Novexx Solutions 64- series User manual

01/13 Rev. 5.05-01 USER MANUAL
Rewinder 2000
Attachment, Setup
General Notes................................................ 2
Intended Purpose....................................... 2
Properties................................................... 2
System requirements ..................................... 3
Printer type................................................. 3
Preparation for peripheral devices ............. 3
Attaching the rewinder ................................... 4
General information about setting up the
printer............................................................. 5
Direction of rotation .................................... 5
Dancer arm deflection ................................ 5
Rotation speed with 64-xx / AP 5.4 ............ 6
Setting up TTX 350 / TTK .............................. 7
Activating the rewinder / Selecting the
Rotation Direction....................................... 7
Setting the sensor current .......................... 8
Adjusting the sensor................................... 9
Setting up 64-xx / AP 5.4 / AP 7.t .................11
Activating the rewinder..............................11
Selecting the direction of rotation..............11
Checking the sensor current setting .........12
Setting the sensor current.........................12
Adjusting the sensor .................................13
Inserting material ..........................................15
Starting .........................................................17
Starting TTX 350 / TTK.............................17
Starting 64-xx / AP 5.4 / AP 7.t .................17
(AP 5.4) Run-in roller for narrow labels ........19
Technical Specifications ...............................20
Index.............................................................21

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General Notes
Intended Purpose
The rewinder option is a peripheral device for label printers of the types
TTK, TTX 350, 64-xx, AP 5.4 and AP 7.t. The device is designed for
winding up label material after it has been printed using one of the printer
types named above.
Properties
As opposed to the stand-alone rewinding devices Junior Rewinder and
Jumbo Rewinder, the rewinder option (subsequently referred to as the
rewinder) is permanently attached to the printer. The printer provides power
for the rewinder motor via a socket on the front, which is also used for
receiving signals relating to the lateral deflection of the bouncer arm.
Rotational speed While the material is being wound up, the rotational speed is controlled via
the lateral deflection of the bouncer arm. The greater the lateral deflection,
the lower the rotational speed. If the label material sags – the bouncer arm
is in this case only slightly deflected – the rewinder increases the rotational
speed in order to make up the "delay". This ensures that the label material
is rolled up evenly tautly. Without lateral deflection - e.g. when the material
is finished – the rewinding process stops after about four seconds.
Direction of rotation The label material can be alternately rolled up with the labels facing
outwards or inwards by reversing the direction of rotation.

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System requirements
Printer type
The rewinder can be operated with the following printer types:
•TTX 350
•TTK
•64-xx
•AP 5.4
•AP 7.t
Preparation for peripheral devices
For using the printers with a rewinder, they must be especially equipped
(see Tab. 1). This so called peripherals preparation consists mainly of an
additional output stage board for the motor of the peripheral device and of
someadditional connection cables.
Printer Peripherals Preparation
64-xx Optional
TTX 350 Optional
TTK Standard
AP 5.4 Standard with printer version „Peripheral“
AP 7.t Standard
Tab. 1 Only the TTK is always equipped with the peripheral preparation. For the other
printer types this is an option.
Peripheral test Do the following, if you are not sure, wether the printer is equipped with
peripheral preparation:
•TTK / TTX 350:
Set parameter SYSP > PEPH to KNIF.
If the printer displays the status message ST68 after the ENTER key is
pressed, the peripheral board is not installed. If ST68 does not appear or if
a different status message is displayed, then the printer has been set up for
peripheral devices.
•64-xx / AP 5.4 / AP 7.t:
Make a service status printout: Call parameter PRINT INFO > Service Status.
64-xx and AP 5.4 printers are equipped with peripheral preparation if the
topic “Peripheraldriver” can be found below the header “Peripheraldriver”
on the printout.
Printer Peripherals preparatioPrinter Peripherals preparation

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Attaching the rewinder
Before beginning service work, switch
off the printer and pull out the mains
power supply plug!
Under no circumstances should you use
the dancer arm as a carrying handle! A
bent dancer arm will cause the device to
malfunction!
The rewinder (1) is attached to the front of the
printer (2) with two screws. The support leg (3)
absorbs some of the strain exerted by the
material roll.
Other options which may be installed or
the cover must be removed before
assembling the rewinder.
Tool
– Allan key 3mm
Assembly / Disassembling
1. Place the printer on a level surface.
Ensure that there is enough room in
front of the printer for the support leg (3)
of the rewinder.
2. Attach the rewinder housing (4) to the
printer recess (5) using the two screws
supplied.
3. Loosen the supporting leg fastening
screw (6). Push down the support leg
until it stands on the surface. Push up
the rewinder a little and at the same time
tighten the fastening screw.
The weight of the material roll should
rest on the support leg.
4. Plug in the connector plug (7).
Under no circumstances should the plug
be attached or removed
when the device is switched
on, as otherwise the device
electronics could be damaged.
12
3
4
5
7
6

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General information about setting up the printer
After mounting the rewinder you must set up the printer for operation with
the new peripheral device. This is done by selecting the appropriate
parameter in the parameter menu of the printer.
Direction of rotation
The rewinder can be operated in two rotation directions, which are
designated in a different way in the parameter menues of the printers.
Printer Designation of the rotation direction
TTK/TTX 350 “DIRL” “DIRR”
64-xx/AP 5.4/AP 7.t “Printing outside” “Printing inside”
Tab. 2 The designations of the rotation direction are different in the parameter menus of
TTK/TTX 350 and 64-xx/AP 5.4/AP 7.t.
•TTK / TTX 350:
The direction of rotation is requested after selecting the rewinder option in
the parameter menu.
•64-xx / AP 5.4 / AP 7.t:
The rotation direction is set by a separate parameter.
Default setting: “Printing outside”.
Dancer arm deflection
In the mode "DIRR"/"Printing inside", material does not wrap itself around
the bouncer arm as much as is the case with "DIRL"/"Printing outside"
(Tab. 2). Particularly with larger roll diameters, the dancer arm would often
shoot from one extreme position to the other. The material would then be
wound up in a jolting manner.
For this reason, the software is adjusted when "Direction of rotation right"
"Printing inside" is selected – it then only uses approximately 50% of the
maximum dancer arm deflection for controlling the motor.

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Rotation speed with 64-xx / AP 5.4
With printers of the types 64-xx / AP 5.4 / AP 7.t, the rewinder rotation
speed depends on the print speed. A low print speed leads to a slower
rewinder rotation as a high print speed. An exception to this rule is the
rotation speed directly after starting the wind-up process.
For details to this, refer to the section Starting on page 17.

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Setting up TTX 350 / TTK
Setup the printer for rewinder-use by performing the three subsequently
described steps:
1. Activating the rewinder / Selecting the Rotation Direction on page 7.
2. Setting the sensor current on page 8.
3. Adjusting the sensor on page 9.
How to perform the steps is explained in the following.
A complete description of the parameters can be found in the chapter "Info
Printouts and Parameters" in the User Manual of the printer.
Activating the rewinder / Selecting the Rotation
Direction
CAUTION! - Selecting a non-existent option can cause the device to
malfunction!
Action Display Note
1. Connect the printer
and switch it on
OFF
2. Press the CUT+FEED
button
INFO
3. Repeatedly press the
CUT button until
SYSP
4. Press the ENTER
button
EMUL
5. Repeatedly press the
CUT button until
PEPH
6. Press the ENTER
button
NONE If a peripheral device has previously not been
set.
7. Repeatedly press the
CUT button until
RWND
Direction of
rotation
8a. Press the ENTER
button
DIRL Step 8a for direction of rotation left.
8b. Press the CUT button DIRR Step 8b for direction of rotation right.
9. Press the ENTER
button
The printer restarts.
The rewinder is now activated. Other previously activated options are
automatically deactivated (see parameter PEPH).

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Setting the sensor current
Befor using the rewinder for the first time, the sensor current must be set by
a potentiometer at the rewinder (see Fig. 1).
Fig. 1 The pot. can be accessed through a slot in the back cover of the rewinder.
Action Display Note
1. Select parameter OTHR > SCHK. SCHK
2. Press the ENTER button Pxxx Other information may be
displayed depending on the
printer type; xxx = variable value.
3. Repeatedly press the CUT button
until
Wxxx
4. Set the rewinder pot. (Fig. 1) so
that a value between 20 and 30 is
displayed.
W20 Bouncer arm in zero position
(Fig. 2); 24 = set value.
5. Move the bouncer arm to the final
position (towards the support leg).
Check the displayed value*.
W141 141 = set value (example) in the
final position; Value difference =
117 (o.k.)
*) The value with the bouncer arm in its final position must be at least 100 higher than the
value in zero position, which was set in step 4. Most important ist the difference between the
two values in the two end positions: the difference must equal/be higher than 100, ideally
110. Repeat step 4 and set a higher value in the zero position, if the difference is too little.
Pot. (P101)
Z0139E.cdr
Turn counter-clockwise =>
Sensor current decreases
Displayed value increases
Turn clockwise =>
Sensor current increases
Displayed value decreases
Rewinder (section)

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Adjusting the sensor
The bouncer arm controls the winding speed of the rewinder by means of a
sensor. Bevor applying the rewinder for the first time, the bouncer arm has
to be brought in both end positions to adjust the sensor.
Fig. 2 Left side: bouncer arm in zero position; right side: bouncer arm in final position.
Action Display Note
1. Select parameter SYSP > PEPH. PEPH
2. Press the ENTER button RWND If the rewinder has already been
set.
3. Repeatedly press the CUT button
until
RADJ
4. Press the ENTER button RNUL Initially setting of the sensor with
the bouncer arm in the zero
position. (See fig. above left)
5. Press the ENTER button xxx xxx = actual sensor value; the
displayed value is altered by
moving the bouncer arm.
6. Move the bouncer arm appr.
5 mm out of the zero position.
Press the ENTER button.
REND
7. Press the ENTER button xxx xxx = actual sensor value; the
displayed value is altered by
moving the bouncer arm.
8. Move the bouncer arm up to the
stop plate in the direction of the
support leg, and then back again
by approx. 5 mm. Press the
ENTER button.
RWND
9. Repeatedly press the CUT+FEED
button until
OFF
Set the value approx. 5 mm before reaching the final or zero position,
respectively!

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CAUTION! - If programming is interrupted by pressing the CUT+FEED
button, the printer uses preset values which may cause the device to
malfunction!
A complete description of the parameters can be found in the chapter "Info
Printouts and Parameters" in the User Manual of the printer being used.

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Setting up 64-xx / AP 5.4 / AP 7.t
Setup the printer for rewinder-use by performing the following steps:
1. Activating the rewinder on page 11.
2. Selecting the direction of rotation on page 11.
3. Setting the sensor current on page 12.
4. Adjusting the sensor on page 13.
How to perform the steps is explained in the following.
A complete description of the parameters can be found in the chapter "Info
Printouts and Parameters" in the User Manual 64-xx.
Activating the rewinder
CAUTION! - Selecting a non-existent option can cause the device to
malfunction!
Set SYSTEM PARAMETERS > Periph. device to “Rewinder”.
The rewinder is now activated. Other previously activated options are
automatically deactivated.
Selecting the direction of rotation
Action Display Note
1. Press the Prog button PRINT INFO
2. Press the Cut button PRINT PARAMETERS
3. Press the Online
button
Print speed
4. Repeatedly press the
Cut button until
Rewind direction
5a. Press the Online
button
Rewind direction
Printing inside
Step 5a for printing
facing inwards
5b. Press the Cut button Rewind direction
Printing outside
Step 5b for printing
facing outwards
6. Press the Online
button
Rewind direction
7. Repeatedly press the
Prog button until
OFFLINE 0 JOBS

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Checking the sensor current setting
(Only for 64-xx and AP 5.4)
Call SERVICE FUNCTION > Rewinder values.
Rewinder Values
xxx <--------------------> yyy
•xxx = Sensor value in zero position
•yyy = Sensor value in final position (Dancer arm at the printer side limit)
The difference yyy – xxx must at least be 80 (best: 100). If the difference is
less, the sensor current setting must be changed, see chapter Setting the
sensor current below.
Setting the sensor current
Befor using the rewinder for the first time, the sensor current must be set by
a potentiometer at the rewinder (see Fig. 3).
Fig. 3 The pot. can be accessed through a slot in the back cover of the rewinder.
Action Display Note
1. Select parameter SERVICE
FUNCTION > Sensor test.
Sensor test
Sens: 0.01 xxx
xxx is the value
supplied by the
sensor
2. Press the Feed button
repeatedly until
Sensor test
Sens: 4.01 xxx
4.01 = sensor
peripheral devices
Pot. (P101)
Z0139E.cdr
Turn counter-clockwise =>
Sensor current decreases
Displayed value increases
Turn clockwise =>
Sensor current increases
Displayed value decreases
Rewinder (section)

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3. Set the rewinder pot.
(Fig. 1) so that a value
between 20 and 30 is
displayed.
Sensor test
Sens: 4.01 27
Bouncer arm in zero
position (Fig. 2); 27 =
set value.
4. Move the bouncer arm to the
final position (towards the
support leg). Check the
displayed value*.
Sensor test
Sens: 4.01 130
130 = set value
(example) in the final
position; Value
difference = 103
(o.k.)
*) The value with the bouncer arm in its final position must be at least 80 higher than the value
in zero position, which was set in step 3. Most important ist the difference between the two
values in the two end positions: the difference must equal/be higher than 80, ideally 100.
Repeat step 3 and set a higher value in the zero position, if the difference is too little.
Adjusting the sensor
The bouncer arm controls the winding speed of the rewinder by means of a
sensor. Bevor applying the rewinder for the first time, the bouncer arm has
to be brought in both end positions to adjust the sensor.
Fig. 4 Left side: bouncer arm in zero position; right side: bouncer arm in final position.
Action Display Note
1. Select parameter SERVICE
FUNCTION > rewinder adjust
rewinder adjust If 0 jobs are stored in
memory.
2. Press the Online button rewinder adjust
Resting pos. xx
xx = actual value
supplied by the
sensor; moving the
bouncer arm alters
the value
3. Move the bouncer arm appr.
5 mm out of its resting (zero)
position. Press the Cut
button.
rewinder adjust
End pos. xx
Mind the notes
following this table!

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8. Move the bouncer arm up to
the stop plate i the direction
of the support leg, and then
back again by approx. 5 mm.
Press the Enter button.
rewinder adjust Mind the notes
following this table!
9. Repeatedly press the Prog
button until
OFFLINE 0 JOBS
Set the value approx. 5 mm before reaching the final or zero position,
respectively!
Press the Cut button in the resting position but the Online button in the end
position!
CAUTION! - If programming is interrupted by pressing the Esc-button, the
printer uses preset values which may cause the device to malfunction!

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Inserting material
Direction of rotation The material – depending on the set direction of rotation – is wound around
the core in a clockwise or anti-clockwise direction (see Fig. 5).
Fig. 5 Left side: direction of rotation = left (labels outside); right side: direction of rotation =
right (labels inside)
Proceed as follows:
1. Remove the guide disk (1). To do so,
open the clamping lever (2). Remove
the clamping bar (3).
2. Feed the end of the material web around
dancer arm and winding core and fix it
with the clamping bar. To do so, push
the clamping bar over the material (4).
If a cardboard core is used: Push the
clamping bar underneath the cardboard
core.
Continued overleaf.
1
2
1
3
4

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3. Remount the guide disk.
The recesses at the inner diameter of
the guide disk (arrows) must be
positioned over the clamping bar
legs (5).
4. Push the guide disk up to the material
edge (6). Close the clamping lever.
The guide disk may not wedge in the
material.
5.
Adjust the material guides (7) on the
bouncer arm by pushing them sideways
until they correspond to the width of the
material.
The material should run evenly, and
there should be a small gap between it
and the material guides.
7
5
6

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Starting
After securing the material end, proceed as follows to start printer and
rewinder:
The printer is set to off-line mode.
Starting TTX 350 / TTK
1. Press the CUT button.
The rewinder starts rewinding, until the bouncer arm reaches the final
position. At that point, the rewinder stops.
2. Switch the printer on-line.
If a printjob has already been loaded, both printing and rewinding start
nearly simultaneously.
Cut button Start or stop the rewinder by pressing the CUT button. This works in on-line
mode as well as in off-line mode.
Material end With no material to rewind, the rewinder stops after approx. 4 s and shows
the status report:
ST13
Press the ON/OFF button to acknowledge the status report.
Starting 64-xx / AP 5.4 / AP 7.t
1. Press the Cut button
The rewinder starts rewinding, until the bouncer arm reaches the final
position. At that point, the rewinder stops.
It is essential to let the bouncer arm initially reach its final position after
starting. Only then, the bouncer arm takes control over the rotation speed
(explanation below).
2. Switch the printer on-line.
If a printjob has already been loaded, both printing and rewinding start
nearly simultaneously.
Cut button Start or stop the rewinder by pressing the Cut button. This works in on-line
mode as well as in off-line mode.
Material end With no material to rewind, the rewinder stops after approx. 6 s and shows
the status report:
Status 5004
Rewinder mat. tear
Press the Online button to acknowledge the status report.


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Rotation speed Pressing the Cut button after securing the material end lets the rewinder
start winding at a comparably slow, constant speed. This startup speed is
independent of the formerly set printspeed and is maintained until the
bouncer arm reaches its final position for the first time after starting. After
having reached the final position, you recognize an alternating motor sound
as well as a changing rotation speed, indicating that the bouncer arm is
from then on controlling the rotation speed.

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(AP 5.4) Run-in roller for
narrow labels
To improve the guiding accuracy of AP 5.4
printers processing very narrow label material,
it is recommended to install an additional run-
in roller (1) (article number A100422).
At older rewinders, an additional hole
according to fig. (2) must be drilled before
installing the run-in roller.
Tools:
2/2.5 mm allen keys
Assembling:
Screw the axle of the run-in roller to the
hole as illustrated (1).
Adjusting:
1. Measure the centre of the label material
and mark it (3).
2. Loosen the set screw (4).
3. Shift the roller on the axle until the
centre groove on the roller (5) is in front
of the mark (3) on the material.
4. Re-tighten the set screw (4).
Material path:
Insert the material so that it runs over
the roller (6).
1
2
3
4
5
6
23.50
30.50
R4.40
R2.10
Countersunk 90°

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Technical Specifications
Motor Stepper motor
Position sampling Infrared light barrier
Rot. direction Free selectable – Rewind direction with label facing outside or inside.
Rewind speed Max. 203 mm/s (8"/s)
Spezification Max. outer-Ø 230 mm
material roll Core Inner-Ø 38/76/102 mm (1,5/3/4")
Min. material width = Minimal print width
Max. material width = Width of the rewinding mandrel
(102/127/152 mm resp. 4/5/6")
Max. roll weight 5 kg
Noise level < 70dB(A)