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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

Contents:

BG 01 Unrolling.....................................1 3.4 Starting up .....................................22

1. Safety .................................................2 3.5 Shutting down ...............................23

2. Technical data ...................................3 3.6 Malfunctioning ..............................24

2.1 Additional units ...............................4 4. Care and maintenance....................26

3. Operation ...........................................5 4.1 Care of machine ............................26

3.1 Operating elements .........................5 4.2 Greasing points on machine........27

3.1.1 Operating panel for web tension 4.2.1 Chain drive and gearwheel drive..27
control............................................6
4.2.2 Plain bearings, threaded spindles and
3.1.2 Operating panel for web edge sliding guides .........................................28
control............................................7
4.2.3 Roller bearings.............................29
3.2 Insert web .......................................17
4.2.4 Compressed air lubrication ..........30
3.2.1 Take over new web .......................17
4.3 Tests to be done ...........................31
3.2.2 Web run ........................................20
4.4 Fast wearing parts 32
3.3 Settings...........................................21

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

BG 01 Unrolling station

The unrolling station provides the material A splice table is provided for splicing the rolls
supply to the downstream units. at an angle. The clamping which is
Unrolling station BG 01 is fitted with a roll necessary for splicing is carried out via
lifting device, whereby rolls of material up to expansion elements.
a diameter of 1250 mm can be carried. The unrolling tension is generated via a
Control of the web edge is carried out by a electronic unwinding controller unit operated
unit of the Erhardt & Leimer company. This by a dancer. The dancer force and thus the
unit ensures the exact web inlet into the unrolling tension can be set via a fine control
printing machine. It can be furnished with valve.
three different scanners:

• Web edge scanner with infrared sensor Common deviations:

for control based on web edge and also
suitable for transparent material to be ATS drive side
printed BDS operating side
ELS inlet side
• Web edge scanner with ultrasonic ALS outlet side
sensors for control based on the web BL overall length
edge for crystal-clear , transparent GG basic shelf
material to be printed

• Combined line/edge of printing for control

based on a printed line or edge of a
printed area.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

1. Safety

The general safety instructions must be

followed. Caution!
Please ensure that all safety equipment is
fitted and ready for operation before the Danger of fire!
machine is switched on. Furthermore a
performance check of the safety equipment Machine is explosion-proof.
should be carried out at the start of each
new shift. After splicing of a new roll the Do not use cleaning fluids of
clamping on the splicing table must be danger class A1 with a flash
loosened.
Care must be taken at open web edges
point under 55°C!
because there is risk of cutting injuries at
these places when the machine is
running.

Caution!
Increased risk of injury:
• through sharp paper edges when
inserting the web.

During normal running operation all

guards have to be fitted.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

2. Technical data

EM 260 EM 410 EM 510 EM 340

Width of material web max. 258 mm 413 mm 516 mm 343 mm
[10,125“] [16,25“] [20,25“] [16,25“]
Weight of rolls: max. 500 kg

Roll diameter EM 260 EM 410 EM 510 EM 340

Paper: max. 1250 mm
Aluminium: max. 700 mm
Core diameter: 3“ (76,2 mm)

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

2. Technical data

2.1 Additional Equipment

• Web edge control

• Splicing table

• Adhesive tape for the unrolling unit

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3. Operation

3.1 Operating elements

13 web edge control
1 unwinding arms
14 photo electric cell for end of roll
2 roll securing and spindle clutch unit
15 knurled screw for photo electric cell
3 pneumatic expansion spindle
16 dancer pressure controller
4 pressure valve at spindle end
17 pressure gauge (dancer pressure)
5 switch¸ lift unwinding arm,
lower unwinding arm 18 operating panel for web edge control

6 operating panel for web tension control 19 photo electric cell for web edge control

7 splicing table 20 lever for roll securing

8 left hand pressure beam 21 roll of material

9 right hand pressure beam

10 switch for left hand pressure beam

11 switch for right hand pressure beam

12 dancer

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.1.1 Operating panel for web

tension conrol 28 potentiometer (dancer position)
positioning of dancer arm
22 tumbler switch
control unit ON/OFF Caution!
This adjustment should only be
23 tumbler switch carried out in an exeptional case.
brake ON/OFF The setting of the dancer "0"
position has already been carried
24 control lamp out at the factory.
lights up when mains voltage is applied

25 control lamp
lights up when brake has been
switched on and is ready for use

26 control lamp
lights up when dancer is ready for use

27 trimming potentiometer (gain)

optimising controlling behaviour of the
dancer arm or amplification factor for
brake

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.1.2 Operating panel for web edge

control
The web edge control ensure that the web
edge always keeps at the same place when
the machine is running. After the web has
been inserted, attention must be paid that
the turning frame of the web edge control is
set at mid-position.This is necessary to
ensure that the web edge is controlled or
aligned towards both sides when the
machine is running.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.1.2.1 Keys and displays

.

Operating voltage display " + 5 V DC "

This indicator lights up when this voltage is applied at
the electronic control.

Digital display
The digital display shows the set values of the various
parameters of the digital web run control. As set in the factory
it displays the shift of web.

"decrease value" key

With the key "decrease value" the parameter value displayed
can be reduced.

"increase value" key

With the key "increase value" the parameter value displayed can
be increased.

Display " web run direction"

Web run direction and the web run direction displayed must
correspond. If this is not the case the display must be inverted.
Either loosen the four fastening screws at the operating unit RT
and switch over the switch on

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

back side of the operating unit or change the web run direction in
the set up-mode:

⇒ set the unit no. and group no for the operating unit in the set up
mode.

⇒ change the displayed value ("0" or "1") in parameter ..6.

"display web run direction " . If "1" is shown set "0" and vice-
versa.

⇒ set unit no. and group no for the controller and leave set up
mode.

"Sensor" keys sensor comp-

These keys are used for setting the web guiding method letely covered
(red)
− left hand edge (left hand sensor)
− right hand edge (right hand sensor) sensor selected
− mid-web (both sensors) (green) sensor free
(red)
When a sensor has been selected the green indicator "sensor
selected" lights up.
sensor comp-
When there is no web in the sensor sight area the red letely covered
indicator "sensor free" lights up. (red)

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When the sensor area is completely covered the red indicator

"sensor completely covered" lights up.
In automatic mode, if one of the red indicators "sensor free" or
"sensor completely covered" lights up, the corresponding
sensor must be newly positioned.

"line sensor" key sensor rage limit

This key is used for setting the guiding criterion: (red)

− light coloured line - light coloured line

− dark line -dark line
− contrast edge
-contrast edge
When one of the red indicators "sensor range limit" lights up the guiding sensor rage limit
criterion has reached the left hand or right hand range (red)
limit (depending on the web run direction). The line sensor must
be newly positioned.

"web position adjustment/ manual adjustment" key

This key is used to pilot the web run control to the right hand or
left hand side in the operating mode "manual".
When the web run control has reached its end position, the actuating drive end position
(red)
indicator lights up in the respective key. The indicator blinks
shortly before the end position is reached.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

In the operating mode "automatic" the keys are used for web position adjustment. When two
keys are pressed simultaneously a web position adjustment setting will be deleted.

The web position adjustment is an electronic shifting of the sensor neutral position and the
desired position of the web is being shifted during automatic operation.

"Sensor signal" display

This display shows the output signal of the sensor selected (left hand, right hand or buzzer
signal.) The further the signal of the light emitting diode tube swings out, the further away the
web edge is from the middle of the sensor optic system.

sensor selected
web run direction

„Sensor signal“ display

„Sensor signal“ display web run direction display

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

"Controller stop" display

When the indicator "controller stop" is flashing, voltage is
applied to input "controller stop", and the operating mode
"automatic" is disabled. The web run controller now only
works in the operating modes "manual operation" or "middle
setting".

select set up mode

"Set up" key
By pressing the "set up" key and also the "increase value"
+
key, one gets into the set up mode (always press the "set up"
key first) and the green light emitting diode on the "set up-
mode" key flashes.

In the set up mode, one can: Setup (green)

− change various parameters
− reset the middle setting of the web run controller system
See description "set up editor".
Automatic (green)
"Automatic" key
When the "automatic" key is pressed, the web run control
system controls in accordance with the signals of the sensors,
and the green indicator on the key lights up. It is possible to
undertake a web shift adjustment via the keys "web
shift/manual setting"
web shift/manual

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

If the indicator flashes the signal "controller stop" is applied,

the automatic operating mode is blocked.

"Middle setting" key

When the key "middle setting" is pressed, the web run Middle setting
controller is positioned on the middle setting stored. The
indicator on the key lights up.

Trimming middle setting Trimming middle setting

By pressing the keys "set up" and "middle setting"
simultaneously the present position of the web run controller
is the new middle setting. +

"Manual operation" key Manual operation (green)

When the "manual operation" key is pressed, the web run
controller can be adjusted to the left hand side or the right
hand side via the keys "web shift/manual setting".

When the key "manual operation" is pressed the indicator on

the key lights up. The indicator flashes while the keys "web
adjusting/manual setting" are pressed.

Before the end position is reached the indicator in the button

"web shift/manual setting" flashes.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.1.2.2 Operation

From feeding the web to the control operating mode.

⇒ Middle setting - web run controller off.

Before inserting the new web always set the web run
controller to operating mode "middle setting" first.

⇒ Setting web shift to "0"

Set web shift on operating unit RE.. to "0"
Set web shift on operating unit RT.. to "0"
(simultaneously pressing both buttons web shift/manual
setting).

⇒ Insert web

⇒ Select sensor - set web guiding type

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

⇒ Sensor positioning
Position the sensors at the web (with a motor driven setting
support VS.. see description RT 4021, if the setting support
is manually adjusted, see sensor description).
Caution !
The sensors must be positioned manually only when the
machine is not running. Danger of injury

⇒ Setting operating mode

Set the operating mode desired ("automatic", "middle
setting" or "manual operation").

− Automatic operation
The web run controller operates according to the signals
of the sensor. In the automatic operating mode a web
shift can be carried out via the operating unit RE.. or via
the buttons "web shift/manual setting".

− Middle setting
If the "middle setting" key is pressed, the web run
controller is positioned to the middle setting stored.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

− Manual operation
In the manual operating mode the web
run controller can be adjusted to the left
hand side or right hand side via the
buttons "web shift/ manual setting".

For further information see the operating

instructions of the Erhardt & Leimer
company in the appendix.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.2 Insert a new web

3.2.1 Feeding in a new web

The following working steps apply both to the • Actuate the valve at the front (4). This
first take-over of a material roll and for a releases the expansion spindle. Pull out
change of material roll. the spindle (3) from the core of the empty
Working steps which must be only be carried material roll.
out for the first take-over or for changing are
specially marked.
• Push the spindle (3) into the core of a new
After the scanning of the roll has stopped the material roll (21)
main drive of the machine:

• Clamp (11) web at the exit side of the • Lower the unwinding arms (1) , turn switch
splicing table (7). (5) anticlockwise to the "down" position.

• Cut off the old web • Roll the new material roll (21) over the
location support of the unwinding arms (1)
.
• Open spindle coupling and roll safety
device (2) by pulling the lever back (20).
Take empty material roll (21) together with
spindle (3) out of the unwinding arms (1).

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

• Lift the unrolling arms (1), turn switch (5) • Put the material web onto the splicing
to the "raise" position. table (7) , align it according to the old web
Caution! and clamp it on the infeed side (10) .
The ball bearings of the spindle must
locate exactly in the location supports of • Cut both web ends simutaneously with a
the unwinding arms. sharp knife ( this cut is diagonal due to the
integrated guidance in the splicing table).

• Align material roll (21) in the transverse • Remove waste material and glue the web
direction ends together

• Expand spindle (3) with pneumatic tool • Loosen both clamping devices (8/9),
(...). Push the nozzle of the pneumatic tool (10/11).
hard into the valve (4) of the spindle (3) .
After expanding, the nozzle should be If there is not any web left in the machine
pulled away quickly from valve 4. take the following steps:

• Put web onto the splicing table (7) and

• Close spindle coupling and roll retainer (2) clamp it on the infeed side (10)
by pulling lever (20) forwards
• Begin to cut the the web diagonally ( this
• Let the spindle coupling (2) snap in by cut is diagonal due to the integrated
turning the material roll (21) slowly guidance in the splicing table).

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

• Remove the waste material and loosen

the clamping device (8) at the infeed side
(10)

• Thread the web in accordance with the

web run indicated (see web run ....).

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.2.2 Web run

Make sure that the web is threaded

according to the drawing shown above. This
is essential to ensure that the unit fulfills ist
function.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.3 Settings
The max. set pressure should not exceed
Web width 2,5 bar.
Dancer (12) should work with as little hunting
When feeding in a new web with a different as possible in the vertical ideal position or 0-
web width, the web run controller must be position. Each adjustment of the unwinding
changed to fit the new web width as follows: tension to the material to be printed also
requires an adjustment of the dancer
• by loosening the knurled screw at the pressure.
holder of the photo electric cell the holder It may be necessary to adjust the control
can be reset on a guiding rail (see also according to the operating conditions.
operating instruction web edge control of The control behaviour depends on the
the Erhardt & Leimer company in the following items:
appendix)
• size of roll (diameter)
• speed (acceleration)
Web tension • web tension setting
• material
The basic requirement for an exactly
registered web transport is a constant web The hunting behaviour of the dancer should
tension at the inlet of the machine. The web be checked, if necessary the gain factor has
tension between unrolling and feeder station to be changed. Too strong hunting of dancer
is produced by the the unwinding brake and (12) can be eliminated via "gain" (27) .
dancer (12) and set via the air pressure in
the pneumatic cylinder on the dancer arm
via pressure control valve (16) The air
pressure is read on gauge (17) .

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.4 Starting up
When a new web has been fed into the
After the first threading of a web the machine or connected with the unwound
components of station 01 must be switched web the operation of station 01 or each
on individually. component is started by pressing the starting
This must be executed as follows: button at the main operating panel of drive
• Set dancer pressure on pressure valve station BG 09.
(16) (setting value about 1.5 bar)
Caution!
The max. value of 2.5 bar should not be
exceeded.

• Set tumbler switch (22) to position "ON" .

Control lamp (24) must now light up.

• Set tumbler switch (23) to position "brake

closed". Control lamp (25) must now light
up. Should the dancer be situated at the
front or back end position the control light
will not light up. In this case the dancer
should be moved manually to the middle
position.

• Select the operation mode "automatic" on

the operating panel of web edge control
(18) ( see also operating instruction web
edge control of the Erhardt & Leimer
company).

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.5 Shutting down

If it is necessary to switch off the unrolling At the beginning or end of a shift it is not
station BG 01 then this can be done in two necessary to switch off the unit, but
ways: functioning tests of the protection devices
should be done.

⇒ by pressing the "OFF" button at the main

control cabinet of drive station BG 09,
this interrupts the total power supply of
the machine.

⇒ by pressing button (22) at the operating

panel of the web run control this switches
off the brake and the dancer controlled
web tension control.

With short stoppages, e.g. splicing of a new

web it is not necessary to switch the
unrolling station BG 01 off.
Should maintenance or cleaning jobs be
done on this station the "OFF" button at the
main control cabinet must be pressed and in
addition the main switch must be switched
off and secured against unoutherized
operation.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

3.6 Malfunctioning
Problem Cause Remedy

Dancer moves to the left • power failure check fuse, replace if

end position necessary

• loose contact on plug-in check plug-in connection on

connection sensor, at the magnetic brake
and on control unit

• there is no pneumatic check fine control valve,

pressure gauge and compressed air
hoses

Dancer is unstable or it • sensor is not trimmed increase amplification by

hunts with a large swing turning the trimming
potentiometer

web run control is not • power failure at the web check fuse, replace if
working run control necessary

web tears when starting • clamping device not open open clamping device on the
(error message on operat- splicing table
ting panel BG 09)

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

Problem Cause Remedy

web is completely pulled • photo electric cell for end put into proper position using
off the core of roll set wrongly the knureled screw

• photo electric cell faulty or check photelectric cell

contaminated replace if necessary

web roll is controlled • web run control set too set web run control more
backwards and forewards sensitively damped
via web run control

unwinding arms stay in • there is no pneumatic check switching valve and

lower end position pressure lifting cylinder, replace if
necessary

Material roll is not braked • power failure at the brake check fuse, replace if
necessary

• brake is open
• spindle is not expanded

• core internal diameter is

too big

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4. Care and maintenance

4.1 Care of the machine The cleaning methods mentioned above do

not harm the paint.
To maintain the quality and functioning of the
machine for a long time it is important to pay Under no cirmustances may cleaning
attention to the following notes for the care rags soaked in solvent, solvent pools or
of the machine: solvent splashes work on the paint over a
longer time period.
Daily care helps to discover possible wear , Avoid putting ink or solvent containers on
too low an oil level, dry sliding surfaces, top of the machine.
loose screws etc. And avoid greater
damage! After cleaning stainless steel parts (black
burnished parts) should these be sprayed
Painted areas should be treated carefully with a thin layer of anticorrosive, e.g.
and ink splashes should be wiped off with a Caramba.
cloth at once.
To dissolve printing ink for inks containing The cleaning of operating panels and
solvents, a light ink thinners is operating elements and all synthetic parts
recommended, e.g. ethyl alcohol, or if used must only be done with a cleaner for
carefully, paint restrainer e.g. synthetic materials, e.g.:
ethoxypropanol.
Lixtop from the company Dreusicke & Co.KG
For water soluble ink use abrasive-free, Rohdestraße 17,
12099 Berlin
soapy domestic cleaning fluids or ammonia Telephone 030/7525081
diluted with water. or
CS-180 from the company Chemaco GmbH
The machine is painted with a two-pot DD- Industriestraße 155
lacquer which is resistant to nomal wear and 50999 Köln
Telephone 02236/66015
tear.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4.2 Greasing points on the machine

4.2.1 Chain drive and gearwheel drive

• rear chain drive for dancer potentiometer

Note:
Open gearwheels and chain drives must
be checked every 200 operating hours for
greasing and if necessary greased with
Nigrin chain grease.

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4.2.2 Plain bearings, threaded

spindles and sliding guides

• carrier on the brake flange

• locking device of the unrolling shaft

Note:
Check these lubricating points daily for
sufficient lubricant film and if necessary
lubricate with gear oil (oil can greasing)

• Esso Saprtan EP 320

• Mobil Mobilgear 632
• Shell Omala Oil 320

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4.2.3 Roller bearings

The closed ball bearings are self-lubricating

(life-long greased)

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4.2.4 Compressed air lubrication

At the rear side of drive station BG 09 is a

maintenance unit which performs the air
lubrication of this unit (see also operation
instruction drive station BG 09).

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Unrolling station BG 01
EM 260/340/410/510 Diameter = 1250 mm

4.3 Tests to be done

Before initial operation of the unrolling unit
the following tests should be carried out:

• functioning test of the safety devices

• functioning test of the brake

• functioning test of the dancer

• "zero position" of dancer

• functioning test of the web tension control

• functioning test of web tension control

• functioning test of the pneumatic

expansion spindle

• functioning test of the splicing table

• functioning test of the roll safety device

and the spindle coupling

• functioning test of the unroller arms

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Unrolling station BG 01
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4.4 Fast wearing parts

Description arsoma code Qty.

tractive force key HMCS 605 - E ATV - Z 001 1
with accessories HMCS -KIT 3
(ATV-K 001)
driver shaft 094 01 054 1
chain wheel potentiometer 094 01 065 1
path roller 094 01 248 6
chain wheel - dancer 094 01 908 1
limit switch with tappet AIR - E001 1
limet switch AIR - E010 2
field 24V DC ATV - F002 1
O-Ring JUS - O002 1
F-plain bearing LAG - G004 4
F-plain bearing LAG - G011 2
F-plain bearing LAG - G026 2
F-plain bearing LAG - G039 2
inner ring LAG - I131 1

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Description arsoma code Qty.

thrust washer LAG - L154 2
thrust washer LAG - L155 4
thrust washer LAG - L156 2
needle sleeve LAG - N046 1
ball bearing LAG - R004 1
ball bearing LAG - R024 12
ball bearing LAG - R037 1
self-clamping ring bearing LAG - S012 1
roller chain MÄD - R001 1
push link MÄD - R011 1
light barrier TEL - L003 1
Einfüllpistole TID - E001 1
expansion hose ¾ x ½ “ TID - E 005 1

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