Web Techniques WT-25 Series User manual

07-1002
Owner's Manual and
Guide to Operations
MODEL WT-25
ROLL LABEL
REWIND MACHINES
910 Bolger Court, Fenton, MO 63026 (USA) [phone] [phone]
IMPORTANT: Read all instructions before using.

07-1002
Table of Contents
Safety Instructions.......................................................... 1
Purpose (General Overview) .......................................... 1
Operator Controls (Web Transport System) .................. 1
Rewind Direction Switch ............................................ 1
Main Speed Control Knob........................................... 1
Start Pushbutton ........................................................ 1
Stop Pushbutton......................................................... 2
Idle Speed Control Knob............................................. 2
Power On/Off Switch (And Power Indicator) ............. 2
Unwind Tension Control............................................. 2
Coreholders .................................................................... 2
Lift-Off Cam-Lock Coreholders ................................... 2
Air Inflatable Coreholders (Optional) ......................... 3
Rewinding....................................................................... 3
Web Path Illustration.................................................. 4
Straightening .............................................................. 4
Counting System............................................................. 4
Programming Deceleration and Stop Points...............4
Determining Preset B (Stop Point) ..............................5
Determining Preset A (Deceleration Count Setting) ...5
Automatic Reset..........................................................5
Electrical Control Adjustments........................................5
Minimum Speed..........................................................5
Deceleration Rate........................................................5
Acceleration Rate........................................................5
Procedure for Re-Programming KEP MC2A9 Counters...6
Unlocking the Counter ................................................6
Setting Scale Factors ...................................................6
Setting Count Mode ....................................................6
Setting the Relay Operation........................................6
Setting the Counter Lock Code....................................6
Locking the Counter ....................................................6

1
SAFETY INSTRUCTIONS
RULES FOR SAFE OPERATION
1. Know your machine. Read and understand the
owner’s manual and labels affixed to the machine.
Learn its applications and limitations as well as the
specific potential hazards peculiar to this machine.
2. Grounding. This machine should be grounded while
in use to protect the operator from electric shock.
Machines which are designed to run on less than
150 volts are equipped with a 3 conductor cord and
3 prong grounding type plug to fit the proper
grounding type receptacle. The cord is long enough
that it should not be necessary to use extension
cords. Temporary extension cords and receptacle
adapters should be used only until a properly
grounded outlet can be installed by a qualified elec-
trician. Use only a 3 wire extension cord of ade-
quate size to handle the rated full load current of
the machine as indicated on the machine name-
plate. If an adapter is used to accommodate a 2
hole receptacle, the grounding ear must be at-
tached to a known ground. Never remove the 3rd
prong (grounding blade) from the plug on the ma-
chine electrical cord.
3. Keep the machine guards in place and in good work-
ing order.
4. Avoid dangerous environments. Do not use the ma-
chine in a damp or wet location. Keep the work area
well lit.
5. Wear proper apparel. No loose clothing (i.e.
neckties) or jewelry to get caught in moving parts.
Wear protective covering to contain long hair.
6. Stay alert. Watch what you are doing. Use common
sense. Do not operate the machine when you are
tired. Do not use the machine after taking drugs, al-
cohol or medications.
READ ALL INSTRUCTIONS AND SAVE THEM FOR FUTURE
REFERENCE.
PURPOSE (GENERAL OVERVIEW)
WT-25LC and WT-25LCI series rewind machines are
made for the purpose of rewinding rolls of narrow web
products. In general, these are paper, film or foil prod-
ucts which are stiff enough to stand on edge (vertically)
throughout the web path of the machine. Cloth and
other woven materials generally do not rewind well (if
at all) on vertical spindle rewind machines. Abrasive
materials (sandpaper rolls, etc.) will damage the ma-
chine and should not be used. It is suggested that you
take a few minutes to become familiar with the controls
and operating characteristics before attempting to
rewind actual rolls.
WARNING
AS WITH ANY MACHINE, CAUTION MUST BE EXERCISED
TO PREVENT INJURY. NEVER OPERATE THE MACHINE
WITH GUARDS REMOVED. THE CONTROL CABINET
DOOR MUST BE KEPT CLOSED (SECURED BY SCREWS)
EXCEPT WHILE INTERNAL ADJUSTMENTS ARE BEING
MADE. ALWAYS EXPECT THE MOTOR TO TURN ON
WHEN THE START PUSHBUTTON IS OPERATED.
CAUTION
BEFORE CONNECTING THE MACHINE TO A SOURCE OF
ELECTRICAL POWER, OPEN THE CONTROL CABINET AND
VISUALLY INSPECT THE CONTROL PANEL TO BE SURE
THAT NO COMPONENTS OR WIRE CONNECTIONS HAVE
WORKED LOOSE IN SHIPMENT. WHEN INSPECTION IS
COMPLETE, CLOSE AND SECURE THE CABINET DOOR.
OPERATOR CONTROLS (WEB
TRANSPORT SYSTEM)
REWIND DIRECTION SWITCH
This switch determines the direction of rotation of the
rewind coreholder. When in the “PRINTING OUT” posi-
tion, the coreholder will turn in a counterclockwise di-
rection for winding with the labels on the outside of the
roll. In the “PRINTING IN” position, the rewind core-
holder will turn clockwise for winding labels on the in-
side of the roll.
MAIN SPEED CONTROL KNOB
Located next to the start pushbutton, the main speed
control knob is used to set the running speed before the
deceleration count is reached. Turning the knob clock-
wise will increase the speed. Rapid speed increases can
cause telescoping of the rewind roll and web breakage.
Therefore, the motor control has been pre-adjusted to
accelerate at an appropriate rate.
START PUSHBUTTON
Pressing of the START pushbutton will perform two
tasks. Most importantly, the motor control is enabled,

2
permitting the motor to run at the set speed. In addi-
tion, the START pushbutton will also reset the counter
to zero if the counter stop setting (Preset B) has been
reached
STOP PUSHBUTTON
The STOP pushbutton provides rapid stopping of the
machine. When pushed, the main drive motor is turned
off and dynamic motor braking is applied. Although it is
also possible to stop the machine by turning the speed
control down to zero, it is recommended that the STOP
pushbutton be used to insure that the machine will not
start again until desired.
IDLE SPEED CONTROL KNOB
The idle speed control knob is located on the control
cabinet on the far right hand side of the machine. When
the deceleration preset number (Preset A on the coun-
ter) is reached, provided you have the COUNT/STAND-
BY switch in the “COUNT” mode, the motor control will
automatically switch from the main speed control knob
to the idle speed control knob to the idle speed control
knob. The speed range of this knob is restricted to only
the lower twenty percent of the speed range. Once the
counter has been reset, the main speed control knob is
reactivated.
POWER ON/OFF SWITCH (AND POWER
INDICATOR)
The POWER ON/OFF switch is used to turn the main
power to the machine on and off. The switch has an
indicator light that illuminates when power is on.
UNWIND TENSION CONTROL
The unwind brake is a mechanical friction type consist-
ing of a brake band wrapped around a drum. An ad-
justing knob on the front of the machine provides a
means of tightening the brake band. Turning the knob
clockwise increases the unwind brake tension. To set
the brake initially, turn the unwind coreholder manually
and adjust the brake tension until a slight amount of
drag can be felt when turning the coreholder. When the
machine is running, make small adjustments as required
to obtain the desired web tension.
COREHOLDERS
Web Techniques rewind machines are available with
various types of coreholders. Lift-off cam-lock core-
holders are supplied as standard equipment. Air inflat-
able coreholders are available as an option. In addition,
some machines are configured with a combination of
both systems (usually a lift-off cam-lock coreholder on
the unwind and an air inflatable coreholder on the re-
wind). An air inflatable coreholder is required on the
rewind position in order to use an optional slitting
attachment.
LIFT-OFF CAM-LOCK COREHOLDERS
As the name implies, these coreholders can be removed
from the machine by simply lifting them straight up
from the table top and out of their sockets. The ad-
vantage of this type of coreholder is that heavy rolls can
be installed and removed by sliding them onto and off
the machine. If your machine is equipped with lift-off
cam-lock coreholders, they will be packaged separately
and must be installed on the machine.
A) Locate the package containing the coreholders. Ob-
serve that there is a slotted shaft protruding from
the lower end of the coreholder.
B) GENTLY lower the shaft into the socket in the un-
wind and rewind spindle. The shaft will probably
come to rest on top of the drive pin inside the spin-
dle and the bottom of the coreholder will be ap-
proximately ⅜ inch above the table top. Simply ro-
tate the coreholder until the drive pin and slot align
and the coreholder drops the rest of the way into its
socket.
C) Remove and install the coreholder several times so
that you become familiar with the “feel” of proper
coreholder engagement. This is important because
when the coreholder is installed by inserting it
through the core of a roll of material, you will not
be able to see that it is fully engaged and will have
to rely on feel.
CAUTION!!
DO NOT lay the coreholder on its side on the table top
when it is removed to change rolls or it may roll off and
become damaged. There is a hole in the table top
immediately to the right side of the pedestal mounted
counter. The purpose of this hole is to provide a place
to store coreholders when changing rolls.
D) Tightening and loosening of the cores is accom-
plished by turning the core on the coreholder. This
causes the cam to rotate and wedge against the in-
side of the core. To install a core, rotate the cam
until it is flush with the body of the coreholder.
Slide the core over the coreholder until it is resting

3
flat on the table. Twist the core until it locks on the
coreholder.
In actual operation the cores will usually lock
themselves once the rewind starts to turn.
However, locking them by hand is preferred be-
cause the web can be drawn tight before starting
the machine, thus reducing the chance of web
breakage. Since the cams will lock regardless of
which way they are turned, it is important that they
be turned the right way or they will again loosen
once web tension is developed. There are two basic
rules for determining which way to rotate the cams
to lock the cores:
(1) On the unwind, the cam should be rotated in
the direction the roll will be turning (usually
counter-clockwise).
(2) On the rewind, the cam should be turned oppo-
site to the direction of rotation (usually clock-
wise).
Until you become familiar with this operation, it
may be desirable to mark the top of the coreholder
with an arrow to indicate the lock and unlock
directions.
When a full roll is wound it can be difficult to
determine which direction it should be rotated to
release it from the coreholder. The two rules to
remember to loosen a core are:
(1) On the rewind, turn the core in the direction in
which the roll was wound (normally counter-
clockwise).
(2) On the unwind, turn the core in a direction
opposite to the direction in which the roll was
turning (normally clockwise)
NOTE
An alternate method of loosening the roll on the rewind
is to hold the roll tight against the top of the table and
turn the coreholder in the direction opposite to the way
it was running.
AIR INFLATABLE COREHOLDERS (OPTIONAL)
Air inflatable coreholders offer the advantage of ex-
panding concentrically over their full length simply by
flipping a switch. Machines which are equipped with a
slitting attachment require this type of coreholder sys-
tem on the rewind. That is so that ganged cores (one for
each slit web) can be individually gripped and driven.
Machines that have been equipped with air inflatable
coreholders require connection to a supply of air pres-
sure. A quick disconnect fitting has been provided for
this purpose (located on the back of the machine just to
the rear of the main drive motor). A mating female dis-
connect is supplied as a convenience in hooking up air.
The machine should be connected to an air source ca-
pable of supplying at least 50 psi. Individual regulators
on the machine allow the operator to adjust the pres-
sure between zero and 50 psi. Very narrow cores re-
quire only a small amount of pressure as excessive pres-
sure may burst the core. The coreholders can then be
inflated and deflated by means of toggle switches lo-
cated next to the pressure regulators.
CHANGING FROM 3-INCH TO 1-INCH AIR INFLATABLE
COREHOLDERS
A) Make sure that the coreholder is deflated.
B) Grasp the coreholder with one hand while loosen-
ing the socket head bolt in the center of the top of
the coreholder.
C) Lift the coreholder from the reroll table.
D) Loosen the four screws and remove the three-inch
coreholder adapter from the rewind spindle.
E) To insure that the adapter and retaining screws are
not lost, assemble the adapter onto the three-inch
coreholder.
F) Insert the one-inch coreholder into the hole in the
rewind spindle and align the mounting holes with
the holes in the flange.
G) Place the one-inch coreholder retaining ring on top
of the coreholder flange and install the four retain-
ing screws.
H) Check the operation of the coreholder by inflating
and deflating.
REWINDING
Learning to use the rewind machine should be accom-
plished in steps. Each step will build upon the previous
step. This will be more efficient than trying to learn how
to do everything at once. The first step will be learning
to thread the machine and operate the motor control to
wind rolls. Once you understand how to do that, you
can move on to setting up the counting system to
measure roll length.
A) Set the COUNT/STAND-BY switch to the “STAND-
BY”. This will make it possible to operate the
machine regardless of how the counter system is
set up.

4
B) Turn the main power ON/OFF switch to the “ON”
position.
C) Install a roll of labels on the unwind. Pull the free
end of the material off the roll until the coreholder
locks. Thread the material as shown in Figure 1.
D) Install a fresh core on the rewind and fasten the
free end of the web to the core with tape.
E) Check the position of the following switches:
SWITCH
POSITION
STOP/BYPASS PRESET
BYPASS
REWIND DIRECTION SWITCH
AS REQUIRED
MAIN SPEED CONTROL
MINIMUM
IDLE SPEED CONTROL
MID RANGE
WEB PATH ILLUSTRATION
Figure 1 Web Path for WT-25
F) Press the START button. Gradually increase the
speed setting until the web begins moving.
G) With the machine running slowly, push against the
face of the web between the last idler roll and the
rewind to determine the web tension. Adjust the
unwind brake tension as necessary to produce the
desired rewind tension.
H) Continue to increase the speed setting until the
machine is running full speed. Then try reducing the
speed. If the web begins to go slack and form a loop
on the top of the machine, the unwind tension is set
too low. Increase the tension to a point where the
web remains stable during acceleration and decel-
eration cycles.
I) Press the STOP button to stop the machine.
STRAIGHTENING
If the rewound roll is not straight due to splices or any
other cause, it may be straightened easily as follows:
A) Place the REWIND DIRECTION switch in the oppo-
site position.
B) Grasp the outer wrap of material on the rewind and
start the machine running very slowly.
C) Allow the roll to expand as it turns in the reverse
direction.
D) Once the roll is loosened all the way to the defect,
stop the motor.
E) Reverse the DIRECTION SWITCH and re-tighten the
roll.
COUNTING SYSTEM
The rewind machine incorporates a bi-directional dual
preset counter. This permits the operator to set sepa-
rate deceleration (Preset A) and stop (Preset B) points.
The counter is driven by means of two magnetically
operated reed switches located in the table top beneath
the counter drive roll. A magnet in the lower end of the
counter drive roll operates the reed switches. The
combined signals from each reed switch allow the
counter to automatically count up or down depending
on the direction of rotation of the counter drive roll.
This is primarily used when pulling defective material
backwards off the rewind roll. Be sure the web is held
against the counter drive roll when it is pulled
backwards.
PROGRAMMING DECELERATION AND STOP
POINTS
To set the final count, press the PRE B button on the
counter once. In approximately two seconds the current
value will be displayed. To change the value, simply
press the button under the digit that you wish to
change. Each time the button is pressed, the digit will
increment by one. When the desired value has been set,
push ENTER once to store the value into memory. To set
the count at which you wish the machine to go into the
deceleration mode, push PRE A and follow the same
procedure as described above. If you do not wish to
have a deceleration period, simply set the final count
Preset B as normal and set Preset A to any number
larger than Preset B.
NOTE
All Rewind Machines are equipped with an electronic
programmable counter. This counter is quite sophisti-
cated and is capable of performing certain functions not
applicable to our usage. While programming the coun-
ter, you will notice “LoC” will appear. This is to let you
know the manufacturer has programmed the counter to
deny access to the functions not required for our
application.

5
While it is possible for the counter to become unlocked
(possibly due to line noise, electrical storms, etc.), it is
important to note that this will disable the counter from
performing as it should. In order to correct the
situation, the counter will need to be re-programmed.
For your convenience, we have provided re-
programming instructions located in the final section of
this manual in the event that this occurs
DETERMINING PRESET B (STOP POINT)
The counter registers one count per ten inches of web
travel when using the standard ten-inch circumference
counter drive roll. This makes it easy to calculate the
appropriate number to enter into the counter in order
to wind a roll of a given number of labels. The number is
calculated as follows:
𝐂𝐨𝐮𝐧𝐭 = (𝑵𝒐.𝒐𝒇 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝒍𝒂𝒃𝒆𝒍𝒔)(𝒓𝒆𝒑𝒆𝒂𝒕 𝒍𝒆𝒏𝒈𝒕𝒉)
𝟏𝟎
EXAMPLE: To wind a roll of 1000 labels of 3 inch repeat
length, the number 300 would be entered as the final
count (Preset B).
𝐂𝐨𝐮𝐧𝐭 = (𝟏𝟎𝟎𝟎)(𝟑)
𝟏𝟎 =𝟑𝟎𝟎
Figure 2 Counter Package
DETERMINING PRESET A (DECELERATION COUNT
SETTING)
The point at which deceleration should begin depends
on many factors (rewind speed, finished roll diameter,
etc.). Therefore you probably will need to test your de-
celeration count setting each time you rewind a new
type of label. The desired technique is to have the ma-
chine stop shortly after it decelerates fully and has sta-
bilized at the lower speed. For the first attempt try a
setting that is fifty counts less than the final count. This
means that the counter will begin to decelerate the
machine 50 counts before the end of the roll.
EXAMPLE: If the final count (Preset B) is 300, then the
deceleration count (Preset A) should be set at 250.
AUTOMATIC RESET
After winding a roll (and reaching the final preset num-
ber), the counter will reset to zero automatically when
the start pushbutton is pressed to start a new roll. This
is the only time automatic resetting can occur. Counting
will proceed normally each time the machine is stopped
and started (without resetting) until Preset B has been
reached. You may reset the counter to zero at any time
by pushing the “RST” button on the counter.
ELECTRICAL CONTROL
ADJUSTMENTS
The following list of settings has been pre-adjusted by
Web Techniques, Inc. to cover most applications. If
these settings are not optimal for your requirements,
adjustments may be made with discretion. These set-
tings are located on the printed circuit board closest to
the terminal blocks on the motor control. The motor
control is located inside the control cabinet.
MINIMUM SPEED
If a higher than zero minimum speed is desired, readjust
the minimum speed by turning the main speed control
knob on the front of the machine to zero setting (full
counterclockwise position). Then adjust the trim poten-
tiometer marked MIN to the desired setting.
DECELERATION RATE
If your labels become loose during the deceleration
period with the web tension set at the necessary level,
you should increase the deceleration rate by turning the
trim potentiometer marked DECEL clockwise. If you feel
that the deceleration period is too long, turn the decel-
eration trim potentiometer counterclockwise to reduce
the deceleration rate.
ACCELERATION RATE
Turning the trim potentiometer marked ACCEL clock-
wise increases the amount of time required for the mo-
tor to reach full speed. The setting should be such that
the web does not break when the motor is started.

6
PROCEDURE FOR RE-
PROGRAMMING KEP MC2A9
COUNTERS
UNLOCKING THE COUNTER
1. Press LOCK. The display will show “CodE” for a few
seconds.
2. When “CodE” disappears, enter the code 13579 and
press ENTER.
3. The counter will then show “un LoC” for a few se-
conds. You are now ready to reprogram the
counter.
SETTING SCALE FACTORS
1. Press PRGM.
2. When “FACtor” appears, press ENTER.
3. When “dP F A” appears, press PRGM. Then press
ENTER.
4. Set “dP F A” to 1 if it is not already set to 1 and
press ENTER.
5. When “dP F b” appears, press PRGM. Then press
ENTER.
6. Set “dP F b” to 1 if it is not already set to 1 and
press ENTER.
7. Press ENTER again.
SETTING COUNT MODE
1. Press PRGM twice.
2. When “Count” appears, press ENTER. Then (if
necessary) press PRGM until “rSt 0” appears.
3. Press ENTER.
4. When “dP LoC” appears, press PRGM. Then press
ENTER.
5. If necessary, press PRGM until “A nEtb” appears.
6. Press ENTER.
7. If necessary, press PRGM until “ASub b” appears.
8. Press ENTER.
9. If necessary, press PRGM until “Hi CPS” appears.
10. Press ENTER.
SETTING THE RELAY OPERATION
1. Press PRGM 4 times (until “rELAY” appears).
2. Press ENTER.
3. Set “A XX.X” to “A 00.0” and press Enter.
4. Set “b XX.X” to “b 00.0” and press Enter.
SETTING THE COUNTER LOCK CODE
1. Press PRGM 3 times (until “LoC” appears).
2. Press ENTER.
3. If necessary, press PRGM until “LC Pr9” appears.
4. Press ENTER.
5. The display will show “CodE” for a few seconds.
When “CodE” disappears, enter the code 13579 and
press ENTER.
LOCKING THE COUNTER
1. Press LOCK. The display will show “CodE” for a few
seconds.
2. When “CodE” disappears, enter the code 13579 and
press ENTER.
3. To verify that the counter is locked, press the PRGM
key. The “LoC” message should appear on the
counter.
NOTE
When locking and unlocking the counter, the procedure
is the same. Each time the Lock code is entered, it will
either lock or unlock the counter