam plate
Checking the movability of the chuck jaws in
the winder plate
• Drive defective Replace the motor winder
• Sensor Reference+Diameter defective Replace the PCB Sensor Diameter
• PCB Spring Contact soiled Clean the contacts
• PCB Spring Contact defective Replace the PCB Spring Contact
• Contacts at the PCB Sensor Labels
worn Replace the PCB Sensor Labels
• PCB Control defective Replace the PCB Control
Table 2 Error treatment

17
6 Block Diagram
Drum-Motor Centering R Swingoff
Periphery
Spring contact Centering L
Ref+Dia
Touchguard
Touch-Motor
PCB Control
Fan Service1
5555158
PCB Sensor Centering L
5907839
PCB Sensors Ref.+Diam.
5555155
Periphery
5555157
PCB Touchgard Sensor
5555156
Service Button
Sensor Applicator locked
Fan
Motor Guard
Motor Winder
PCB Spring Contacts PCB Sensor Labels Motor Transport
PCB Sensor Centering R
5907839
5551423
5551621
5551619
5988548 5555183 5555197
5988151
5551423
5555198
5555199
5555159
5907838
5555138
Fig. 16 Block diagram

18 18
7 Index
B
Belt ...................................................11
Block diagram...................................17
C
Cam plate.........................................12
Centering panels
Adjusting.....................................14
Replacing......................................9
Covers................................................7
D
Diameter recognition ........................15
E
Error treatment .................................16
G
Guard Plate ......................................10
I
Important information..........................4
L
Locking lever ....................................12
P
PCB Control......................................13
PCB Sensor Labels............................8
S
Safety instructions..............................4
Service door .......................................7
Shoulder screws...............................10
T
Tools...................................................6
Transport module ...............................8