Web Techniques WT-25LC User manual

07-1036 Metric CDR
Owner's Manual and
Guide to Operations
MODEL WT-25LC & WT-25LCI
ROLL LABEL
REWIND MACHINES
910 Bolger Court, Fenton, MO 63026 (USA) [phone] [phone]
IMPORTANT: Read all instructions before using.

07-1036
Table of Contents
Safety Instructions.......................................................... 1
Purpose (General Overview) .......................................... 1
Operator Controls (Web Transport System) .................. 1
Rewind Direction Switch ............................................ 1
Main Speed Control Knob........................................... 2
Start Pushbutton ........................................................ 2
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....................................................................... 4
Web Path Illustrations................................................ 4
Straightening .............................................................. 4
Counting System............................................................. 5
Programming Deceleration and Stop Points .............. 5
Determining Preset B (Stop Point) ............................. 5
Determining Preset A (Deceleration Count Setting) .. 5
Automatic Reset (Length Mode Only)........................ 6
Photoelectric Counting System ...................................... 6
Thru-Beam Scanner .................................................... 6
Capacitance Scanner (Optional) ................................. 6
Speed of Operation .................................................... 6
Accuracy of Counting.................................................. 6
Photoelectric Counting System Controls........................ 7
Stop at Preset/Bypass Preset Switch.......................... 7
Count Labels/Count Length Switch.............................7
Dark Energize/Light Energize Switch...........................7
Count Up/Count Down Switch ....................................7
Count/Standby Switch.................................................7
Manually Increment Counter Pushbutton ..................7
Sensitivity Adjustment ................................................7
Resetting The Counter ................................................8
Photoelectric Counting System Set-Up...........................8
SK1 Auto Adjust Thru-Beam Scanner Operation.........8
Adjusting Count at the Beginning of a Roll .................8
Detecting Punched Holes............................................9
Electrical Control Adjustments........................................9
Minimum Speed..........................................................9
Deceleration Rate........................................................9
Acceleration Rate........................................................9
Strobe Light Set-Up (Optional)........................................9
Set-Up..........................................................................9
Operation ..................................................................10
Procedure for Re-Programming WT-25 Series Counters
.......................................................................................10
Unlocking the Counter ..............................................10
Setting Scale Factors .................................................10
Setting Count Mode ..................................................10
Setting the Relay Operation......................................10
Setting the Counter Lock Code..................................10
Locking the Counter ..................................................10

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07-1036
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.
WARNING
Machines equipped with strobe lights. These machines
emit a stroboscopic, flashing light. Viewing of this light
may trigger epileptic seizures in persons with photosen-
sitive epilepsy.
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. The machines are
equipped with a counting system that can be set to
measure roll length or to photoelectrically count labels.
In addition, WT-25LCI machines are equipped with a
strobe light system to permit visual inspection of the
labels at high speeds. It is suggested that you take a few
minutes to become familiar with the controls and oper-
ating 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.

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07-1036
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,
permitting the motor to run at the set speed. In addi-
tion, when operating the counting system in the length
mode, the START pushbutton will also reset the counter
to zero if the counter stop setting (Preset B) has been
reached. Automatic reset to zero does not take place in
the photoelectric counting mode because the operator
may have already set an initial count into the counter to
account for labels that have passed the scanner.
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 STOP AT PRE-
SET/BYPASS PRESET switch in the “STOP AT PRESET”
mode, the motor control will automatically switch from
the main 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 3/8 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

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07-1036
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
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.

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07-1036
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 or count labels. If you have a model
WT-25LCI, you can then learn the operation of the
strobe light.
A) Set the STOP AT PRESET/BYPASS PRESET switch on
the label counting system to the “BYPASS PRESET”
position (this is the leftmost rocker switch on the
label counting system panel). This will make it pos-
sible to operate the machine regardless of how the
counter system is set up.
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 1A
(WT-25LC) or Figure 1B (WT-25LCI).
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 ILLUSTRATIONS
Figure 1A Web Path for WT-25LC Models
Figure 1B Web Path for WT-25LCI Models
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.

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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 counting system can be operated in either the pho-
toelectric counting mode or the length counting mode.
In the length counting mode, the counter is driven by
means of two magnetically operated proximity switches
located in the table top beneath the counter drive roll.
A magnet in the lower end of the counter drive roll op-
erates the proximity switches. The combined signals
from each proximity switch allow the counter to auto-
matically 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. When counting
photoelectrically, the operator must place the COUNT
UP/COUNT DOWN switch in the “COUNT DOWN” posi-
tion before pulling the labels backwards. The switch
must be returned to the “COUNT UP” position before
moving the labels forward again. The MANUALLY IN-
CREMENT COUNTER pushbutton will illuminate when
the COUNT UP/COUNT DOWN switch is in the “COUNT
DOWN” position in order to remind the operator that
the counter is set for counting backwards and that the
switch must be placed in the “COUNT UP” position be-
fore resuming operation.
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.
While it is possible for the counter program to become
scrambled (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 cor-
rect the situation, the counter will need to be re-pro-
grammed. 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)
LENGTH MODE COUNTING
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
LABEL COUNTING MODE
Every label is counted as it passes through the scanner.
No calculations are required. Set Preset B to the desired
total label count.
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 150 counts less than the final count. This
means that the counter will begin to decelerate the
machine 150 counts (15M) before the end of the roll.
EXAMPLE: If the final count (Preset B) is 750, then the
deceleration count (Preset A) should be set at 600.

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07-1036
AUTOMATIC RESET (LENGTH MODE ONLY)
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.
PHOTOELECTRIC COUNTING
SYSTEM
THRU-BEAM SCANNER
The photoelectric counting system has been designed
to operate with several types of scanners. For most
pressure sensitive labels, a thru-beam scanner is the
logical choice. This is the easiest type of scanner to set
up and use. A thru-beam scanner is supplied as stand-
ard equipment (unless the machine is ordered with an-
other type of scanner in place of the thru-beam scan-
ner). Labels on a liner material (with a space between
each label) can be detected by sensing the difference in
thickness of the web (due to the difference in light pen-
etration ability). A light source is placed on one side of
the web and a photocell on the other. Signals from the
photocell are processed by an amplifier circuit which
functions as an output switch to drive an electronic
counter. The number of labels passing the photocell are
thus registered on the display of the counter.
CAPACITANCE SCANNER (OPTIONAL)
A capacitance type scanner is available for use when
thru-beam scanning is not possible. A typical example is
when counting clear labels on a clear liner. The capaci-
tance scanner uses a non-contact electronic probe to
detect the presence of labels. The capacitance scanner
will not detect cross scored labels or other labels that
do not have a space between them. The sensor is not
recommended for use with "conductive" inks, i.e., me-
tallic, carbon filled, etc. Please refer to the LRD Scanner
Supplemental Instructions, if this optional scanner was
purchased for use on a WT-25LC/LCI Rewind Machine.
SPEED OF OPERATION
Because of the variations in each application it is impos-
sible to guarantee a maximum speed of operation. Such
things as color, intensity, contrast, target size, etc. all
play a significant role in the speed with which labels can
be accurately counted. However, the counter system is
capable of accurately detecting and counting high con-
trast targets ⅛ inch wide at maximum machine speed.
ACCURACY OF COUNTING
Under normal conditions, a properly trained and disci-
plined operator using well organized methods and
techniques can obtain 100% accuracy using the photo-
electric counting system. However due to circumstances
beyond its control, Web Techniques, Inc. can make no
guarantees as to the accuracy of count. The following
factors which can affect accuracy should be kept in
mind when using the photoelectric counting system:
1) DISTANCE FROM THE PHOTODETECTOR TO END OF
OPERATION. For example, if the counting system is
used to count the number of labels on a roll, it is
important to consider the number of labels that
have already passed the scanner location during the
threading operation.
2) OPERATIONS TAKING PLACE DOWNSTREAM FROM
THE PHOTODETECTOR. Allowance must be made for
splicing and other operations that affect labels
which have already been counted.
3) SPLICES IN THE WEB. If the roll contains splices,
these may each be mistaken for a label and counted
as such.
4) TAPE AT END OF THE ROLL. It is a common practice
to tape the end of the web to the core on which it is
wound. If the tape is not transparent and is in the
path of the scanner, it may be counted as a label.
Also, even if the tape is clear, if paper cores are
being used, the tape may lift off part of the paper
core which may then be counted.
5) PRINTING ON THE LINER OF CERTAIN PRESSURE
SENSITIVE MATERIALS. Many label stock manufac-
turers print patterns or their trade name on the
liner of pressure sensitive stocks. When the thru-
beam scanning method is used to count labels, this
printing may be detected. Usually careful adjust-
ment of the sensitivity control can eliminate this
problem.
6) IMPROPER SET-UP OF THE COUNTING SYSTEM. Care
must be exercised in adjusting the automatic sensi-
tivity control properly. With proper adjustment, the
photoelectric devices can be made to ignore such
problems as flutter in the web.
7) ELECTRICAL INTERFERENCE FROM NEARBY EQUIP-
MENT. The photoelectric counting system incorpo-
rates sensitive logic gates which can be affected by
electrical noise. Filtering has been employed to the
extent that it could be, without reducing the speed
of operation. If random counts are observed when

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07-1036
adjacent machinery is operated, noise suppression
should be applied at the source.
8) SPEED AFFECTS REFLECTIVE SCANNERS. Under cer-
tain conditions, it may be necessary to operate the
machine at a slower speed for accurate counting.
PHOTOELECTRIC COUNTING
SYSTEM CONTROLS
Figure 2 Counter Package
STOP AT PRESET/BYPASS PRESET SWITCH
The counter is a predetermined counter which can be
used to stop the machine at any preset count up to
99999. When the switch is in the “STOP AT PRESET” po-
sition the counter will provide deceleration and stop
signals. If the machine is running fast enough that addi-
tional labels pass the scanner while stopping, the addi-
tional labels will be counted. In the “BYPASS PRESET”
position, the counter will continue counting and the
machine will not decelerate or stop.
COUNT LABELS/COUNT LENGTH SWITCH
This switch allows the operator to select one of two
modes of counting. In the length mode the counter in-
dicates the length of web that has passed through the
machine. In the label mode, individual labels may be
counted.
DARK ENERGIZE/LIGHT ENERGIZE SWITCH
This switch controls the mode of operation of the pho-
toelectric amplifier. In the DARK ENERGIZE position, the
counter will add one count each time the photocell has
detected a label or printed mark. In the “LIGHT ENER-
GIZE” position, the counter will add one count each
time a punched hole has been detected (light emitted
through the hole). Note that it is normal for the counter
to add one count each time this switch is operated. Be
sure to reset the counter after selecting the proper
mode.
COUNT UP/COUNT DOWN SWITCH
This switch only functions in the photoelectric counting
mode (bi-directional counting is automatic in the length
mode). Placing the switch in the “COUNT DOWN” posi-
tion causes the counter to subtract counts each time a
label passes through the scanner. In order to remind the
operator that the switch is in the “COUNT DOWN” posi-
tion, the MANUALLY INCREMENT COUNTER pushbutton
will illuminate. Whenever the button is illuminated, the
MANUALLY INCREMENT COUNTER pushbutton will sub-
tract one count from the counter each time it is pushed.
Normal counting is restored when the switch is placed
in the “COUNT UP” position.
COUNT/STANDBY SWITCH
The COUNT/STANDBY switch is used to disable the
counter. When placed in the “STANDBY” mode, the
counter will ignore signals from the scanner. This is
useful when making splices or removing bad material
from a roll.
MANUALLY INCREMENT COUNTER PUSHBUTTON
This pushbutton allows the operator to add to the count
(one count each time the pushbutton is depressed). This
feature is used at the start of a roll to record any labels
that have already passed the scanner location. The
pushbutton can also be used to subtract counts (such as
when a counted label is removed) by first operating the
COUNT UP/ COUNT DOWN switch.
SENSITIVITY ADJUSTMENT (USED WITH SCANNERS
WHICH REQUIRE AN EXTERNAL SENSITIVITY
ADJUSTMENT)
The thru-beam and capacitance type scanners used
with WT-25LC/LCI machines have built in sensitivity
controls. The sensitivity adjustment on the counter
package is not used with these devices and it does not
matter where the knob is positioned. On occasion, a
special scanner which requires an external sensitivity
adjustment (i.e., a reflective scanner) may be used for a
unique application. The sensitivity adjustment is used
with these types of scanners to adjust the gain of the
photoelectric amplifier. When properly set, the output
of the amplifier will turn off when no label is present
and turn on when a label is detected. When detecting
holes, the adjustment should be set so that it does not
register except in the presence of a hole.

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07-1036
RESETTING THE COUNTER
When operating in the photoelectric counting mode,
the counter must be manually reset to zero by means of
the “RST” button on the counter.
PHOTOELECTRIC COUNTING
SYSTEM SET-UP
A) An extended idler roll shaft has been provided for
mounting the scanner on the idler roll closest to the
front of the machine. Install the scanner assembly
on the extended idler roll shaft. The scanner should
be positioned so that it is located in the web path
between the two idler rolls.
B) Connect the plug from the scanner to the scanner
socket on the counter. Note that the plug is polar-
ized so that it can only be inserted when it is
properly aligned with the socket.
C) Turn the POWER “ON/OFF” switch to the “ON” posi-
tion. If the counter does not register zero, press the
counter reset button to zero the counter.
D) Place the COUNT LABELS/COUNT LENGTH switch in
the “COUNT LABELS” position and the
COUNT/STANDBY switch in the “COUNT” position.
SK1 AUTO ADJUST THRU-BEAM SCANNER
OPERATION
The SK1 scanner is an optoelectronic slot sensor that is
used for detecting pressure sensitive labels on a liner
that have a space between them. The sensor has an au-
tomatic adjustment feature to set its sensitivity for de-
tecting labels. The scanner does not require any mainte-
nance other than to periodically clean the optical sensor
with a soft cloth and check that the electrical connec-
tions remain tight.
NOTE
The following procedures assume that it is desired to
count pressure sensitive labels on a liner where there is
a gap between labels. A discussion of the procedure for
counting labels with punched holes will follow.
A) Place the DARK ENERGIZE/LIGHT ENERGIZE switch
in the “DARK ENERGIZE” position.
B) Observe the LED's (visible in the window next to the
"Auto Adjust" button) when no material is within
the slot sensor. The green LED should be illumi-
nated. If the red and green LED's are both illumi-
nated, the scanner is "locked" in a previous setting
and automatic adjustment will not take place. If the
scanner is locked, depress and hold the "Auto Ad-
just" button on the side of the sensor for six (6) se-
conds to unlock the scanner.
C) Place a strip of label material into the slot of the
scanner. Align scanner in the center of the gap
between the labels until the green led comes on.
D) While observing the LED's, press the "Auto Adjust"
button until both the red and green LED's illuminate
-- then release the button. The red LED will begin to
blink indicating that the scanner is learning the
transparency of the liner material. After the liner
transparency has been learned, the red LED will
turn off and the green LED will turn on.
E) Move the strip of labels until a label enters the sen-
sor slot. The green LED will turn off each time a la-
bel is present and will turn on again as the gap be-
tween labels passes through the sensor.
NOTE
1. The sensor learns the degree of transparency of the
liner material. When a label passes through the scanner,
the transparency decreases. The scanner is normally
sensitive enough to detect the label material even if
there is no printing on the label. In some instances
(where there is only a small difference in contrast be-
tween the label (target) and the liner), it is necessary to
use the "Precise Sensitivity Setting" of the scanner. This
is accomplished the same as in steps B-E above except
that instead of pressing the "Auto Adjust" button one
time (in step D), the button should be released briefly
when the red LED first turns on, and pressed again a
second time within one (1) second. The green LED will
begin to blink indicating that the scanner is learning the
transparency of the liner material. If the button is not
pushed a second time before the LED begins blinking,
the "standard" sensitivity setting will be made rather
than the "precise" sensitivity setting.
2. If the yellow and red LED's blink simultaneously, the
liner material is not sufficiently transparent or the con-
nection cable has a short circuit.
3. The sensor remembers the last sensitivity setting
when power is turned off. However, to ensure accurate
counting, the "Auto Adjust" procedure should be com-
pleted each time a different type of label is being
counted.
ADJUSTING COUNT AT THE BEGINNING OF A ROLL
Count the number of labels between the photocell and
the beginning of the roll (DO NOT count the label that is
inside the scanner--it will be counted when it passes the
scanner). Set the LED display (count) so that it registers

9
07-1036
all labels that have passed the scanner location. The
count can be increased manually by pressing the MAN-
UALLY INCREMENT COUNTER button once for each
count. If it is necessary to adjust the counter negatively,
place the COUNT UP/COUNT DOWN switch in the
“COUNT DOWN” position and press the MANUALLY IN-
CREMENT COUNTER button. Be sure to return the
switch to the “COUNT UP” position before continuing. If
the counter has a large error (or has not been reset
since the last roll was run) simply press the counter re-
set button to set it to zero before using the MANUALLY
INCREMENT COUNTER button.
DETECTING PUNCHED HOLES
A) Place the DARK ENERGIZE/LIGHT ENERGIZE switch
in the "LIGHT ENERGIZE" position.
B) Observe the LED's (visible in the window next to the
"Auto Adjust" button) when no material is within
the slot sensor. The green LED should be illumi-
nated. If the red and green LED's are both illumi-
nated, the scanner is "locked" in a previous setting
and automatic adjustment will not take place. If the
scanner is locked, depress and hold the "Auto Ad-
just" button on the side of the sensor for six (6) se-
conds to unlock the scanner.
C) Remove all material from the slot in the sensor.
D) While observing the LED's, press the "Auto Adjust"
button until both the red and green LED's illuminate
-- the release the button. The red LED will begin to
blink indicating that the scanner is learning the
"clear slot" or "hole" condition. After the "hole con-
dition" has been learned, the red LED will turn off
and the green LED will turn on.
E) Move the strip of labels until a label enters the sen-
sor slot. The green LED will turn off and will turn on
again each time a hole passes through the sensor.
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.
STROBE LIGHT SET-UP
(OPTIONAL)
SET-UP
1) Unpack the Web Techniques Stroboscope Control
Unit and Strobe Lamp.
2) A mounting bracket for the control unit is provided
on the right end of the machine foot rest. Insert the
strobe light power cord into the power cord recep-
tacle on the back of the control unit. Place the con-
trol unit on the mounting bracket. Connect the
Strobe Light Synchronization Cable (cable which has
a 3 pin circular DIN connector) to the input labeled
“TRIGGER” on the control unit.
3) Locate the mounting base for the floating arm lamp
on the front left corner of the table top and install
the lamp using the screws supplied (orient the lamp
so that the cable exits to the left). Connect the ca-
ble from the lamp to the “LAMP” connector on the
control unit. Use the plastic cable ties provided with
the lamp to route the cable along the back of the
machine to the control unit.
WARNING
Always turn off power before detaching the strobe lamp
connector from control unit. 600 volt DC is present at
this connector.

10
07-1036
4) Turn the control unit power switch to the "ON" po-
sition. From this point forward, the strobe control
will be powered up at the same time the rewind
machine master power switch is turned on.
5) Place the “TRIGGER-TEST-MANUAL” switch in the
“TRIGGER” position.
OPERATION
1) Press the Start Push Button. Increase the machine
speed as necessary for the strobe lamp to operate
effectively and observe the labels. If the flash rate
does not appear steady, adjust the Sensitivity Ad-
justment until the labels appear stopped.
2) When the reroll table is operating and counting
individual labels, the strobe light will flash in syn-
chronization with each label.
CAUTION
Any time the machine is running and the strobe light
suddenly appears to become erratic, this is a signal that
the scanner is missing labels and the count will not be
right (unless there actually are labels missing from the
web). Another cause for erratic flashing may be that the
flash tube needs replacing. To determine this, place the
control unit in the “TEST” mode. If the light continues to
flash erratically or not at all, replace the flash tube
(available from Web Techniques).
PROCEDURE FOR RE-
PROGRAMMING WT-25 SERIES
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