Automatic Splicer

MODEL SP-1

Version V4 8-2011

Operation and Maintenance

Manual

BUTLER AUTOMATIC INC BUTLER.AUTOMATIC.INC

Campanelli Business Park 7 Routes des Jeunes
41 Leona Drive CH-1227 Acacias Geneva
USA- Middleborough, MA 02340 Switzerland

Tel. (1) 508 923 0544 Tel. (41) 22 342 60 10

Fax (1) 508 923 0886 Fax (41) 22 342 70 21
Website : www.butlerautomatic.com
E-mail : [email protected]

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 NOTICE
Butler Automatic Incorporated supplies all data necessary for the proper instruction, operation, testing, and maintenance of its
products. Butler Automatic retains all proprietary rights in and to the information disclosed. This information shall not be
reproduced, copied, or used in whole or in part for purposes other than those for which it is furnished, without written
authorization from Butler Automatic Inc.
A copy of the Operators’ Manual is furnished with each Splicer. Additional copies can be purchased from the Customer
Service / Parts Department, Butler Automatic Inc., 41 Leona Drive, Middleborough MA 02346. (508) 923-0544

We suggest that you copy the information from your machine nameplate into the space above label.
DISCLAIMERS
Information in this document is subject to change without notice.
Butler Automatic Inc., reserves the right to make changes to machine features, specifications, components and/or control
systems, without notice.
These machines are constructed for maximum operator safety when used under standard operating conditions, for the

purpose intended, when recommended instructions are followed.

All personnel engaged in the use of the machine should become familiar with its operation as described in this manual.
PROPER OPERATION OF THE MACHINE PROMOTES SAFETY FOR THE OPERATOR AND ALL WORKERS IN
THE VICINITY.
Particular attention MUST be paid to the appropriate pages of this manual where WARNINGS and CAUTIONS are clearly
written for your protection. Becoming familiar with materials, machine inspection, speed limitations, guard maintenance and
total user responsibility, will assist you in learning potential areas in need of observation for danger.
In reading the guidelines for safety in the manual, it should be recognized that it is the responsibility of each individual to
observe the safety rules as outlined. ALL WARNING and CAUTION labels must be observed and obeyed. ALL ACTUAL or
POTENTIAL danger areas must be reported. Butler Automatic disclaims all liability for any damages, which may result from
disregard of safety and operator instructions detailed in this manual.
WARNING!
CARELESS OR INCORRECT
LOADING AND UNLOADING OPERATIONS
CAN CAUSE HAZARDOUS CONDITIONS,
WHICH MAY RESULT IN SERIOUS INJURY
TO PERSONS OR EQUIPMENT.

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Table Of Contents
NOTICE 2
DISCLAIMERS 2
WARNING! 2
TABLE OF CONTENTS 3
TECHNICAL CHARACTERISTICS SP1 SPLICER 6
MAXIMUM REGISTER MARK DISTANCE: CONSULT FACTORY 6

SPLICER OPERATION
NOTE! 8
WARNING AND CAUTION LABELS 8
OPERATING SAFETY 13
A. ROLL LOADING/ROLL REMOVAL 13
B. WEB-UP 13
C. SPLICE PREPARATION 13
D. MACHINE GUARDS 13
E. UPPER AND LOWER ROLL AREAS 13
F. ACCUMULATOR / DANCER AREA 13
G. SPLICE HEAD PROTECTIONS 13
H. LOCKOUT/TAGOUT SAFETY PRECAUTIONS 14
I. E-STOP 14
SIDELAY CONTROL TOUCHSWITCHES 32
“FAULT” INDICATOR FLASHING. STATUS – ALARM. 33
FAULT CONDITIONS 33
OPTIONAL CONTROLS. 34
INITIAL ROLL LOADING/WEBUP 38
PNEUMATIC ROLL DRIVE LIFTERS 38
WEBBING UP THE SPLICER 54
GO TO RUN 56
THE SPLICE CYCLE 56
OPERATIONAL DIFFERENCES 56
SPLICE MODE VARIATIONS 56
SPLICE ACTUATION 56
AUTO-SPLICE BY ROLL DIAMETER 57
TAPE APPLICATION 68
IN-REGISTER SPLICING 72
REGISTER SWITCH SETTINGS 72
SETUP 73
MEASURE DISTANCE 74
WEB PATH THROUGH SENSOR ASSEMBLY 79

SPLICER MAINTENANCE
AUTOMATIC SPLICE ACTUATION 82

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THE SPLICE CYCLE 83
OPERATIONAL DIFFERENCES 83
SPLICE MODE VARIATIONS 83
CORE DETECTOR SENSOR OPERATION 85
QC50 CORE DETECTOR SENSOR 87
FEATURES 87
OVERVIEW 88
SENSOR CONFIGURATION 89
OUTPUTS 89
SENSING MODES 89
RUN MODE 89
SENSOR PROGRAMMING 90
SENSOR PROGRAMMING CHART 90
REVIEW OF SETTINGS 90
NON-INITIALIZATION DISPLAY MESSAGES 91
END OF ROLL TAPE SENSOR OPTION 92
SETUP: 94
END OF ROLL TAPE SENSOR CALIBRATION 95
SIDELAY CONTROL 96
AUTO ALIGNER SIDELAY (SENSOR) 97
EXAMPLE OF ALIGNER OPERATION. 98
OTHER OPTIONS- ALERT INDICATORS 100
INTERFACE OPTIONS 101
NIP BAR REPLACEMENT 101
REPLACING THE CUT KNIFE 102
ATTENTION! 102
KNIFE BLADES ARE EXTREMELY SHARP. 102
TAKE PARTICULAR CARE NEAR THE KNIFE AND WEAR GLOVES OR PROTECTION . 102
INSTRUCTIONS FOR REPLACEMENT OF KNIFE HOLDER ASSEMBLY 103
KNIFE CYLINDER REPLACEMENT 106
REINSTALLATION 106
REPLACEMENT OF CUT KNIVES 107
REPLACING THE KNIFE PIVOT SPRING. 108
SPLICING HEAD PIVOT SECTION ALIGNMENT 109
REGISTER SENSOR INFORMATION 111
SENSOR GAP 112
SENSOR ANGLE 112
SENSOR PROGRAMMING 112
“TEACH” THE REGISTER MARK SENSOR. 113
STATUS 1, NORMAL, ON OR OFF. 115

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 STATUS 2, ALARM STATE. 115
WEB PATH THROUGH SENSOR ASSEMBLY 117
DRIVE SYSTEM SERVICE 120
ROLL DRIVE DIRECTION CHANGE. 120
ROLL DRIVE BELT REVERSAL. 120
ROLL DRIVE BELT REPLACEMENT. 120
ROLL DRIVE BEARING REPLACEMENT. 120
DRIVE MOTOR REMOVAL 120
DRIVE MODULE DISASSEMBLY 124
BELT REMOVAL 126
BEARING REPLACEMENT 129
CALIBRATIONS & TROUBLESHOOTING 131
W.I.F. & W.O.F. SENSORS 133
W.O.F. SENSOR. 1 SENS. 133
W.I.F. SENSOR. 10 SENS. 134
W.I.F. & W.O.F. SENSORS 135
DANCER SENSORS. 137
DANCER “ZONE” SENSORS. 2, 3 SENS. 138
DANCER “EMPTY” SENSOR. 7 SENS. 139
AUTO-SPLICE/IMMINENT SENSORS 140
SETTING THE AUTO-SPLICE DIAMETER. 142
SPLICE IMMINENT ALARM 142
ADJUSTABLE FORCE VACUUM 143
SYSTEM FAULTS 146
ADDITIONAL L.E.D. INFORMATION. 146
SYSTEM FAULT INDICATOR 146
“FAULT” INDICATOR FLASHING. STATUS – ALARM. 147
FAULT CONDITIONS 147
APPENDIX A- GENERIC SPLICER TERMS GLOSSARY 151

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SPLICER OPERATION
Technical Characteristics SP1 Splicer

Model shown is 18” 450 mm diameter capacity and 19” 475 mm width. Drawings are available for
each model.

AUTOMATIC SPLICER SP1

Specifications are Model Dependant Specifications on chart are for 25” 625 mm wide model

EMPTY WEIGHT (Varies with model width) :

18” Diameter -1100 lbs. 500 kg
24” Diameter – 1300 lbs. 590 KG
POWER SUPPLY : 220 VAC Single Phase – 60Hz – 2.50kW
AIR : AIR CLEAN AND DRY 70 – 110 PSI (6-8 bar) – (30Nl/mn maxi)

MAXIMUM SPEED : 120 -600 fpm depending on configuration

MATERIAL: Flexible films, paper ad laminates
MAXIMUM ROLL DIAMETER : 18” 450 mm / 24” 600 mm / 30” 750 mm
CORE DIAMETER : 2.75”, 3”, 5”, 6”
MAXIMUM ROLL WEIGHT: 275 lbs. or consult factory
MAXIMUM WEB WIDTH : 9.5“, 13“, 19“, 25“, 29“ 35“
MAXIMUM REGISTER MARK DISTANCE: Consult Factory

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HEALTH AND SECURITY INSTRUCTIONS
This splicer has been made to maximize operator safety provided the machine is used under
the specified operating conditions and the recommended instructions in this manual are
followed.

Any operators using this machine must familiarize themselves with the operating procedures
and set forth in this manual. Correct operation of the machine will help insure the safety of
the operator and those near the machine.

Special attention must be paid to those pages in this manual which describe warnings and
precautions necessary for your protection.

It is the operators’ responsibility to familiarize themselves with all aspects of this manual to
properly utilize the equipment and to gain better understand the areas of the machine which
demand particular attention to insure operator safety.

It is each operator’s responsibility to read and follow all safety and operational indications
contained in this manual. The zones of real and potential danger are indicated in this
manual. Butler Automatic refuses all responsibility for damages caused by operator
inattention or misuse of the equipment excepting indications contained in this manual.

ATTENTION
GENERAL SAFETY INSTRUCTIONS

To avoid accidents or damage to the equipment :

• Be vigilant and use common sense.
• Familiarize yourself with the safety and operating instructions contained in this
manual. Learn the zones of the equipment which require extra precautions for
security.
• All personnel using the equipment must be properly trained and follow the operating
procedures contained in this manual which help guard safety of the operator and
those around the equipment. All personnel engaged in the use of the splicer must
learn its operation prior to attempting any splicing. PROPER OPERATION
PROMOTES SAFETY FOR THE OPERATOR AND ALL WORKERS IN THE
VICINITY.
• For your own protection, pay particular attention to all WARNING and CAUTION
LABELS, on the machine, and those noted in this manual.
• For your safety pay particular attention to all safety related items in this manual
• Take care near moving equipment. Never touch a moving web or part of the
machine.
• Never leave tools or objects on a running machine, as they may fall and cause
damage.
• Never make machine adjustments while the equipment is in use.
• Use caution around the machine when it is in operation. Do not place your hands
close to moving rollers. Use some other means to clear the machine.
• Do not make any adjustments or repairs to the equipment, unless you are qualified to
do so.

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 • Do not make any modifications to the equipment, or attempt to defeat any safety
features.
• Do not remove any guards, machine covers, or other parts of the splicer.
• Keep machine doors closed and secured at all times.
• Report any accidents to your supervisor immediately.
• Report any missing guards or machine damage to your supervisor immediately.

NOTE!
In some of the illustrations in this manual, the machine guards may have been removed. This
has been done purely for illustrative purposes only and should not be done under any
condition for normal machine operation.

WARNING AND CAUTION LABELS

As with any machinery within an industrial environment, certain precautions must be
observed and performed to avoid personal injury or damage to the machine! Some of the
Figures within this manual may show or illustrate components without the machine guards in
place or the warning and caution labels affixed. This has been done for illustrative purposes
only!
DO NOT ALLOW THE SPLICER TO BE OPERATED WITH ANY OF THE GUARDS
REMOVED OR ANY LIMIT SWITCHES BYPASSED OR INOPERATIVE!
FOLLOW THE INSTRUCTIONS ON THE WARNING AND CAUTION LABELS AT ALL
TIMES!
IF ANY LABELS OR GUARDS ARE MISSING FROM THE MACHINE, DO NOT OPERATE
THE SPLICER! CONTACT BUTLER AUTOMATIC INC. FOR REPLACEMENT PARTS.
In the following section, there are reproductions of the graphic sections of the Safety,
Warning, Caution and Danger Labels that may appear on the Butler Splicers. The purpose of
the label will be explained, following the illustration.
IN ADDITION, THERE ARE PHOTOGRAPHS OF TWO LOCK-OUT/TAG-OUT POINTS ON
THE SPLICER.

P071898
Caution, Mechanical Hazard.
Pinch Point/Crush Hazard
Keep hands and fingers clear of this area. The machinery parts, in this area, could cause an
injury by compression of hands or fingers.

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P071900
Danger, Mechanical Hazard.
Cut Hazard.
Keep hands and fingers clear of this area while operating the machinery. The machinery
parts, in this area, could cause an injury by cutting hands or fingers.
Lock out power and compressed air sources before servicing the machine.

P071902
Warning, Mechanical Hazard.
Entanglement Hazard (Belt Drive).
Moving parts can crush and cut.
Keep guards in place.
Lock out power and compressed air sources before servicing the machine.

P071903
Caution, Burn Hazard
Hot Surface.
Some Splicers may he equipped with Heat-Seal Splicing Heads. These Splicing Heads
contain parts that may reach temperatures that could cause a burn.
Allow these parts to cool before servicing.

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P071905
Energy Hazard(s)
Notice. Lock Out in the De-Energized State.
This equipment is supplied with an electrical disconnect that may be locked (Locked Out)
with the power kept in the OFF (De-Energized) state.
Always shut off and lock out the electrical power before servicing the machinery.

MAIN POWER SWITCH.

This switch controls the incoming power to the splicer.

Electrical System Locked Out

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This equipment is supplied with a pneumatic disconnect that may be locked (Locked Out)
with the compressed air kept in the OFF (De-Energized) state.
Always shut off and lock out the pneumatic supply before servicing the machinery.

Pneumatic System Locked Out

P071897
Electrical Hazard.
Danger. Electrical Shock Hazard.
This equipment is supplied with High-Voltage Electricity. Contact with electrical components
will cause electrical shock or burn.
Turn off and lock out power before servicing.

B050432-001

– THIS UNIT HAS MORE

THAN ONE POWER
SOURCE.

– TO AVOID ELECTRIC
SHOCK, DISCONNECT ALL
SOURCES BEFORE
SERVICING.

B050433-001 English
B050433-002 French
B050333-003 German
Electrical Hazard.
Danger. Electrical Shock Hazard.
This equipment is supplied with Electrical Power from more than one source. (Example:
Process Machine power for Emergency Stop Circuit).

Contact with electrical components will cause electrical shock or burn.

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Turn off and lock out ALL POWER before servicing
P071906
General Hazard.
Warning. No access for unauthorized persons.
Avoid injury.
This unit is to be serviced by trained personnel only.

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OPERATING SAFETY
A good machine operator is always conscious of safety. Long hair should be bound up,
jewelry and watches should be removed, and loose clothing should be secured.
The following areas of potential hazard should be noted:

A. ROLL LOADING/ROLL REMOVAL

MAKE SURE the roll is fully supported by the Roll shaft.

DO NOT stand under a suspended load at any time. Take special care when opening and
closing shafts to follow operator instructions contained in this manual and pay attention of
devices when loading and unloading rolls. (Zone 1)

B. WEB-UP

DO NOT touch any roller until you are sure that it has stopped rotating. Rollers may appear
to be stationary while they are still rotating. Touching a moving roller can cause injury to
hand or arm.

C. SPLICE PREPARATION

DO NOT touch the Running Roll Lead-in Roller(s) until you are sure they have stopped
rotating. Touching a moving roller can cause injury to hand or arm. Stay away from moving
SPLICING HEAD PARTS. Wait for completion of cycle before attempting SPLICE
PREPARATION. DO NOT attempt any correction to a Prepared Splice while a splicing cycle
is under way. (Zone 2) Splice head knives are protected by guards, but operators should use
caution when in their proximity. When cutting the web for splice preparation take all
precautions to avoid cutting yourself. Use gloves or follow your plants standard safety
procedures.

D. MACHINE GUARDS

Never remove the machine guarding and interlocking protections. Be aware of all guards and
the dangers they are guarding. Report any missing or damaged guards.

E. UPPER AND LOWER ROLL AREAS

The design and configuration of the roll drive system minimizes any risk to the operator. It is
the operators responsibility to keep clear of the roll drive. (Zone 1)

F. ACCUMULATOR / DANCER AREA

The dancer is a gravity powered system which is designed to minimize any operator risk.
The operator should be prudent an use common sense to avoid any moving parts in this
area of the machine. (Zone 3)

G. SPLICE HEAD PROTECTIONS

The splice head is composed of an upper and lower half. Only the half of the head which
corresponds with the web which is not unwinding should be opened during run for splice
preparation. For proper splicing, the two halves of the splice head must remain closed after

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the splice has been prepared. Opening the head during the splice cycle will interrupt and
stop the action of the nip and or cut knife. The mechanical design of the splice head nip
action causes the head to stay locked closed while the nips are actuated and the knife can
be energized. The tip of the knife is rounded to minimize cut risk from direct contact.

H. LOCKOUT/TAGOUT SAFETY PRECAUTIONS

Both the Electrical System and the Pneumatic System have been provided with lockable
disconnects. (See Page 5, 7-9, for examples).
These disconnects must be secured with whatever devices and tags your company provides.
The electrical disconnect interrupts the High Voltage Supply to the Splicer.
The pneumatic valve not only interrupts the compressed air supply to the Splicer, it also
vents air pressure from within the splicer to atmosphere.

I. E-STOP

The Splicer E-Stop button must be joined to the process E-Stop circuit allowing the splicer
and production line to be rapidly stopped in case of danger. To restart the machine the E-
Stop switch must be mechanically deactivated by turning it, then the reset button must be
pressed.

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SECURITY DURING MAINTENANCE
It is the responsibility of maintenance personnel, as with machine operators, to familiarize
themselves with all aspects of machine operation. Maintenance personnel must follow the
instructions found in the section OPERATING SAFETY. All personnel concerned with
maintenance of this equipment must pay particular attention to the following:

A. General

• Never lubricate or clean a machine which is in operation.

• Never make adjustment to the machine under power or in operation.
• Always use appropriate lock out procedures as prescribed by your company for
machinery. A machine that is not locked out must be considered dangerous and may
start as part of the process machine to which it is connected.
• Only trained, qualified and authorized personnel should perform work of any kind on
this machine.
• Replace defective parts with Butler standard parts only.
• Never replace fuses with fuses of a higher rating.

B. Electrical Danger

Certain elements of the splicer are always under power and dangerous. Cut the electric
circuit before starting work on the splicer. The main interrupter is lockable and must be
locked out to make certain that the machine stays safe during maintenance, and avoid power
being restored to the machine during repair or maintenance. Lockout tag out is provided on
the exterior of the electrical control enclosure as well as on the disconnect mounted inside
the enclosure.

C. Security during work on the pneumatic system

Extreme attention must be given to any work performed on tubing and the pneumatic system
of the splicer. Air must be removed and locked out before any service is performed on the
pneumatic system. If a tube detaches, compressed air or particles many cause injury.

D. Dancer zone

Never work in the dancer zone when it is moving or under tension. The dancer should be
blocked in position by unwinding web to fill the dancer and removing any tension from the
web. If work must be performed with the dancer raised, the dancer must be blocked in
position. Never rely on the web to hold the dancer in position.

E. Splice head zone

The cut knives are very sharp. Use extreme care when working with or around the knife
assembly. The knives may be accessible during a maintenance intervention on the splicing
head. Place a shield around the knives or remove the knife assembly before starting work in
the splice head. Be careful to follow plant safety rules and use protective gloves if required.

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INTRODUCTION
The automatic splicer from Butler is a machine which permits rolls of materials to be
unwound into a production line and automatically spliced to eliminate process stops and
associated waste from roll change over. The splicer automatically controls unwinding
process tension and joins in a new roll assuring a continuous flow of paper into the
production process.

The Butler SP-1 splicer is known as a « zero speed splicer” due to the fact that the splice is
performed with the new web stopped and the process fed from the integral accumulator.

This manual and instructions presents the technical characteristics and proper usage,
control, installation and maintenance of the Butler Series SP-1 splicer.

This splicer is designed for Low Tension operation. With the In-Register Option, splices can
be made to precisely keep the printed image alignment through roll change over.
Standard SP1 Splicers are manufactured to accept one of three different roll diameters. 18”
[450 mm], or 24” [600 mm]. 30” (750 mm). Standard web widths are 9.5” [235mm], 19” [475
mm], 25” [625 mm], 29” [725 mm] or 35” [875 mm].

This machine has an integral Drive System, which is used to drive the rolls of material, for
unwinding and control of the web feed at low tension. The Splicing Head allows for One-Step
Splice Preparation. The Splice Joint is prepared on the same Vacuum Nip Bar that is used to
seal the webs together at Splice Time.

OVERVIEW OF THE SPLICER (A)

This figure shows the Operator Side of the Splicer and the Splicing Head.
This is a Left-Hand Splicer. Viewed from the Operator Side, the Web exits to the viewers’
left. SP1 Splicers are available in Left-Hand or Right-Hand configurations, as needed.

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DESCRIPTION

17
General Elements
The SP-1 splicer is composed of three primary elements:

1) The roll unwind

2) The splice head
3) The festoon / Accumulator

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MACHINE OVERVIEW
The following section shows web up and the general sequence of function of the SP-1
automatic splicer system.

WEB UP

WEB UP COUNTER CLOCKWISE ROLL ROTATION

The splicer can be configured for either clockwise or counter clockwise unwind to accommodate
rewind orientation or operation with a turn bar. See maintenance section for information on
direction conversion.

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WEB UP

WEB UP CLOCKWISE ROLL ROTATION

Web introduction and passage. The passage as shown in either the CW or CCW web up
diagram must be followed for proper function of the splicer. The web is first passed through
the splice head and then pass the turn roller and into the accumulator. The passage of the
web through the accumulator is done by passing the web in an “S” around the rollers in the
fixed upper position and the moveable dancer rollers. This passage creates the festooning
which is the storage needed as a buffer to feed the process while the splice is completed.

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Refilling the accumulator. The roll is driven by the roll drive modules to unwind and refill
the accumulator. The dancer rolls descend and create the garlands of the accumulator as
web is fed, which is the accumulated reserve to create a buffer for automatic splicing. Upon
start up the roll will unwind faster than the process to fill the accumulator.

Running Position. Until the dancer rollers reach the equilibrium position, the accumulator is
refilled to bring these rollers to their normal run position fully filled. When the dancer reaches
its full running position, the unwind velocity is controlled to match the unwind speed with the
process speed and hold the dancer steady.

Roll Loading. The empty core position is used to load the new roll which will be prepared for
the next splice.

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Splice Preparation. The new roll is placed into position on the open shaft position. The
operator places the end new web onto the vacuum preparation bar and applies adhesive.
(See Splice Preparation)

22
Splice Cycle. When the running roll reaches a preset diameter, the control automatically
actuates the splice cycle. (The splice is also equipped with a manual splice button) The
expired roll is slowed to a stop. The web is pressed onto the leading edge of the prepared
new roll which is held on the vacuum preparation bar. The old web is severed off. During this
change the process is fed from the reserve in the accumulator. The new roll then unwinds to
refill the accumulator and the splicer is ready for a new roll of material to be loaded.

The new roll unwinds into the machine. The splicer is ready for a new roll of material and
a new splice preparation for the next automatic roll change. No production loss. Automatic
roll splicing increases process productivity, while reducing waste and down time.

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OPERATION OF SPLICER

Operator Controls

The operator control panel must be used for operation of the splicer, including splice
preparation and running the machine. For ease of use, the control panel is located next to
the splice head.

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 Upper Roll Select

Register Splice
Vacuum

Manual Splice

Fault Indicator Lower Roll Select

Sidelay

Reset

E-Stop

Optional Auto-
align

Splice Actuation
Select

Knife
Release

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MAIN POWER SWITCH.
This switch controls the incoming power to the splicer.

Main Switch Lockout.

The switch may be locked in the off position, while the splicer is being serviced or an
operator is entering unsafe zones in the machine. We recommend that operators consult
with their plant safety personnel and rules to ensure they use this feature in accordance with
plant safety regulations.

26
EMERGENCY STOP BUTTON.
The RED, Emergency Stop pushbutton is the Splicer Stop Button. It MAY also be used to
stop the Process Line. (This function requires additional wiring on the part of the
customer).
To stop your splicer, push the button IN.
The button assembly is a locking (detent) arrangement. Once the button has been pushed in,
it will remain locked in.
Before re-starting the machine, rotate the button clockwise, to allow it to spring OUT, and
restore normal operations.
After releasing the Emergency Stop Button, push the RESET Button.

RESET BUTTON.
This GREEN Push-button is used to start or restart the splicer.
If power to the splicer is interrupted or, if the Emergency Stop Pushbutton is used, the
RESET Button must be pushed IN, to return to the operational state.

27
Operator Touch Panel

NEVER USE A HARD OR SHARP OBJECT ON THE PANEL.

USE YOUR FINGERS ONLY, FOR SWITCH OPERATION.

Upper and Lower Roll Select Touch Switches

This button allows the operator to select the running roll. This is used when the machine is
being started up and is only activated when the machine is not pulling web.

Upper/Lower Roll Graphic

Use this Touch Switch, to select the Upper/lower Roll as the Running Roll.

28
When ON, the GREEN L.E.D. Indicator at the Upper Left corner, confirms that the Upper Roll
has been selected as the running Roll,
A similar Touch Switch is used to select the Lower Roll.

Splicing Head Graphic

The Splicing Head Graphic contains four L.E.D. Indicators and three Touch Switches.

Manual Splice
The manual splice button allows the operator to actuate a splice manually by pressing the
splice button. The indicator “Splice Ready” must be illuminated for the machine to be ready
for splice. Preparation of a splice will automatically leave the machine in the ready state for
splice. If the splice is not prepared, at splice time the splice ready light will flash as a warning
indicator.

Manual Splice Graphic

When the Green L.E.D. at the Upper Left Corner, is ON, the SP-1 Splicer is ready to accept
a Splice Command, either from the Automatic Splice Diameter Sensing System, or from this
Manual Splice Touch Switch.
In order for the “Splice Ready” L.E.D. to come on;
1). The Vacuum must be ON.
2). The Splicing Head must have been opened since the last splice.
3). Both sections of the Splicing Head must be closed.

« Splice Ready » Indicator

The light on the manual splice button illuminates to indicate that the splicer is ready to
perform a manual or automatic splice. This light will flash warning if the splicer has reached
splice imminent diameter and the machine has not been made ready for splice, or another
fault is present.

29
If the roll runs down to the Auto-Splice Diameter, and the Splicer is not “Ready”, the Splicer
OK Signal to the Press/Process Line will be dropped and the Line should stop.

It should be noted that register splice requires web to be fed into the process. If the machine
is stopped, pressing manual splice with register turned will not actuate a register splice. At
stop, the accumulator is at the bottom, so feeding web is not possible. Thus after pressing
the splice button, the system will time out after 5 seconds and a non register splice will be
made.

Vacuum
The vacuum select button on the splice head allows the operator to manually turn on and off
the vacuum supplied to the non running side of the splice head on the vacuum preparation
bars. The vacuum will automatically turn on to the prep bars when the splice head is opened.
When the splice head is closed and the splice ready indicator is illuminated, the splice head
must be opened to turn off the vacuum manually. This is done to avoid an inadvertent loss of
vacuum and the resulting missed splice.

Vacuum Graphic
Vacuum, for holding the web in the Splicing Head is supplied by an integral venturi or
optional vacuum pump system.
During Splice Preparation, the Vacuum System will normally be turned ON, automatically,
when one of the Splicing Head sections is opened, after a splice.
After a splice has been completed, the Vacuum System will be turned off automatically.
The Green L.E.D. Indicator at the Upper Left Corner will be ON or OFF, to show the state of
the Vacuum System.
The Vacuum Touch Switch may be used to manually control the Vacuum System.
At the end of the Splice Cycle, the Vacuum is automatically turned off, when it is no longer
needed.
THE VACUUM SYSTEM CANNOT BE TURNED OFF MANUALLY, IF BOTH SECTIONS OF
THE SPLICING HEAD ARE CLOSED.
To turn the Vacuum System off, manually, you must open one section of the Splicing Head
and press the vacuum button again.
If you wish to turn the vacuum ON or OFF Manually, press the Vacuum button when one
section of the splice head is open. If the vacuum has been turned of manually, the vacuum
will not turn on automatically when the head is opened until after the next splice has been
made. In this case vacuum will need to be turned on when needed by pressing the selector
switch.

30
Venturi valve (2 of 4)
There are two Venturi Valves mounted within each section of the Splicing Head. One valve is
attached to each Vacuum Nip Bar, and one valve is attached to each Vacuum Splice
Preparation Bar.
When Vacuum is activated, the Vacuum Solenoid Valve is energized and air pressure is
supplied to the appropriate venturi in the splice head to provide vacuum for the splice
preparation.

VACUUM Select SOLENOID valve

The solenoid valve automatically directs the vacuum to the correct section of the Splicing
Head (Upper or Lower) depending on which position is selected as the Running Roll.
If the Upper Roll is the Running Roll, the Vacuum will be directed to the LOWER section of
the Splicing Head, etc.
When compressed air applied a Vacuum Venturi Valve, it creates suction at the port that is
connected to a Nip Bar or Splice Preparation Bar. This suction is sufficient to hold the web in
the Splicing Head.
TO INCREASE THE HOLDING POWER ON THE WEB, THE FLOW CONTROLS
SHOW ABOVE CAN BE OPENED AND ANY UNUSED VACUUM HOLES MAY BE
COVERED BY TAPE.

31
When taping the unused holes on the Nip Bar Rubber, apply only one thickness of a light
tape, such as Electrical Tape.
Masking Tape should never be used.
Replace the tape as needed. Do not apply multiple strips. Excess tape buildup, will reduce
the sealing strength applied to the Splice Joint by causing uneven nip pressure.

Register Splice
This button allows the operator to select the splice in register feature. The splice joint is then
made a preset distance back from the register mark on the print impression. This allows the
operator to set up the new web in the correct place to keep the image in close registration
during splice.

Register Splice Graphic

Use this Touch Switch to select the Register Splice Function of the SP1 Splicer.
When the Green L.E.D. Indicator, at the Upper Left Corner, is ON, Register Splicing has
been selected.
When this L.E.D. is OFF, Splices will be made without regard to the Registration Marks on
the web.
The YELLOW L.E.D. Indicator, at the Lower Right corner, should FLASH, each time a Web
Registration Mark is detected by the Registration Mark Sensor.

SIDELAY CONTROL TOUCHSWITCHES

Sidelay Select Graphic

Each of the triangles in the Sidelay Graphic covers a Touch Switch. Use these switches to
move the SP1 Splicer, across the unit centerline, to align the running web.
Travel of the splicer is limited to approximately 1 Inch [25 mm] on either side of the
centerline.
If you attempt to go beyond the range of movement, a slip-clutch within the Sidelay Linear
Actuator should prevent damage to the machine.
Push on the arrow with the point that is facing in the direction that you want the web to move.

32
SYSTEM FAULT L.E.D.
This L.E.D. is located in the lower left side of the operator panel just above the Butler Logo.
This light signals a system fault with a red flashing light.

SYSTEM FAULT (STATUS) L.E.D.

The RED L.E.D., located above and to the left of the Butler Logo provides Information about
the status of the splicer. IF THE “FAULT” INDICATOR IS OFF, THE MACHINE STATUS IS
NORMAL.

“FAULT” Indicator FLASHING.

STATUS – ALARM.
The System Fault Indicator will be flashing ON/OFF at ½ Second Intervals, when an
abnormal condition has been detected.
At the same time, the indicator starts flashing, the “Splicer is OK.” Signal, to the
Press/Process Line, will drop out.
When the OK. Signal drops out, the line should stop.
FAULT CONDITIONS
A Fault is reported when:
a). There is an alarm signal from the Roll Drive Motor Controller to the P.L.C.
WHAT TO DO: CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE.
b). A Web Break has been detected. If the web breaks, the Dancer will drop to the
bottom and the Dancer “B” Sensor will send a signal to the P.L.C.
WHAT TO DO: RE-WEB THE SPLICER AND START AGAIN.
c). The Dancer is near the top of its’ travel. The “Dancer Empty” Sensor will send a
signal to the P.L.C.
If the roll cannot turn easily, the web cannot unwind properly. The Dancer will be pulled up
and the “Dancer Empty” Sensor will switch states.
WHAT TO DO: CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE.

Reset
The reset button permits the operator to reset the splicer for start up after an E-Stop, opening
the interlocked electrical enclosure door, or a loss of power.

E-Stop

33
The E-Stop button allows the operator to stop the machine in case of an emergency or
urgent need to stop the process. To reset the E-Stop, you will need to pull out and turn the
button, then press the reset button.

Knife Release Pushbutton

This pushbutton is used to retract a jammed knife into its home position so that it is ready for
operation or maintenance. If the knife becomes dull, it can become jammed in the middle of
its stroke. This pushbutton is used to retract the knife. The head should never be forced
open.

OPTIONAL CONTROLS.

Core Splice
This option uses a sensor on the roll drive to sense the color of the core. When the core is
sensed, the splice is actuated and the web is backed up to the last register mark for an in
register splice. The control switch can be toggled to either use standard diameter splice (OD-
Outside Diameter) or core detect splice. This option is only capable of a maximum web
speed of 170 fpm.

34
 Splice- Core/OD

End Tape Sense

This option uses a sensor mounted after the splice head to detect a band of tape applied to
the unwinding roll by the film/web manufacturer. The splicer activates the end of roll tape
sense when the splice imminent diameter has been reached and then automatically activates
the splice when the tape marker passes under the sensor. The control switch can be toggled
to either use standard diameter splice (OD- Outside Diameter) or end of roll tape sense
splice (end).

Splice- END/OD

35
Auto Align
This option uses a sensor on the machine output to automatically shift the machine laterally
to keep the web tracking in the same position. A sensor is mounted on an adjustment handle
as near to the splicer as practical. When the web moves out of alignment in the sensor, the
splicer will shift in increments back into position. The sensor is a dead band sensor and it is
capable of keeping web aligned within ±1/16”. This option must be set up by a qualified
technician, as proper function requires both pulse length and path delay to calibrated and
entered. The control switch is an illuminated button (Illuminated is on). Flashing light
indicates that alignment was not reached in the anticipated number of alignment pulses.
Reset requires that the option is turned off. The web is verified for proper alignment
manually, and the option is turned on again.

Auto Align

Remote Operator Panel/Sidelay

The remote operator panel moves the splicer control to a remote panel which can be located
on another piece of equipment. The machine is configured to be able to accept 24 VDC input
signals to actuate the machine sidelay from a remote location.

SPLICER STATES

Ready: Shows that the splicer is ready for run and all systems are operating normally.

Fault: Shows that the machine is in a fault state.

ALARM / FAULT STATES:

Drive Not Ready: Shows that the motor drive has a fault which must be corrected. Press
Reset to clear. If it does not immediately clear, press E-Stop wait 20 seconds and then
remove E-Stop and press reset.

Dancer Empty: Signals that the accumulator is empty and has reached its top stop. To clear
you need to raise the roll drive from the running roll and let enough paper unwind so that the
dancer drops below the top of travel sensor. The lower the roll drive and press reset. The
splicer will refill and be ready to run.

Web Break : The web has broken, causing the dancer to drop to the bottom stops. Web up
the machine and press reset to put the splicer back into the ready state.

36
E-STOP: The E-Stop button has been pressed triggering the E-Stop of the machine.
Disengage the E-Stop switch and press reset. The splicer is then back in the ready state.

Register Mark Fault : This fault shows that the splicer is not properly reading the register
marks on the film when register splice has been selected. The splice ready light on the
operator touch panel will now flash until the fault is corrected. If the fault is not corrected at
autosplice diameter, the splicer will make a time out splice which will not be in register. The
fault must be manually corrected (verify eye is correctly positioned, printed register marks
are OK, eye is clean, or reset register eye) and then the splicer will automatically clear the
fault.

Splice not ready: This signals that the splice head is open or has not been opened at all
and that the preset splice diameter has been reached. The splicer ready signal is removed
causing the process to stop. The splice must now be prepared in the splice head and reset
must be pressed. When the process is restarted an automatic splice will be made.

37
ROLL LOADING
The SP-1 splicer is equipped with integral swing out shafts. The shafts are latched into position
for running, and then when released swing out through the frame for easy loading from the front
or side of the machine. Your splicer may be equipped with the optional LIFT AND LOAD™
System for the Upper Roll shaft, to allow the operator to lower the upper roll for loading nearer to
the ground.

DURING ROLL LOADING, BOTH ROLLS MUST BE INSTALLED SO THAT

THEY UNWIND IN THE SAME DIRECTION.

INITIAL ROLL LOADING/WEBUP

SAFETY FIRST!
THE ROLLS OF MATERIAL ARE HEAVY.
USE SAFE LIFTING PROCEDURES AND EQUIPMENT TO
AVOID BACK INJURIES.
GET HELP IF NECESSARY.

Position a new roll near the splicer.

Any core plugs should be removed, at this time. Any outer wrappers may be slit, and left on
the floor to protect the roll from damage.
If the roll position is not clear, remove the old roll.
For the roll to be removed, raise the Roll Drive Module.

Pneumatic Roll Drive Lifters

The Splicer is equipped with pneumatic cylinders that are used to lift the Roll Drive Modules.
The pneumatic lift feature is standard on SP1 Splicers

Upper Drive Lift Cylinder

The figure shows the Upper Drive Module Cylinder in the extended condition. The Upper
Drive Module has been lifted off the Upper Roll and it will stay in the lifted position as long as
air pressure is applied to the bottom of the air cylinder. Each Lift Cylinder is controlled by its’
own manual, lever action valve, mounted on the Splicer side frame beside the splice head.

38
 Roll Drive Lift
Switches

Roll Drive Lift Switches

Drive Lift Switch/Valve (raise Module)

Move the lever UP, to raise the Roll Drive Module. (With optional roll drive auto-engage,
this function is controlled with switches on the control enclosure. See option)

Drive Lift Switch/Valve (lower Module)

Move the lever DOWN, to lower the Roll Drive Module. The roll drive will slowly descend to
the roll when the switch is down as air is released through the drive flow control. (With
optional roll drive auto-engage, this function is controlled with switches on the control
enclosure. See option)

39
 CAUTION!
DO NOT ATTEMPT TO MOVE THE ROLLSHAFT UNLESS THE ROLL
DRIVE MODULE IS UP.
YOU COULD BE INJURED IF THE SHAFT WERE TO SWING OUT,
UNEXPECTEDLY.

Roll Shaft Latch

To open the shaft position, the latch must be manually released. Grasp the end of the shaft
and pull the shaft towards you. Let the latch will drop back down.

ROLLSHAFT CLEAR

Swing the Roll shaft out, to a convenient loading position.

Remove the clamp from the free end of the shaft.
Remove the Core Adapter from the free end of the shaft.
Pull the core off the Roll shaft.
It is very important to position the roll on the shaft correctly, so that the web position is the
same from both unwind positions. Once the roll and shaft are in the splicer, the webs must
be precisely aligned to each other during splice preparation.
The entire splicer may be moved to align the running web to the Process Line.
It is difficult to adjust a roll on a shaft when it is in the splicer. We include index marks on the
roll shafts which should be used to have precise positioning alignment between the running
roll and new roll.

40
These indexes are placed with Zero, on the Splicer Centerline and Index measurements
going out from the center. There is an allowance included for the Roll Clamps and the
flanges of the Roll Adapters.
For example, if you install a roll and adjust the Roll shaft clamps so that the outside edge of
each clamp lines up with the same number, the web will be in the center of the splicer when
you place it on the Splicing Head Preparation Bar.

CLAMPS & INDEX MARKS

In the above example, each clamp is set at the 23.1 Index Mark.

Roll shaft Indexes

The roll is held in position by two clamp collars. These clamp collars uses an integral ratchet
handle to tighten.

Clamps and adapters

41
Removable roll clamps
The rolls of material are secured with two clamps.
The clamp closest to the Roll shaft pivot remains in place.
The outside clamp is loosened by rotation the lever counter-clockwise. Pulling the lever away
from the clamp and moving it to a new spot allows you to reposition the lever. The two
clamps are used to hold the running roll and core adapters in place.

CORE ADAPTERS (Typical)

Install one of the appropriate adapters on the shaft and slide it up against the Inside clamp.

Core adapter
Remove the core adapter(s) from the core and be sure to insert them into the new roll. This
part ensures proper performance of the splicer. Failure to use this part will lead to autosplice
diameter faults and cause excess wear on the support shaft. The core adapter allows easy
change between core sizes.

42
Pivot shaft out for unloading

Remove outer clamp collar

Remove butt roll and take out core adapters for reuse

43
Put inner core adapter on shaft and load new roll

Add outer core adapter into roll core

Install outer clamp

With the new roll loaded onto the shaft, install the “Outside” Roll Clamp on the Roll shaft.

44
LIFT AND LOAD™ SYSTEM

The LIFT AND LOAD™ System allows the operator to position the Upper Roll shaft at a
reduced height, to improve the ergonomics of upper shaft loading.
The LIFT AND LOAD™ System attaches the Upper Roll shaft to a pneumatic cylinder. When
the Upper Roll shaft is clear of the Splicing Head, the cylinder allows the Upper Roll shaft to
be lowered to a convenient height.

Approximate Heights from floor.

18” Diameter Roll = 38”.
[457.2 mm Roll = 965.2 mm].
24” Diameter Roll = 42 ½”.
[609.6 mm Roll = 1079.5 mm].

LIFT AND LOAD™ ASSEMBLY

The LIFT AND LOAD™ System is mounted on the outside of the splicer frame.
The top of the lift cylinder is attached to the Roll shaft Pivot and it travels within a guide track.
This system allows the upper roll to be brought down for easiest loading and roll positioning.

45
 Lift and Load Control
Switch/Valve

LIFT AND LOAD™ control valve (A)

A valve, similar to the one shown above, is used to control the LIFT AND LOAD™ cylinder.

THE LIFT AND LOAD™ CONTROL VALVE MUST BE KEPT IN THE UP

POSITION, EXCEPT WHEN CHANGING ROLLS AND THE SHAFT MUST
BE LOWERED.
IF THE CYLINDER IS NOT KEPT FULLY EXTENDED, THE ROLLSHAFT
WILL NOT BE LEVEL, WHILE THE ROLL IS UNWINDING.

To load a new roll, swing the Roll shaft out, and move the valve handle down.
There are two “Stops” installed, as part of the system.
1. A Hexagon-Head bolt is inserted into the bottom of the Roll shaft.
2. A Roll pin is inserted into the Roll shaft Collar.

46
Roll shaft Stop (A)
If the cylinder IS NOT fully extended (with air pressure applied) the stop will not clear the
side frame of the splicer, when you try to swing the Roll shaft out. These features prevent an
operator from improper use of this system which could lead to an unsafe condition.

Roll shaft Stop (B)

If the cylinder IS fully extended (with air pressure applied) the shaft stop will clear the side
frame of the splicer, when you try to swing the Roll shaft out.

Swing Stop
With the control switch in the up position, swing the Roll shaft out, gently, to the swing stop.
This stop is adjustable for best loading position. The control switch can then be lowered to
lower the upper shaft into load position.

47
LIFT AND LOAD™ CONTROL VALVE (B)
Move the valve handle, down, to lower the Roll shaft to loading height.

Roll shaft up (A)

48
Roll shaft down

Install the new roll on the shaft. Slide the new roll onto the Operator Side adapter.
Slide the free end adapter onto the shaft.
Insert the free end adapter into the core.
Slide the free end clamp onto the shaft.
Slide the free end clamp down the shaft, until the both clamps are against the adapters.
There should be no visible space between the clamp(s) and the adapter(s).

49
Roll shaft Clamp with Handle
The outer Roll shaft Clamp is secured by the use of a permanent handle. If you pull the
handle up, you can rotate the handle without turning the clamp screw. This action is used to
ratchet open the shaft clamp.
WHEN YOU HAVE SECURED THE CLAMP, BE SURE TO POSITION THE
HANDLE PARALLEL TO THE SIDE OF THE ROLL

When the new roll is securely in position on the LIFT AND LOAD™ System, raise the Roll
shaft.

LIFT AND LOAD™ control valve (C)

Move the valve switch UP, to raise the Roll shaft.

50
Roll shaft up (B)
After the New Roll has been secured and the Roll shaft is in the raised position, swing the
Roll shaft back into the splicer. As the Roll shaft approaches the Roll shaft support saddles,
the shaft end will lift the Roll shaft latch.

Roll shaft going in

When the shaft is fully over the support saddle, the latch will drop down, to securely latch the
Roll shaft into the run position.

Roll shaft latched in position

You may lower the Roll Drive Module, at this time, or, you may leave it up. For web up of the
splicer the roll drive should be left in the up position. With the Roll Drive Module left in the up

51
position, it is easier to turn the roll to web up or bring the leading edge of the web to the
splice head. After web up or splice preparation you must lower the roll drive to be ready for
run or automatic splice.

52
WEB UP
First E-stop should be pressed before web passage. The splicer must have the web passed
through before it is ready for operation. To pass the web through the splicer, the future
running roll must have its roll drive raised. The web is then unwound and passed through the
splice head, through the register sensor and festoon clamp and finally the accumulator.
The web must be pulled through the splicer per the web up diagram in the manual. It is
critical to respect the exact web path for the splicer to function properly. When the web is
passed out of the splicer, the roll drive is lowered and the Estop released and the splicer
reset button is pressed to make the splicer ready to run. (the green light is illuminated on the
operator panel roll position icon) The drive motor is now under power and the accumulator is
automatically refilled.

ATTENTION- VERIFY AFTER WEB UP THAT THE PROPER RUNNING ROLL IS

SELECTED ON THE OPERATOR CONTROL PANEL UPON RESET

LOADING THE NEW ROLL

Open the shaft which corresponds with the non running roll. The outer shaft clamp must be
released and removed. Remove the spent core from the shaft. Remove the core adapters
from the spent core and place them into the new roll. Load a new roll onto the shaft. Push
the roll entirely onto the shaft up against the collar stop. Place the outer shaft clamp in
position and tighten it to hold the roll. Be careful to respect the correct direction of unwind for
the new roll. Pass the web through to the splice head and thread the machine according to
the following diagram.

WEB-UP PATH
A. Upper Roll Position. 2. Head Lead-Out Roller.
a. Alternate Web Path. 3. Register Mark Sensor.
B. Lower Roll Position. 4. Pre-Nip Bar & Gripper.
b. Alternate Web Path. 5. Fixed Finger Rollers.
1. Splicing Head. 6. Dancer Rollers.
(The number of Dancer Rollers and Fixed Finger Rollers may change,
according to the speed specifications for each splicer).

53
WEBBING UP THE SPLICER
When loading the rolls, ensure that the Registration Marks will be facing the Register Mark
Sensor, as the web leaves the Splicing Head and in the correct orientation for the production
process. Always refer to the web up diagram on the machine before web passage. After the
roll has been loaded, bring the web through the Splicing Head.

1a

3 5

4
6 7

1b

WEB PATH through Splicing Head

(ILLUSTRATION ONLY, NOT TO SCALE).

1. Web Paths.
1a. Upper Web Path
1b. Lower Web Path.
2. Knife Cylinder.
3. Knife Cylinder. Holder.
4. Knife Holder.
5. Knife Anvil.
6. Nip Bar(s).
7. Register Mark Sensor.

Pass the web through the Splicing Head. Then, thread the web according to the web up diagram.

54
Web Passage
The web is passed through the splice head, then threaded through the accumulator. It is
important that the indicated web path is respected for proper function of the splicer.

SPLICER WEBBED UP
When the splicer has been webbed up, the web will look like the web shown in Figure 67.

55
GO TO RUN

Once the splicer has been webbed up and the Drive Module has been lowered onto the roll, you
are ready to go to RUN.
Rotate the Emergency Stop Button CLOCKWISE, to release it.
Push the RUN Button.
Verify that the correct roll has been selected as the Running Roll.

THE SPLICE CYCLE

Splice action varies, depending on the method of Splice Initiation and if Register Splice has been
selected. The standard splice cycle operates by receiving the splice actuation from a sensor or
push button, decelerating the running roll to a stop, firing the nip into the web to seal the splice
joint, cutting off the expired web from the splice, opening the splice head and reaccelerating the
roll. During this cycle, the process is fed from the accumulator at the output of the splicer so the
process does not need to slow down.

There are a number of different ways for the splicer to react, when a request to make a splice is
received. Following, is a list of some of the items that will affect the Splice Cycle.

Operational Differences

WEB RUNNING
WEB STOPPED
REGISTER SELECTED (ON)
REGISTER NOT SELECTED (OFF)
MANUAL SPLICE REQUEST
AUTO-SPLICE (DIAMETER REACHED)
AUTO-SPLICE (CORE DETECTED)
AUTO-SPLICE (WEB WRAP DETECTED)

SPLICE MODE VARIATIONS

The sequence of operation of your splicer is effected by the mode of operation selected. A
thorough review of splice cycle operations can be found in the maintenance section of this
manual.

SPLICE ACTUATION
Your Splicer is equipped with a Roll Diameter Auto-Splice Sensor System. It may also have an
optional splice actuation trigger system which can either have a Core Detector Auto-Splice
Sensor System or a tape flag detector.
There will be differences in the machine response, during an Auto-Splice, depending on the
components in the system.

56
Auto-Splice by Roll Diameter

Splice imminent & auto splice sensors

The Standard SP1 Splicer uses an Auto Splice sensor that is triggered by “seeing” the presence
of a metal rod, approaching the face of the sensor.
These rods (Upper and Lower) are attached to the pivot shafts for the Roll Drive Modules.
As the roll decreases in size, and the Roll Drive Module gets closer to the core, the rod swings in
an arc. The sensor closest to the side frame is the Auto Splice Sensor. The second sensor is the
Splice Imminent Sensor. The Splice Imminent Sensor is used to provide a Pre-Splice signal, so
that the operator may verify the alignment of the running web, just before Auto-Splice.
Rotating the rod on the Pivot Shaft and then adjusting the “Flag” which is described in the
maintenance section adjusts the “Trigger Points” of the two sensors.

57
Splice Diameter Sensors
The image shows the pivot shaft and attachment collar, the rod and the sensors.
If there will be sufficient material left on the core, at splice time, the roll will be decelerated to a
“Look” Speed. The “Look” Speed is a low speed that allows time for a Register Mark to be “seen”
and reported to the computer to allow the roll to be stopped accurately for repeatable register
splice accuracy.
Then, the roll will be driven FORWARD, until the Register Mark Sensor “sees” a mark. As soon
as the Register Mark Sensor “sees” a mark, the web will be stopped, the Web Nip will be closed
and the Splicing Head will be actuated.

58
Core Splice

This option uses a sensor on the roll drive to sense the color of the core. When the core is
sensed, the splice is actuated and the web is backed up to the last register mark for an in
register splice. The control switch can be toggled to either use standard diameter splice (OD-
Outside Diameter) or core detect splice. This option is only capable of a maximum web
speed of 170 fpm.

Splice- Core/OD

When the Roll Core Detector Auto Splice OPTION is used, the Sensor is activated when the
Splice Imminent Sensor diameter is reached.

Core Detector Auto-Splice

Core Detector
The Core Detector Auto Splice Sensor is shown in this image.
When the sensor detects the color of the core, the roll is stopped and the Roll Drive Motor will
reverse direction. The Roll Drive Motor will then go to the “Look” Speed. The “Look” Speed allows
for repeatable detection and triggering of an in register splice.
The expired roll is driven BACKWARD, until the Register Mark Sensor “sees” a mark.
This direction change will wrap web around the core to prevent losing the web, off the core.
As soon as the Register Mark Sensor “sees” a mark, the web will be stopped, the Web Nip will be
closed and the Splicing Head will be actuated.

59
Splice Preparation
The following information covers the steps needed to prepare a standard “Butt” Splice on the
SP1 Splicer.
In these pictures, the Lower roll is the Running Roll and the Upper Roll is the New Roll.

New Roll in Upper Position.

Load the New Roll
If the Drive is down, raise it so the roll can turn freely.

Drive UP
Pull some web off the roll.

60
Web Ready
Bring the web down, onto the open Splicing Head.
Lead the web outside of the two Splicing Head Idler Rollers and onto the vacuum preparation
bars.
Pull enough web to reach past the Lower Section of the Splicing Head.
Make sure to pull the web straight, and evenly from the new roll.
NOTE! The roller closest to the Nip Bar is a pivot roller (the Compensator Roller) on spring-
loaded mountings. At Splice Time, the spring-mounted roller will be allowed to move toward
the Nip, as the Nip actuates. This movement provides the extra amount of web that is
needed when the Nip Bar moves.

The splicer is equipped with a Vacuum Select Solenoid Valve, it will automatically direct the
vacuum to the correct section (Upper or Lower) of the Splicing Head.

DO NOT OPEN THE SECTION OF THE SPLICING HEAD FOR THE

RUNNING ROLL.
PARTS OF THE HEAD MAY CAUSE A WEB BREAK, WHEN THE HEAD
SECTION PIVOTS OPEN OR CAUSE DAMAGE TO SPLICE HEAD PARTS.

Open the (Upper or Lower) section of the Splicing Head (opposite the running web half of the
head) and place the web on the Nip Bar and Vacuum Plate.

61
 SAFETY FIRST!
USE CAUTION, WHENEVER A SECTION OF THE SPLICING
HEAD IS OPENED.
THE CUTTING KNIFE IS VERY SHARP

CUTTING KNIFE (1 OF 2 BLADES)

Under normal conditions, your fingers should not be anywhere near the Knife Blades.

Upper Knife & Guard

The machine has guards to protect the operator from the possibility of inadvertent contact
with the Knife Blade. Operators must always use caution when in this area to avoid the
knives.

62
Lower Knife & Guard
Each guard is only effective when the Knife Holder is in the proper position. If there is a
splicer fault which leads to the knife assembly getting stuck out of position, call maintenance
and exercise extreme caution.

Open the Splicing Head.

When either section of the Splicing Head is opened, after a previous splice, the Vacuum will
be automatically turned on. The Vacuum Select Solenoid Valve will apply the vacuum to the
Non-Running Roll side of the splice head.

63
Splice Head Lock.
The splice head is equipped with latches which are mechanically held clear of the non
running side of the splice head so that the splice head is free to be opened on the non
running side, but latched closed on the running side. If both sides are latched closed this
indicates that the knife is stuck in the middle of its stroke. The knife home button should be
pressed to retract the knife and then maintenance should be called to correct the cause of
the fault condition.

Vacuum Plate/Preparation Bar

Each Vacuum Plate is equipped with a measuring scale, to assist you in aligning the side of
the New Web to the side of the Running Web. The top edge of this plate is the reference
point for preparing an exact butt splice. The web should be cut against this surface.

64
Web to Nip bar
Now, put the web on the Vacuum Bar and the Nip Bar.
The web must now be placed in precise registration for an In-Register Splice.

Place the new web in the head.

When a section of the Splicing Head is opened, after a previous splice, the Vacuum is turned
on, automatically. If, for some reason, the vacuum does not turned on automatically, use the
Manual Vacuum ON/OFF Pushbutton, on the control touch panel. (If vacuum is turned off, it
must be turned back on manually)
Pull the web taught and straight.
Lay the web on the Nip Bar and the Vacuum Plate. The vacuum will hold the web in place.
Use the Tape Measure affixed to the Vacuum Plate to ensure that the new web is aligned to
the running web.
Pull the web until your reference point is at the leading edge of the Prep Bar/Vacuum Plate.
(The cutting guide will be the leading edge of the Preparation Bar).

65
Trim the web.
Use a sharp blade to cut off the excess web. Place the blade against the edge of the Nip Bar
and cut completely across the web.

Cut Web
Cut the leading edge of the splice joint and remove any scrap material from the Splicing
Head Area.

66
Web trimmed
When you trim the web, the remaining web will be held on the Vacuum Plate.
The web should look as it is shown above.

67
TAPE APPLICATION
The splicer has a tape dispenser mounted on it for operator convenience. The scale below
the applicator uses the same index lengths found on the roll shaft and also splice head for
easy set up and alignment. 2” [50 mm] wide, Single-Faced, Package Sealing Tape is often
for Splice Joint. The best tape depends upon material to be spliced, temperature and other
environmental issues. Butler Automatic carries special tapes if you have any difficulties with
tape splices coming apart and failing.

With the new web held on the Nip Bar and the Vacuum Plate, get a length of tape slightly
less than the width of the web.
For example, a 24” [60.9 cm] web would get a 23” [58.4 cm] length of tape approximately.
Apply the Single-Faced Tape to the Silicone Rubber Covered Nip Bar, WITH THE
ADHESIVE SIDE FACING OUT FROM THE WEB AND THE PREP BAR.
Half of the tape will overhang the Leading Edge of the Incoming Web.
The side of the Splicing Tape should be as close to the edge of the Nip Bar as you can place
it, with no overhang. The tape should not overhang the sides of the web.

Apply Splicing Tape

Place the tape evenly on the Nip Bar. The vacuum will hold the tape.

68
Tape on Nip Bar
The tape is no ready for web transfer.

“Slip” the Web

Grasp the edges of the new web, above the tape.

Reposition the web

Gently, slip the leading edge of the new web out, from under the tape.
The Vacuum on the Preparation Bar will pull the tape in. You will now move the web to apply
it onto the tape.

69
Apply the Web onto the Tape
Pull the web to the same position that it was in when it was cut off. Place the leading edge of
the new roll onto the Splicing Tape. Press the web down, to adhere the web onto the tape. At
this point, the Splice Joint should look as in above figure. The Vacuum will hold the back of
the tape on both the Preparation Bar, and the Nip Bar. The tape will hold the leading edge of
the new web. Check the incoming web to make sure the edges are aligned to the running
web. Adjust the new web, as needed, for proper alignment. In cases where the web has
extreme curl, the attachment to the tape must be started in the middle and the web must be
held off the tape, slowly pressing it down as you work your way outward on both sides.

Slack the Web (a)

Before you can close the Splicing Head, you must put some slack in the web, to prevent
pulling the web back, as the head section rotates closed.

70
Head Closed
With the web slack, rotate the open section of the Splicing Head to the closed position.
Bring the head section fully closed. Verify that the splice joint has not been pulled back from
it’s proper position on the vacuum bars.

Head Limit Switches

When both sections of the Splicing Head are fully closed, these two limit switches will signal
the P.L.C. that the Head is in the “Safe” & Ready condition.

71
Splice ready indicator
The Splice Ready Indicator L.E.D. comes on when the splice is ready and indicates that the
machine is ready for a splice cycle actuation.

IN-REGISTER SPLICING

Register SPLICE on/off Switch

Verify that the Register Splice Switch is set correctly, for the type of splice, you will be
making. The green light in the upper left corner of the selector button will illuminate green.
The yellow light in the lower right corner flashes to indicate when a register mark is detected
by the register sensor.
REGISTER SWITCH SETTINGS
OFF = Standard Splice (Register Mark Not Used).
ON = In-Register Splicing enabled.

72
SETUP

In-Register Splicing requires some initial setup of the splicer.

If you will not be making an In-Register Splice, no precise placement of a Registration Mark
is necessary.
In order to trim the incoming web at the correct point, you must determine the distance
between the Register Mark Sensor and the Splice Preparation Cut-off Guide in the Splicing
Head. The register system has scales located along the register supports system. This scale
indicates the distance from the register eye back to the cut point. The measure point for
reference on the scale is the edge of the Delran register support closest to the splice head as
read against the scale. When a register splice is made, the system slows down to a scan
speed. When the register mark is seen, the web is stopped and the splice is made. Thus the
running web is stopped with the register mark under the register sensor, and the new splice
must be prepared to be in alignment with this position. Measurement X shows the distance
back from the register eye where the splice will be made. The newly prepared web must be
made in precise registration to the cut point.

73
MEASURE DISTANCE

Measure distance to sensor

“A” represents the aiming point for the Light Beam from the Register Mark Sensor.
”B” is the edge of the Splicing Head Nip Bar. The Nip Bar has foam rubber glued to its’ face.
”C” the Splicing Head Nip Bar.
“D” is the Splicing Head Vacuum Plate.
“X” represents the distance between Point “A”, and Point “B”.
With the Splicing Head Sections in the CLOSED Position, set a ruler, scale, or measuring
tape, in the Splicer.

74
Find distance “X”
The measuring device should follow the Web path BACK, through the Splicing Head,
The Leading Edge of the measuring device (or any reference mark) should be just at the
edge of the Light Beam that is closest to the Splicing Head.
Measure the distance from the edge of the Light Beam to the edge of the Nip Bar.
Look into the Splicing Head and find position “B”. Look at the measuring device to determine
the distance from point “A”. Write this measurement down.
Distance “X” is shown on the scale located in the register splice adjustment.

ALTERNATE METHOD REGISTER SPLICE SET UP

When you make a splice the previously running web will be stopped in a specific place for
register splice. Find the place on the image where the splicer stopped on this last splice, and
then use that as the reference cut point for the set up of your register splices. This will make
splice preparation in the correct place for register splice.

75
Sensor Bracket Assembly Positioning

The Bi-Directional Sensor Bracket Assembly is mounted behind the Splicing Head.

B
B
C
. D

BI-DIRECTIONAL Sensor ASSEMBLY

A. Festoon Area.
B. Long Axis Adjusters.
C. Cross-Web Adjuster.
D. Splicing Head.

ANYTIME A SENSOR IS MOVED, YOU SHOULD CHECK THE OPERATION OF THE

SENSOR, IN THE NEW LOCATION.
IF NECESSARY, REPEAT THE CALIBRATION PROCEDURE.
See Maintenance section of this manual for sensor calibration.

CROSS-WEB ADJUSTER (A)

The block, that holds the Register Mark Sensor, can slide across the rods of the assembly.

76
CROSS-WEB ADJUSTER (B)
The large black knob, on the side of the slider block, is used to lock the Sensor Holder Block
in place.
Loosen the knob and slide the sensor across the web until the light beam from the Register
Mark Sensor is on a Register Mark. If the web is not transparent, you might have to use a
mirror to see the mark.
When the sensor light beam is in the correct position, secure the block by tightening the
knob.

LONG AXIS ADJUSTER lock

Each of the two end blocks, have locking knobs that are used to lock the rods in place.
To change the distance between the Register Mark Sensor and the Splicing Head, loosen
both knobs and slide the rod assembly along the web.

77
LONG AXIS ADJUSTER Block (A)
When the sensor is at the new location, push the Control Side Block against the support.

LONG AXIS ADJUSTER Block (B)

When the Control Side Block is against the support, the assembly will be at right angles to
the direction of web travel. Any adjustments in the CROSS-WEB directions will be in a
straight line.
Lock the Control Side Block in position and then lock the block on the other side of the
assembly.

78
WEB PATH THROUGH SENSOR ASSEMBLY

Web path at sensor (A)

This shows the web passing through the Register Mark Sensor Bracket Assembly. Note that
the web passes OVER the first shaft (1), UNDER the middle shaft (2), and OVER the third
shaft (3).

Web path at sensor (b)

79
Web path at sensor (C)
The figure shows the web path using the Bi-Directional Sensor Bracket Assembly. The
image shows the web, as viewed from the Operator Side of the Splicer.
The top three shafts of the assembly are used to modify the web path. With the web
threaded as shown, web “flutter” is reduced.
If the web were to go between the two rollers without any support, it may move up and down,
away from the sensor.

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INSTALLATION

The splicer is a compact unit which is fully self contained and sits upon four adjustable feet.
The weight of the machine is approximately 1100 lbs. The machine can be moved by a
standard fork lift capable of carrying this weight. Please see electrical schematics for
interconnection electrical and with the process. The machine is equipped with a pneumatic
disconnect and must be connected to plant air.

It is important that proper rigging equipment is used to move the equipment and that riggers
with proper safety training are responsible for moving and erecting the machine. The
machine is shipped with wooden shims under the front and back base laterals. These shims
are required for moving the machine to avoid damage when lifting with forks under the base
pate, but must be removed before operation for proper function upon installation.

The machines have a hole in each side frame indicated with a shackle label. These holes are
located at the approximate center of gravity of the machine and may be used for moving the
machine. Warning: The base plate must be securely strapped to the machine cross laterals
to avoid severe damage to sidelay motor assembly.

The installation site must be fully prepared before the machine is brought into position. A
centerline must be drawn on the ground where the splicer will be installed. With the machine
in the middle of it’s sidelay travel the idler rollers must be centered on this center line. The
leveling feet of the machine are used to level the splicer. We recommend that level is made
to within .003 per foot. The tram of the machine is also critical for proper web tracking. The
tram must be within .003” per foot. The alignment tolerance is affected by material being run.
It is very important that when installing this machine on older equipment that the entire web
path is leveled and trammed for proper web tracking.

It must be noted that the entire machine slides on its base. This requires that the electrical
and pneumatic connections are made with flexible connectors.

The splicer includes outputs to signal to the process that the machine is in the ready state for
run. This signal and the E-stop signal must be connected to the process machine control.
Remote sidelay is also available to respond to a 24 VDC input signal. Please refer to
interconnection diagram for more details.

We highly recommend that a Butler Technician inspect the machine installation before it is
finally bolted to the floor.

81
SPLICER MAINTENANCE
Before using this section of the manual it is critical to familiarize yourself with the safety
warnings and directions at the beginning of the manual. We highly recommend using safety
gloves when working near the cutting knife, and all lock out and other safety procedures
must be followed when performing maintenance of any kind on this machine.

Automatic Splice Actuation

The SP1 Splicer uses an Auto Splice sensor that is triggered by “seeing” the presence of an
adjustable rod with detector plate, approaching the face of the splice actuation sensor. These
rods (Upper and Lower) are attached to the pivot shafts for the Roll Drive Modules. As the
roll decreases in size, and the Roll Drive Module gets closer to the core, the rod swings in an
arc.

Standard Splice Actuation Sensors

This image shows the pivot shaft and attachment collar, the rod and the sensors.
The sensor closest to the side frame is the Auto Splice Sensor. The second sensor is the
Splice Imminent Sensor.

82
Splice Imminent & auto splice sensors
Rotating the rod on the Pivot Shaft and then adjusting the “Flag” above adjusts the “Trigger
Points” of the two sensors.

THE SPLICE CYCLE

Splice action varies, depending on the method of Splice Initiation and if Register Splice has
been selected.
There are a number of different ways for the splicer to react, when a request to make a
splice is received. Following, is a list of some of the items that will affect the Splice Cycle.

Operational Differences

WEB RUNNING
WEB STOPPED
REGISTER SELECTED (ON)
REGISTER NOT SELECTED (OFF)
MANUAL SPLICE REQUEST
AUTO-SPLICE (DIAMETER REACHED)
AUTO-SPLICE (CORE DETECTED)
AUTO-SPLICE (WEB WRAP DETECTED)

SPLICE MODE VARIATIONS

Following are descriptions of the Splice Sequence of Operations, under various conditions.

1. MANUAL SPLICE: 2. MANUAL SPLICE:

WEB STOPPED (Static Splice). WEB RUNNING (Running Splice).
IMMEDIATE SPLICE. IMMEDIATE SPLICE.
Register Splice Switch OFF. Register Splice Switch OFF.
OR: Initiate (Push Switch).
Register Splice Switch ON. Decel (Stop Drive).
Initiate (Push Touch Switch). Web stops.
Web stops. Detect Zero-Speed. (No W.l.F. Pulses).
Detect Zero-Speed. (No W.l.F. Pulses). Web Nip (“Pre-Nip”) actuates.
Head actuates (Seals). Head actuates (Seals).
Knife cuts web. Knife cuts web.
Switch (Rolls and Controls). Switch (Rolls and Controls).
Vacuum Off. Vacuum Off.

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3. MANUAL SPLICE:
WEB RUNNING (Running Splice). 6. CORE DETECT AUTO-SPLICE:
IN-REGISTER SPLICE. WEB RUNNING (Running Splice)
Register Splice Switch ON. IMMEDIATE SPLICE
Initiate (Push Switch) Register Splice Switch OFF.
DECEL (Drive slow Down). (Your technicians will adjust the Core
GO TO “Look” Speed. Detector Sensors and their Amplifiers).
Find Register Mark. Initiate (Core Detector Sensor).
Stop Drive. DECEL (Drive Slows).
Web stops. Stop Drive.
Detect Zero-Speed. (No W.l.F. Pulses). Web stops.
Web Nip (“Pre-Nip”) actuates. Detect Zero-Speed. (No W.l.F. Pulses).
Head actuates (Seals). Head actuates (Seals).
CUT. Knife cuts web.
Switch (Rolls and Controls). Switch (Rolls and Controls).
Vacuum Off. Vacuum Off.

4. AUTO-SPLICE (DIAMETER): 7. CORE DETECT AUTO-SPLICE:

WEB RUNNING (Running Splice) WEB RUNNING (Running Splice)
IMMEDIATE SPLICE. IN-REGISTER SPLICE.
Register Splice Switch OFF. Register Splice Switch ON.
(The Auto-Splice Diameter will be preset (Your technicians will adjust the Core
by your technicians). Detector Sensors and their Amplifiers).
Initiate (Diameter Sensor). Initiate (Core Detector Sensor).
DECEL (Drive Stop). DECEL (Drive Slows).
Web stops. STOP DRIVE.
Zero-Speed Detect (W.l.F. Stop). REVERSE DRIVE.
Head actuates (Seals). GO TO “Look” Speed.
Knife cuts web. Find Registration Mark.
Switch (Rolls and Controls). Stop Drive.
Vacuum Off. Web stops.
Detect Zero-Speed. (No W.l.F. Pulses).
5. AUTO-SPLICE (DIAMETER): Web Nip (“Pre-Nip”) actuates.
WEB RUNNING (Running Splice) Head actuates (Seals).
IN-REGISTER SPLICE. Knife cuts web.
Register Splice Switch ON. Switch (Rolls and Controls).
(The Auto-Splice Diameter will be preset Vacuum Off.
by your technicians).
Initiate (Diameter Sensor). 8. WEB-WRAP SPLICE:
DECEL (Drive Slows). WEB RUNNING (Running Splice).
GO TO “Look” Speed. IMMEDIATE SPLICE
Find Registration Mark. Register Splice Switch OFF.
Stop Drive. (Your technicians will preset the Web
Web stops. Wrap Sensor).
Detect Zero-Speed. (No W.l.F. Pulses). Initiate (Web Wrap Sensor).
Web Nip (“Pre-Nip”) actuates. DECEL (Drive Slows).
Head actuates (Seals). STOP DRIVE.
Knife cuts web. Web stops.
Switch (Rolls and Controls). Detect Zero-Speed. (No W.l.F. Pulses).
Vacuum Off. Web Nip (“Pre-Nip”) actuates.
“Look” Speed, is a low speed that allows Head actuates (Seals).
time for a Register Mark to be detected Knife cuts web.
and reported to the computer.

84
Switch (Rolls and Controls). STOP DRIVE.
Vacuum Off. REVERSE DRIVE.
GO TO “Look” Speed.
9. WEB-WRAP SPLICE: Find Registration Mark.
WEB RUNNING (Running Splice). Stop Drive.
IN-REGISTER SPLICE. Web stops.
Register Splice Switch ON. Detect Zero-Speed. (No W.l.F. Pulses).
(Your technicians will preset the Web Head actuates (Seals).
Wrap Sensor). Knife cuts web.
Initiate (Web Wrap Sensor). Switch (Rolls and Controls).
DECEL (Drive Slows). Vacuum Off.

ROLL CORE DETECTOR SYSTEM

The Splice Imminent Signal is used to turn on the Core Detector Auto Splice System.
When the Roll Core Detector System, Auto Splice OPTION is used, the Auto Splice Signal
comes from a color Sensor that is attached to the roll drive and positioned to look at the roll
surface.

Auto Splice Sensors

The Core Detector Auto Splice Sensor Assembly is attached to the roll drive. The entire
assembly is adjustable for best focal angle. The sensor should be mounted ½ inch from the
roll surface of a roll at core splice diameter. This distance may need to be altered slightly
during set up if the sensor has difficulties distinguishing between any specific colors. This
option includes a sensor on both the upper and lower roll drive.

The Auto-Splice Sensor uses a White L.E.D. for a Light Source. The white light is directed at
some nearby surface and the light is reflected back o a photodiode receiver in the sensor
housing. The reflected light changes color, depending on the color of the surface that is
reflecting the light from the sensor. Electronic color filters in the sensor can be adjusted so
that only a certain color may cause the sensor to send out a signal.

CORE DETECTOR SENSOR OPERATION

1. A white Light is projected from the sensor, onto the surface of the unwinding roll. While
there is still some web on the core, the white light will not shine on the Kraft-Paper-colored
Core.
2 The color of the light reflected from the WEB/Film does not match the color that the sensor
has been adjusted to “see”.

85
3. When the last wrap of web is unwinding from the core, the core will be exposed to the
white light from the sensor.
4. The color of the light reflected from the CORE matches the color that the sensor has been
adjusted to “see”.
When the correct color is “recognized” by the sensor, a signal is sent to the computer to
initiate an Auto-Splice operation.
If the colors of the cores change, you may have to recalibrate the sensor.
While there is web on the core, the color of the reflected light beam will be the color of the
web.
Since the sensor has been calibrated to see only the color of the core, there will be no signal
to the P.L.C.
The end of the web is usually taped onto the core, with double-faced tape. When the last
wrap of the web clears the core, the sensor no longer “sees” the Web-Colored reflected
beam. The color of the reflected beam changes to the color of the core, and a signal will be
sent to the P.L.C. When the P.L.C. gets the “CORE” signal, an Auto-Splice Sequence will be
started.
When used with the Register Splice OPTION, the Roll Drive Motor, upon splice actuation,
the drive will reverse the direction of the unwinding roll at a slow scan speed. The web is
rewound until a register mark is detected. The Roll Drive Motor will then stop, and the
Splicing Head will be actuated. If the Register Splice OPTION is NOT used, the Roll Drive
Motor will bring the unwinding roll to a stop, and the Splicing Head will be actuated.

If the web is completely taped to the core, the core will continue to rotate, pulling the end of
the web to the other side of the core and rewinding the web and the sensor will not detect the
core. In effect, the web will “wrap-up” around the core. In this case the diameter splice option
will need to be selected until properly wound rolls can be used.

86
Core Detect Sensor Information

QC50 CORE DETECTOR SENSOR

FEATURES
Compact, self-contained design

87
Analyzes and compares color to color, or varying intensities of one color
Fast 335-microsecond sensing response time
Easy-to-set programming options for 1 2, or 3 colors
Three programming parameters: channel, sensing mode, and tolerance level
10 tolerance levels to allow for product variation
Output OFF-delay (6 options); selection applies to all three color channels
Gated color detection option (also called inhibiting, synchronization or windowing)
4 LEDs plus 4-digit display show configuration and operating status
Non-volatile memory for data retention
8-pin quick-disconnect with a 3-position swivel connector
Choose models with either 3 NPN or 3 PNP outputs, one for each color channel

OVERVIEW
The true QC50 is an easy-to-use, compact true color sensor that uses modulated white light with
red, green, and blue (R, C, B) electronic filters to scan for the presence of one, two or three colors.
Its compact size allows it to be mounted almost anywhere. Configuration options include
Programming mode for color detection parameters and Setup mode for selecting an adjustable
output OFF-delay when needed.
The sensor has three solid-state outputs that may be individually set for color differentiation or for
color-plus-intensity differentiation (see Sensing Modes below).
The sensor has two push buttons, Set and Select, plus a 4-digit LCD display, an Output LED, and
three Output Status LEDs (one for each sensing output), for easy programming and status
monitoring during operation.

QC50 Color Sensor Features

88
SENSOR CONFIGURATION

Outputs
The QC50 can be programmed to sense one, two or three colors. Three outputs are available for
this purpose. When a programmed color is sensed, the Yellow Output (“OUT”) indicator and the
associated green Output Status LED turn ON, and the respective output conducts. The sensor is
wired at the factory so all three channels may be used on different core colors.

Sensing Modes
The QC50 Color Sensor functions in one of two sensing modes: Color only (expressed as “C” on the
4-digit display) or Color-Plus-Intensity (expressed as “C_I”). In Color sensing mode, only colors are
sensed. This is most useful for sorting obvious color differences (for example red or black or green).
The Color-Plus-Intensity option refines the sensors’ capabilities to include grayscale as well,
broadening the spectrum of colors and shades, which the sensor can be programmed to detect. This
feature allows “batch” sorting or identifying within a color family (foe example, light blue or medium
blue or dark blue). The factory setting is C. Webs that have coloring similar to the core color may
require C_I Mode.
TOLERANCE LEVELS
The Color Sensor can be configured to enable color detection at any of 10 levels of tolerance (0 to
9). The higher the number, the greater the level of tolerance, or range of acceptance, when the
sensor attempts to detect a color.
A tolerance level of 9 (expressed as “toL9” on the 4-digit display) permits the sensor to accept a
wider range of target conditions, compared to a tolerance level of 0 (expressed as “toL0” on the 4-
digit display) causes the sensor to discriminate more precisely and accept a narrower range or target
conditions. The normal factory setting is 4.

Run Mode
Normal operation of the QC50 Color Sensor is called Run mode. The LED indicators and the 4-digit
display indicate the sensor’s current operational status. For Example, if the Color sensor is detecting
the color for which output 1 is programmed, the indicators will appear:
Output (“Out”) LED: ON yellow
Output 1 Status LED: ON green
4-digit display: run

Fig. 1. A quick guide to QC50 sensor programming

89
 SENSOR PROGRAMMING
Programming mode determines the colors the sensor will detect for each of the three outputs.
Repeat the following steps for each output. Refer to Figure 84 for a quick overview of this process.
SENSOR PROGRAMMING CHART
NOTE: The sensor has a 12-second time-out. If a period longer than 12 seconds elapses between
steps, sensor will return to Run mode without saving settings.

SENSOR PROGRAMMING CHART

* If the color being taught is out of the sensors range, a “FAIL” message will appear in the 4-digit display, followed
by a “Hi” or “Lo” message (indicating too much or too little light, respectively).
* *Remembering Settings: Save selected sensor settings by clicking the Set push button at the end of
Programming mode.
The settings are saved in the sensor’s “EEPROM” memory and the sensor remembers the current settings, even
after being powered off.

REVIEW OF SETTINGS
To review the sensor’s settings, press Select for 2 seconds or more. The output channel, sensing mode, and
tolerance level will then be displayed sequentially (see Figure 85), followed by the delay interval (applicable to all
channels). At the end of the sequence, the display will indicate “run” or “rund” (depending on the delay setting).

90
REVIEW SETTINGS

Non-Initialization Display Messages

When using a sensor for the first time, the message “E2Pr” may be displayed (see Figure 86). This indicates
the memory has yet to be used. To correct this situation, set up a channel according to the procedure
described earlier in “Programming Mode”. When any channel is set up successfully, a “run” or “rund”
message is displayed.

Channel non-initialization message and response

91 -
END OF ROLL TAPE SENSOR OPTION

Sensors behind Splicing Head

A. Registration Mark Sensor.
B. End of Roll Tape Sensor.

End of Roll Tape Sensor (A)

As an OPTION, your splicer may be equipped with an optical color contrast sensor. This sensor is located
next to (or under) the Lead-Out roller for the Splicing Head.
The sensor will either “Look Up” at the Web or “Look Down” at the web, as required.
The mounting bracket allows for the sensor to be positioned at the correct location on either side of the web
centerline.
In this special application, the maker of the web will apply a distinctive piece of “Marker” Tape to the
web, as it is being wound on the core. Placement of the tape will be at a defined distance from the end of
the web.

92 -
 A
B

Fig. 2. web simulation graphic

A. End of Web taped onto core.
B. Roll Core.
C. Marker Tape.
If the Auto-Splice Mode Selector Switch is set to END, the standard Auto-splice by Outside Diameter System
will not function.
Instead, the roll will continue unwinding until the End of Roll Tape Sensor “sees” the contrasting tape. Then,
the Splice sequence will be initiated.

93 -
AUTO-SPLICE MODE SELECTOR

End of Roll Tape Sensor (B)

The sensor is installed with the lens close to the web.

SETUP:

Unwind a roll normally and save the last few feet of web on the core, with the tape within reach.
Install the core and web on the splicer and lead the web through the Splicing Head.
Position the marker tape in front of the sensor lens. Keep tension on the web so that the correct distance
from the sensor is maintained.
Adjust the lateral position of the sensor, until the light beam from the sensor is showing on the Marker Tape.

Sensor position clamp knobs

Loosen the clamp knobs, move the sensor bracket and then secure the clamps
Calibrate the End of Roll Tape Sensor.

94 -
End of Roll Tape Sensor calibration

Sensor Controls

Control panel: The teach-in button can be locked against accidental actuation with “run”. In an undefined
switching position, no teach-in procedure can be triggered.
Light/dark-switching not required. Unit switches on the object to be detected, that was under the light spot
during the first teach-in procedure (Marker Tape or standard web).
Setting via push button:
1. Select TEACH, using the rotating switch.

Controls, TEACH SELECTED

2. Position the Marker Tape under the light spot.
– Trigger first teach-in procedure via teach-in button. (Push and hold for more than 1 second).
3. Position the standard web under the light spot.
– Trigger second teach-in procedure via teach-in button.

95 -
4. Select RUN, using rotating switch.

Controls, RUN SELECTED

Acknowledgement:
After the first teach-in procedure, the red transmission light flashes and the function signal slowly indicates
that a second teach-in procedure must be triggered.
-- LED and Q flash quickly = insufficient contrast.
-- LED and Q do not flash = teach-in completed.

SIDELAY CONTROL
To adjust the alignment of the web, as it goes into the process line, the splicer may be moved (sidelayed) on
its’ base.
For a full explanation of Manual Sidelay Control, please see the SP1 Operators’ Manual.
A Single-Phase, Reversible Direction A.C. Motor, is used to drive a ball screw, within a Linear Actuator,

SIDELAY LINEAR ACTUATOR

Sidelay Travel is approximately 1 Inch [25mm] to either side of the unit centerline.

96 -
Manual Control of the Sidelay Actuator comes from the Directional Control Arrow Membrane Switches, at
the bottom of the Operators’ Control Panel.

SIDELAY CONTROL SWITCHES

AUTO ALIGNER SIDELAY (Sensor)

The alignment Sensor is located at the edge of the web, after the web exits from the SP1 Splicer. It is
important that he sensor is mounted as close to the splicer output roller as possible. This allows for a
minimum path delay and fastest alignment response.

SENSOR AND ADJUSTER ASSEMBLY

The sensor contains a pair of Retro-Reflective, Infra-Red Photocells. The entire assembly has two machined
holes so that it can be mounted to the nearest surface at the output of the splicer. The letters “F” for Front
and “R” for Rear, on the face of the sensor identify the two Photo-Eyes. The sensor assembly is mounted on
a slide screw for lateral adjustment. The aligner sensors control the splicer sidelay when the auto align
feature is activated. When the sensor is moved sideways, the entire splicer will respond with side
movements to bring the web into alignment with the sensor. Thus the sensor position becomes the
controlling element for web position.

97 -
SENSOR
When the web is in front of an eye, the reflected light beam is detected by the eye

EXAMPLE OF ALIGNER OPERATION.

If the web were to move to the LEFT, BOTH the “F” and “R” sensors would see their reflected light beams.
The Splicer Controller would recognize this condition and the Splicer Sidelay Motor (Linear Actuator) would
be turned on to move the Splicer and output web to the RIGHT, to correct the web position. The splicer will
move in discrete increments of approximately 1/30th inch. The aligner will pulse one increment, wait for the
programmed path delay to see if the web reaches the proper position, then repeat another pulse until
alignment is reached.

The Sensor and its’ Adjustment Arm should be attached to a part of the Press/Process line that does not
move when the Splicer Sidelay is used. The web must first pass over the Eye marked “F” and then over the
Eye marked “R”.

SET FOR REDUCED WEB MOVEMENT.

The sensor “Dead band” range is 0.0625” to 0.50” [1.5 mm to 13mm]. To increase or decrease the “dead
band” before adjustment the sensor is loosened and the two halves are moved to either create a large or
smaller offset between the two sensors in the assembly. During the installation of the splicer, the program
must be updated to adjust the sidelay increment for accurate response per increment and input the path
delay to have the correct wait period before the next pulse is made (so sensor will not hunt back and forth).

Once the Web Position has been established and the sensor has been place correctly, push the AUTO
ALIGN Button to turn the Automatic Alignment System ON.

98 -
AUTO-ALIGN PUSHBUTTON

When Auto-Align ON has been selected, the Indicator Light in the pushbutton will come ON to confirm the
selection. At this point, anytime the web moves out of position, a correction will be made, by moving the
splicer, to bring the web back, into alignment. The Splicer Sidelay Linear Actuator is mechanically limited to
approximately 2” [50 mm] of travel. When the actuator tube has been fully retracted (or fully extended) an
Internal Slip-Clutch will prevent damage to the actuator motor. During Manual Sidelay Operation, the Splicer
Operator would not keep the Sidelay Linear Actuator Motor running, for long periods resulting in an overload
trip. During Automatic Sidelay Operation the system will go into a conflict mode after 20 attempted
adjustments to avoid any damage to machine components. The auto align selector light will flash for
indication of this fault. The operator should then verify web position, check and correct sensor position, and
turn the option off and then on again.

99 -
OTHER OPTIONS- ALERT INDICATORS

CONTROL CABINET
In addition to the Splicer Controls, your SP1 Splicer could be equipped with additional indicators.

100 -
CONTROL CABINET
A light tower can be attached to the top of the Controls Cabinet.
The standard light stack is equipped with three lights with red yellow and green to indicate the various splicer
states.

INTERFACE OPTIONS
The Butler SP1 Splicer can supply information to or collect information from, the process line control system.
Your Maintenance Department will be advised of the available options that are installed on your splicer.

SPLICE HEAD
Nip bar replacement

101 -
Unscrew the two outside nylstop M4 fasteners. Remove the air connected to the bar. Remove the nip bar and
replace. Replace the pneumatic (vacuum) tube. Screw back in the two fasteners. After fully fastening the screws,
back them out 1/3 turn to leave some play in the system to avoid mechanical binding.

Replacing The Cut Knife

ATTENTION!
KNIFE BLADES ARE EXTREMELY SHARP.
TAKE PARTICULAR CARE NEAR THE KNIFE AND WEAR GLOVES OR PROTECTION .

The knife blades should not be replaced while the knife assembly is inside the splicing head. Butler Automatic
recommends an extra knife holder assembly for knife replacement.
knife holder (Ref. Butler # L064994-601) the existing holder can be reused by replacing the worn blades with
new blades.
blades (Ref. Butler # A064692-001) These knives must be installed on the holder so that the blade edge just
comes back over the support anvil. The knife holder is then ready for an easy replacement if the knives should be
worn again.

102 -
Instructions for Replacement
of Knife Holder assembly

Knife holder in removal position

The knife holder must be at one or the
other side of the cylinder stroke.
Splice Head
Cut all electric and pneumatic
power to the machine. Lock out
tag out the splicer before you
attempt any service on the
splice head. Verify that no
stored energy is in the
pneumatic circuit.

Open the two halves of the splice head.

Open the upper half of the

splice head

103
Move the knife holder.
Remove pneumatic tubing
Move the knife holder to the
middle of the splice head to gain By depressing the collar, the air line can
be removed from the fitting.
more room to work on the
device.
Remove outside large diameter screw on
each side of the knife cut cylinder.

Pneumatic disconnections (2).

There are two pneumatic connections on the
knife cyclinder which must be disconnected.
(One on each end of the cylinder)

Knife cylinder support screws

Do not change the adjustment of the
screws on the front of the knife cylinder
support. These are factory set and should
not need adjustment.

104 -
Accentric adjustment. Knife holder on anvil/guide.
An accentric is used to align each end of
the knife cylinder. This is a factory setting.

Knife Cylinder and support

Remove the knife cylinder and support and place
on a bench.

Remove Screws.
Remove the two large screws. If you need to
remove the knife cylinder and support,
examine the knife holder assembly. This
should normally remain in the splice head on
the anvil/guide bar. Make sure that during this
operation that the knife holder remains in the
splice head and does not fall onto the floor.

Knife Holder
If necessary replace the entire knife holder
assembly as a unit

105 -
Knife Cylinder Replacement

REINSTALLATION

Knife Cylinder with support.

The Knife cylinder is supported by a set of plastic
supports and a rubber strip inside the support.

Reinstallation of cylinder.
Reinstall the knife support, the knife cylinder,
and knife holder. Move the knife cylinder and
support to align the cylinder with the knife and
reattach.
Install the Cylinder inside the support.
Slide the new cylinder with the pneumatic fittings
installed in its support. Take care not to damage
the plastic strips and rubber supports while
replacing the cylinder.

Reinstall screws
Install the two large screws to the knife cylinder
Cylinder Slide Screws. support. Replace the pneuamtic pipes. Test the
Remove the two screws from the cylinder slide pneumatic connection by pulling gently on the
from the old cylinder. Install these screws on the tube into the fitting. The tube must remain firmly
new cylinder. in place. Restore pneumatic pressure to the
machine. Restore electricity.

106
 Replacement of Cut Knives
ATTENTION!
THE KNIFE BLADES ARE EXTREMELY
SHARP.
TAKE EVERY POSSIBLE PRECAUTION
WHEN WORKING WITH OR AROUND THE
KNIFE.

The cut knives (2) (Ref. Butler # A064692-001)

are fixed on a rotating pivot (Ref. Butler #
B064485-001) by four screws.Under each pivot is
Rotary Pivot aligned.
a rotary spring (Ref. Butler # A064523-001).
Gently turn the pivot counter clockwise until it is
in the proper alignment.

Knife support with two knives

Gently unscrew the four knife screws. Gently
slide out the knife and remove from assembly. Repalce Knife.
Slide the new knife into the screws attached to
the pivot. The knife must be facing left. Always
leave clearance between the back of the knife
and the knife holder. To verify knife position use
a 10 mm X 10 mm bar. The sharp edge of the
knife must come down just past the edge of this
square bar.

Rotary Pivot.
When the knife is removed from the assembly,
the pivot will turn approximately 90 degrees.
When reinstalling the new knives, the pivots must
be first turn back to position.

107
 Replacing the knife pivot spring.
There is a torsion spring attached to each knife
pivot. The torsion spring is located under each
knife pivot. The torsion spring (Ref. Butler #
A064523) is centered under the rotary pivot (
Ref. Butler # B064485).

The V groove of the knife must pass the square

bar, and the top of the knife must pass the bar by
6-7 mm.

Tightening screws.
Knife Holder
For the correct attachment of the knives, the
If the spring must be changed, first remove and
screws must be properly tightened.
restock the knife. Unscrew the screw holding the
pivot from the opposite side of the assembly. Do
not lose the washer. Remove the rotary pivot.
The torsion spring sits around the rotary pivot
and each end of the pivot is inserted into a 1 mm
hole, one side on the pivot and one side on the
knife holder assembly.

Verify the rotation of the knife.

The knife must easily pivot and return to cut
position.
After replacing and checking both knives, the
assembly is ready to go into stock.

Knife Holder Assembly.

Identification.
A Representation of Rotary Pivot
B Representation of Rotary Pivot
1 Rotary Pivot
2 Upper end of Spring
3 Center of Rotary Pivot
4 Lower end of Spring

108
SPLICING HEAD PIVOT SECTION ALIGNMENT
The two pivoting sections of the splicing head contain the Splicing Head Nip Bars.
If these two bars are not parallel to each other, the Splice Joint will not seal properly and it may
come apart. Each of the four, Black, handles for the pivoting section, has a socket-head setscrew
installed in the shaft for the handle.

Handle & setscrew (A)

These setscrews are used to adjust the closed position of the Head Sections.

Handle & setscrew (b)

Once the screw has been adjusted, a stop-nut is used to lock the screw in place.

109
Side plates
By aligning the side plate of the Pivot Section to the side plate of the Head, the parallelism of the Nip
Bars is assured. Use an Adjustable Square to check the position of the Pivot Section.

TEST 1
Place the body of the square against the Head Side Plate and move the blade until it touches the
side plate of the Pivot Section.
The actual distance is not critical.

110
TEST 2
Move the square down and place the body of the square against the Head Side Plate.
Make sure that the fit at the top and at the bottom are the same. Adjust the Socket Head Setscrews
until the fit is the same at the top and bottom of each of the four side plates of the Pivot Sections.
Lock the setscrews.

Pneumatic Manifold

Splicer splice head cylinders are controlled pneumatically by use of a pneumatic manifold.

The manifold is mounted on the machine frame and is wired to splicer interface circuit board via 25
pin D-Sub connector and cable. Manifold and cable are suitable for use in non caustic wash down
environment rated for IP56 or IP65 depending on the wash down option selected.

REGISTER SENSOR INFORMATION

Register Mark Sensor Location

The Register Mark Sensor is located on a bar, between the Splicing Head and the Web Nip Bar.
The sensor is a retro-reflective photocell sensor, with a visible (red) beam of light.

111
Installed sensor.

SENSOR GAP
Place a length of precision key stock or a stack of feeler gauges equal to 0.50” [12.7mm] on the
adjacent idler roller and adjust the vertical spacing from the lens to the roller.

SENSOR ANGLE
The Register Mark Sensor is installed at an angle of 15° to the web. The holes for the mounting
screws that go through the sensor are offset to provide the correct angle.
Lateral adjustment (across the web) may be obtained by loosening the two large black knobs in the
mounting block.
Install the web in the splicer. Adjust the side position of the web, as needed for the correct running
position.
Move the beam of the sensor to a position where the red light is centered on a Registration Mark.
Tighten the two large black knobs in the mounting block, to maintain the position of the sensor.
The lens of the sensor must be cleaned occasionally.
Use a clean, soft cloth. Do not use any solvents around the sensor.
Check the operation of the sensor regularly.
The Register Mark Sensor has Yellow L.E.D. on the control end.
The Yellow L.E.D. should flash, whenever the sensor “sees” a Register Mark passing by the light
beam.
INPUT L.E.D. # 0.1 on the C.P.U. should be on whenever the Yellow L.E.D. on the Register Mark
Sensor is on.

SENSOR PROGRAMMING

SENSOR END VIEW.

In this view, the “Teach–In” Button is above the YELLOW L.E.D., on the right end.
Position a Registration Mark, on the roller, in front of the light beam.
112
Click the “Teach-In” button on the end of the sensor.
The red sender light and the Yellow L.E.D. will blink slowly.
Move the web so that the Registration Mark is NOT in front of the light beam.
Click the “Teach-In” button.
The Yellow L.E.D. will turn off.
Verify the operation of the sensor by alternating a Register Mark and a blank space, under the light
beam.
The Yellow L.E.D. should flash, whenever the sensor “sees” a Register Mark.

CALIBRATION OF REGISTER SENSOR

An LED on the register button can be used as a reference to see that the register sensor is
working properly. In the case that recalibration is required, use the following procedure:
- Move the web with register mark near the register eye within the 10 mm detection range.
- Move the register mark under the register eye and press the button until the LED on the
sensor starts to flash.
- Move the sensor eye over the web background and press on the setting button on the eye
again.

The following is a more detailed explanation of this system set up.

Loosen the knobs to slide the sensor bracket across the web.
It may be necessary to relocate the Sensor Cable.
Always make sure that the Sensor Cable is not in a position to touch the web or any rollers.
Apply tension to the web to keep it straight.
Adjust the sensor position, to center the light beam on a Register Mark.
Move the web to shift the Register Mark light beam on and off the target.
You must have the Yellow LED ON STEADY, whenever a Register Mark is “seen” by the sensor.
“TEACH” THE REGISTER MARK SENSOR.
The sensor contains a transmitter for a beam of light and a receiver for a reflected beam.
Whenever the product is changed, the Register Mark Sensor must be checked to ensure that the
Register Marks can be recognized. The sensor may have to be reset for different contrast Register
Marks.
If necessary, complete the following steps.
When you are finished, you must have the Yellow LED ON STEADY, whenever a Register Mark is
“seen” by the sensor.

Register Mark Sensor

NOTE! The color of the light beam is automatically selected by the sensor, during the set-up “Teach”
operation that follows.

113
The sensor will automatically select between a Red, White, Blue, or Green colored beam, according
to the color and density contrast between the body of the web and the color of the Registration Mark.

Register mark Sensor Parts

A. Transmitter
B. Receiver.
C. “Teach In” Button.
D. Status Indicator L.E.D.

1. Position a Register Mark with the Beam of Light on the mark.

2. Press the Teach-In button and release it. The RED Sender Light and the Status Indicator L.E.D.
should blink slowly.
3. Move the Register Mark so that the Beam of Light is NOT on the mark.
4. Press the Teach-In button and release it. The RED Sender Light should come ON, steady.
5. Move a Register Mark back and forth, opposite the Beam of Light. The Status Indicator L.E.D.
should come on, at each mark.
6. Whenever the Status Indicator on the sensor flashes, the indicator on the Register Splice Graphic
(on the Operators’ Panel) should also flash.

114
Register Splice Graphic
7. The YELLOW L.E.D. Indicator, at the Lower Right corner, should FLASH, each time a Web
Registration Mark is detected by the Registration Mark Sensor.

REGISTER SPLICE TOUCH SWITCH AND Indicator Lamps (A)

The GREEN L.E.D. in Upper Left Corner verifies the status of the Register Splice Option.
ON = In-Register Splicing selected.
OFF = In-Register Splicing NOT selected.

STATUS 1, NORMAL, ON or OFF.

When a SPLICE command is recognized, with In-Register Splicing selected, the P.L.C. will “Look”
for a Registration Mark on the web, before stopping the web and firing the Splicing Head.
When a SPLICE command is recognized, with In-Register Splicing NOT selected, the P.L.C. will
decelerate the Running Roll to a stop, and actuate the Splicing Head, without regard to the position
of any Registration Marks on the web.

STATUS 2, ALARM STATE.

If the GREEN Register Splice ON/OFF Indicator Light is flashing at Equal Intervals, the status has
changed.
This equal interval flash shows that the Registration Mark Sensor has not “found” a continuous
group of Registration Marks. Missed marks could be due to a number of causes.
Check position of the sensor to the marks.
Clean the lens.
“Teach” the sensor again.
Have the Maintenance Department to check the operation of the sensor and the P.L.C.
CONDITIONS:
a). Register Splicing must be selected ON.
b). The web must be running at a speed greater than 25% of normal speed.
c). Registration Marks must be missed for two minutes.
Unless conditions are corrected, the roll will run down and an Automatic Splice will be initiated at the
pre-set diameter.
The Registration Marks will not be used to position the Splice Joint.

115
REGISTER SPLICE TOUCH SWITCH AND Indicator Lamps (B)
The YELLOW Register Mark Confirmation Sensor L.E.D. in the Lower Right Corner will be triggered,
for a short duration, when Register Marks are being “seen”.
In order to make this confirmation of the Registration Marks;
1. The Sensor must be positioned correctly, so that the Light Beam strikes the web, on the
Registration Marks. Move the Sensor, as needed.
2. The sensor must be clean and operating correctly.
3. The web must be unwinding and correctly oriented.
4. The Register Splice Selector Switch must be set to ON.
If you were to attempt to make an “In-Register” Splice without “seeing” any Web Registration Marks,
you will make a splice, but it will not be “In-Register”.
At Splice Time, the computer will be “looking” for a Registration Mark before firing the Splicing Head.
The Splice Cycle will stay in slow-speed mode while it “looks” for a mark. The Dancer will be drawn
up, until the system is shut down or times out to fire the splice.

116
WEB PATH THROUGH SENSOR ASSEMBLY

Web path at sensor (A)

This figure shows the web passing through the Register Mark Sensor Bracket Assembly. Note that
the web passes OVER the first shaft (1), UNDER the middle shaft (2), and OVER the third shaft (3).

Web path at sensor (b)

Web path at sensor (C)

This figure shows the modified web path, when using the Bi-Directional Sensor Bracket
Assembly. The graphic shows the web, as viewed from the Operator Side of the Splicer.

117
The top three shafts of the assembly are used to modify the web path. With the web threaded as
shown above so that web “flutter” is reduced.
If the web were to go between the two rollers without any support, it may move up and down, away
from the

118
Dancer Adjustment.

The dancer rollers must always remain parallel with the fixed top rollers. If a web jam or web
break causes misalignment in the dancer, a level must be used to restore the level by adjusting
the connection of the dancer support belts to the movable dancer system.

The dancer level can be adjusted by loosening the two connection bolts to the Delran belt
connection and adjusting them up or down as needed.

The dancer drive belts can also be tightened if required, using the tightener at the bottom of the
belt course. The lower drive belt sprocket is attached to a pivot bar which acts as a tightening
device. See sensor adjustment section later in the section for information on dancer sensor
adjustment.

119
DRIVE SYSTEM SERVICE
Roll Drive Direction Change.
Roll Drive Belt Reversal.
Roll Drive Belt Replacement.
Roll Drive Bearing Replacement.

NOTE!
THE ROLL DRIVE MAY BE SERVICED, EITHER ON THE SPLICER OR ON A WORKBENCH,
AS YOU PREFER.

This section covers the servicing of the mechanical components of the Roll Drive System. In
addition to information on bearing and belt replacement, this section may be used if the rotation
of the Roll Drive System must be reversed.
NOTE! There are variations in the mounting of the Roll Drive Module, (Surface Drive Assembly)
depending on the size of the rolls that will be running on the splicer. In some versions, the part that
attaches to the Pivot Shaft is integral to the Main Casting of the Roll Drive Module.
In some cases, the Pivot Arm and the Roll Drive Module are separate parts that are bolted together.
They may be taken apart, leaving the Pivot Arm on the Pivot Shaft.
Please review the next few pages and decide what the best method is, for servicing your splicer.
The two Roll Drive Modules are arranged to unwind the webs in the standard direction for that
application as specified with the order.
If a change in unwind direction is required, it can be done by your maintenance department.
NOTE!
IF THE ROTATION OF THE
MOTORS IS CHANGED, THE DRIVE BELTS MUST BE
REVERSED.
THE BELTS MUST DRIVE IN THE DIRECTION OF THE ARROW ON THE BELT, AT ALL
TIMES. WRONG DIRECTION WILL SIGNIFICANTLY SHORTEN THEIR LIFE EXPECTANCY

ARROW ON BELT
At the time the splicer was assembled, there was a visible arrow on the Drive Belt. Over time, the
markings might wear away. BEFORE YOU SERVICE THE MODULE, MARK THE BELT
ROTATION.
If the belt is not driving in the direction of the arrow, it could fail at the splice joint in the belt.
Before performing ANY service on the Drive System:
1. Remove the web from the Festoon.
2. Remove the Rolls and Roll shafts from the Splicer.
3. Lower the Drive Roll Modules to the limits of their Cylinder Travel.
4. Turn off and Lock Out the Compressed Air Supply and the Electrical Power for the Splicer.

DRIVE MOTOR REMOVAL

120
Cut wire ties
Cut any wire ties that are used to hold the motor power cable on the arm and on the Drive Module.
With the wire ties cut, the Upper Motor should be able to be placed on the plate over the Dancer.
The Lower Motor should be able to be placed on the base of the splicer.

Remove bolts
The drive motor is a hollow shaft gear motor. The drive is supported by a flange mount to the drive
casting. Remove the four locking nuts which secure the motor. Four set screws remain in the casting
to secure the flange and spacer. These set screws are lock tighted into place for ease of assembly
and disassembly.

121
Remove the Motor (A).
A. TWO Keys.
With the bolt removed, slide the motor off the pulley shaft.

NOTE!
BE CAREFUL NOT TO LOSE
THE TWO KEYS FOR THE
PULLEY SHAFT.

Store the keys in a safe place, to prevent loss or damage.

CAUTION!
THE MOTOR ASSEMBLY
WEIGHS APPROXIMATELY
19 POUNDS [8.6 KG.].

Remove the Motor (B).

Place the motor in a safe and secure location. For added safety, you should tie the motor in place.

122
Install keys & motor
Install the two keys in the drive shaft keyway.
If needed, pull on the belt to rotate the drive shaft to place the keyway on the top.
Align the keys with the keyway in the motor sleeve and slide the motor onto the drive shaft.

Remove mounting bolts

OPTIONAL: Remove the bolts that are holding the Drive Module onto the Pivot. Remove the Roll
Drive Module from the Splicer.

123
MODULE ON BENCH.
OPTIONAL: Place the Drive module on a workbench.

Drive module disassembly

Without the weight of the motor on the driveshaft, you may disassemble the Drive Module.

Remove the SIDE PLATE screws

Remove the three Hex-Head bolts that hold the side plate to the main casting.
Store the bolts in a safe place, to prevent loss or damage.

124
Bolts removed
With the bolts removed, the side plate may be removed.

Side plate coming off

The main casting and the side plate hold the bearings for the shafts, in precise alignment.
The bearings are pressed onto the shafts and are a slip-fit into the bearing housings in the main
casting and the side plate.
If the side plate cannot be removed by hand, it may be necessary to pry it away from the main
casting.
NOTE!
USE CAUTION WHEN APPLYING FORCE TO THE PARTS OF THE DRIVE MODULE.
DO NOT DAMAGE THE BELT.
DO NOT DAMAGE THE PULLEY FLANGES.
DO NOT DAMAGE THE
CASTINGS.

125
Remove side plate
The side plate will come off and leave the three shafts and their bearings in place.
However, one, or more of the shaft and bearing sets may come out with the side cover. Be prepared
to recover any parts that may be dropped. The side plate will be held by the alignment dowel pins at
each end of the casting. It is recommended that the pulleys are pushed fully back before removal of
the side plate.

NOTE!
AS YOU DISASSEMBLE THE ROLL DRIVE MODULE, MAKE NOTES ON WHAT PART WAS
USED IN WHAT LOCATION.

THE 30” MACHINE USES SPACERS IN THE DRIVE BEARING SEATS.

RETURN THE MODULE TO THE SAME CONFIGURATION ON

ASSEMBLY.

BELT REMOVAL
The drive belt is made with special plies and fibers, to resist stretching. It is covered with Linatex
which is a food grade covering commonly used in form fill seal applications to drive the web. These
belts have a long life, but will need periodic inspection and replacement upon signs of wear.

Belt Removal (A)

The belt is held in the unit by the flanges on the pulleys. There is no significant tension on the belt.

126
Belt Removal (b).
Remove one of the Idler Pulleys by pulling the assembly out of the Bearing Socket. This will free the
belt, for removal.

BELT REMOVAL (C).

BELT REMOVAL (D).

The Drive Belt may now be replaced or reversed.
While the pulleys are accessible, check the security of the set-screws. The set-screws must be
tightened against the flats on the shafts.

127
BELT direction arrow
The arrow on the belt indicates the direction that the belt MUST travel, during operation.
If the roll unwind direction is reversed, by changing the motor rotation, the belt MUST also be
reversed.
If the bearings must be replaced, continue into the next section. If not, re-assemble the Roll Drive
Module.

BELT Replacement (A)

Install the belt, with the arrow facing in the correct direction. Replace the pulley which was removed.

BELT Replacement (A)

Replace casting side plate by sliding it onto dowel pins. Press the casting closed.

128
Secure Casting
Tighten bolts to secure casting cover side plate.

Drive Module ready

Restore the electrical power and air pressure to the splicer and resume normal operation.

BEARING REPLACEMENT

With the belt removed, by following the previous instructions, you may replace the bearings.
If the drive Belts are in good condition and you only need to replace bearings, they may be replaced
now. Bearings should always be replaced in sets of two per shaft. Replacing a single bearing on a
shaft may result in more work, in the long run. All six bearings, within the Roll Drive Module are
identical. There are two short shafts for the Idler Pulleys and a longer shaft for the Driving Pulley.
Assembly of the bearings onto the shafts follows the same procedures for both the Idler Shafts and
the Driving Shaft.

129
Electrical Enclosure.

Any work on the electrical systems of this machine must only be performed by trained and qualified
personnel, taking all precautions to avoid injury or damage to the machine. If any qualified personnel
modify the equipment to perform a functional test, proper precautions must be taken and the
machine must be returned to original state immediately after.
Refer to the electrical schematics and program listing. The electrical enclosure contains:

- A Frequency controller for control of the drive motor- roll is driven at a varying speed to
control dancer position.
- A PLC to control the functions of the machine and different cycles of operation.
- A 24 volt power supply feeding power to the relays and controls required for machine
functions.

Electrical Adjustments

Splicer Interface Circuit Board

Butler Automatic has designed an interface circuit board for use in SP1 product line. Splicer interface
circuit board was designed to accommodate additional non-standard circuits while allowing for one
custom stainless steel electrical enclosure. This circuit board is hard wired to machine control PLC
and to operator touch panel that is mounted on the electrical enclosure. See section on operator
touch panel for operation and description of this panel. The circuitry of the interface board is shown
on the SP1 electrical schematics.

130
Calibrations & Troubleshooting
The PLC has output and input LEDs which can be used to help troubleshoot any problem with
splicer operation. Refer to schematics and other electrical drawings for more information.

Wiring Diagram Excerpt A (PNP)

Wiring Diagram Excerpt B (PNP)

131
 W.O.F. I:0/0
A A A
U U N
X. X. A
L
I O O
PLC N U G
24BWA T

Allen Bradley P.L.C. (pnp) Layout

L.E.D.s for L.E.D.s for

OUTPUTS OUTPUTS
O 0.0  O 0.7 O 1.0  O 1.1

W.O.F. I 0.0

L.E.D.s for L.E.D.s for

INPUTS INPUTS
I 0.0  I 0.7 I 1.0  I 1.5

Siemens P.L.C. Layout

132
 The SP-1 uses PNP Central Processing Units from either Siemens or Allen Bradley for the
P.L.C. computers and associated sensor inputs.
W.I.F. & W.O.F. Sensors
NOTE! In some of the following text and figures, mention is made of “Code Wheels” on the W.I.F.
and W.O.F. Rollers. On later machines, the Code Wheels have been replaced with notched rollers.

W.I.F. Sensor/Roller a
Figure 149 shows a W.I.F. Roller without a Code Wheel.

W.I.F./W.O.F. Roller
This figure shows the end of a new, “notched” roller.
The “notches” serve the same purpose as the teeth on the Code Wheels.
The W.I.F. and W.O.F. Sensors can “see” the difference between metal and no metal on the end
of the rollers, and they create a string of pulses, as the condition changes.
W.O.F. Sensor. 1 SENS.
The W.O.F. (Web Out of Festoon) Sensor is mounted at the end of the LAST Fixed Finger Idler
Roll. A Code Wheel is attached to the roller. The sensor sends out one digital pulse, each time one
of the teeth in the Code Wheel passes in front of the sensor.
The P.L.C. uses these pulses to calculate the speed of the press or process unit.
The sensor has a built-in L.E.D. for troubleshooting. W.O.F. Pulses may also be checked at the
P.L.C.
CALIBRATION: The gap (space) between the sensor and the Code Wheel should be set to
approximately 0.015” [0.38 mm]. The sensor should be centered over the Code Wheel.

W.O.F. Sensor/Code Wheel

W.I.F. Sensor. 10 SENS.

W.I.F. Sensor/Code Wheel

The W.I.F. (Web Into Festoon) Sensor is mounted at the end of the FIRST Fixed Finger Idler Roll.
A Code Wheel is attached to the roller. The sensor sends out one digital pulse, each time one of
the teeth in the Code Wheel passes in front of the sensor.
The P.L.C. uses these pulses to calculate the speed of the web.
The sensor has a built-in L.E.D. for troubleshooting. W.I.F. Pulses may also be checked at the
P.L.C.
CALIBRATION: The gap (space) between the sensor and the Code Wheel should be set to
approximately 0.015” [0.38 mm]. The sensor should be centered over the Code Wheel.
Alternate “Encoder” WIF / WOF Sensors

The first roller in the fixed rollers at the top of the accumulator is the WIF (web into festoon) roller.
This roller is used to calculate the diameter of the unwinding roll by comparing idler roll pulses (541
per revolution) with roll pulses (4 per revolution). This comparison allows us to quickly calculate the
actual diameter of the unwinding roll for precise speed control of the unwinding roll. The last roller
in the fixed rollers at the top of the accumulator is the WOF roller (web out of festoon). This roller
picks up pulses to give a precise reading of process speed. The roll surface drive follows the
process speed during normal run conditions.

W.I.F. & W.O.F. Sensors

This splicer uses “Ring Magnets” for W.I.F. & W.O.F. Sensors. This newer system provides higher
resolution for W.I.F. and W.O.F. Signals.

W.I.F. Sensor/”Ring MAGNET”

In addition to the higher resolution, the direction of web movement can be monitored.

NOTE: Consult the Wiring Diagrams for your splicer, as needed.

CALIBRATION: The gap (space) between the sensor and the “Ring Magnet” must be set to.03” [.8
mm]. The sensor must be centered over the Code Wheel.
“Ring Magnet” Sensor Calibration
Dancer Sensors.

Dancer Sensors
Dancer sensors are used to verify the location of the dancer and change the drive output state in
the program. The dancer sensors have a range of 4 mm and are normally set at .020 - .030”.

The top dancer sensor senses that the splicer has run out of storage and thus must stop the
process.

The dancer has two lower sensors. When the dancer is above these sensors, the PLC gives the
drive a command to run at 15% faster than the process. When the dancer reaches the top sensor
a signal to match process speed is given to the drive. When two sensor are actuated the unwind
speed is slowed by 15%. When the lower sensor alone reads, the roll is stopped. If the unwind
output speed causes the web to be unwound either slightly too slow or too fast, the error is slowly
integrated into the control output speed to correct for this.
The Wiring Diagrams contain a table and a drawing, which explain the purpose of 2SENS (Sensor
“A”, Upper Dancer Sensor) and 3SENS (Sensor “B”, Lower Dancer Sensor). There are three
sensors (2, 3, 7 SENS) that are used to monitor the position of the Dancer. A Steel Bar “Target” on
the Dancer Side Plate is used to “trigger” the Sensors.
2 Sensor and 3 Sensor are at the BOTTOM of the Dancer travel. 7 Sensor is at the TOP of the
Dancer travel.
Dancer “Zone” Sensors. 2, 3 SENS.

Dancer “ZONE” sensors. 2, 3 SENS.

Using the signals from these two sensors, the P.L.C. will speed up, slow down or stop the Running
Roll Drive Motor, as needed.
The sensors have built-in L.E.D.s for troubleshooting. 2SENS and 3SENS outputs may also be
checked at the P.L.C.
CALIBRATION: The gap (space) between the sensors (White Arrows) and the target (Black Arrow)
should be set to approximately 0.02” [0.38 mm]. The vertical spacing of the sensors and the target
is determined by their attachment to the splicer and should not be changed.
Dancer “empty” Sensor. 7 SENS.

Dancer “empty” sensor. 7 SENS.

7SENS monitors the Top-Most position of the Dancer travel.
If the Dancer Target reaches 7SENS, the Dancer is about to run out of storage. A signal will be
sent out, that will stop the press or process unit.
Under normal conditions, the Dancer should be DOWN, at the area of 2SENS and 3SENS, except
during the Splice Cycle.
Actuation of 7SENS indicates an abnormal condition.
The sensor has a built-in L.E.D. for troubleshooting. 7SENS may also be checked at the P.L.C.
CALIBRATION: The gap (space) between the sensor and the target should be set to approximately
0.015” [0.38 mm]. The vertical spacing of the sensor and the target is determined by their
attachment to the splicer and should not be changed.
Auto-Splice/Imminent Sensors

Roll diameter Auto-Splice sensor System

If your splicer is equipped with the Roll Diameter Auto-Splice System, there will usually be two
sensors for each roll position, mounted in brackets, on the splicer side frame. The arrow points to
the sensors and the oval outlines the Threaded Rod and Collar.

1 2

Roll diameter Auto-Splice sensors

1. Auto-Splice.
2. Splice Imminent.

In the standard, dual sensor arrangement, the sensors will be arranged as shown in Figure 156.
If your splicer is equipped with the Roll Core Detector Auto-Splice System, the sensor bracket
will only have a single sensor. This single sensor will be used as the Splice Imminent Sensor.
5SENS (Upper) or 6SENS (Lower) are used to initiate an Auto-Splice sequence before the web
runs off the Running Roll Core.
A “trigger” arm, made from a length of threaded rod, is attached to the pivot shaft for the Roll
Drive Module.

Rod and 2 sensors

As the Roll Diameter decreases, the Roll Drive Module pivots, to follow the outside diameter of the
Running Roll.
As the Roll Drive Module pivots, the locking collar and support rod move also.
When the rod swings down to the area in front of the sensor, a signal is sent to the P.L.C.
The position of the arm and thus autosplice diameter is adjusted by loosening the clamp collar and
rotating the pivot shaft to actuate at the correct diameter.
1). The rod goes through the collar and bottoms out against the pivot shaft. The threaded rod
secured to the collar and pivot shaft with hexagon nuts.
There are two additional nuts on the threaded rod.

Locking Collar
The rod/split collar assembly is secured to the Pivot Shaft by tightening a socket head cap screw
which squeezes the split collar onto the pivot shaft.

The Upper and Lower sensors are enabled separately. When the Upper Roll is running, the
5SENS (Upper) is enabled through Line 40. Line 41 will only enable 6SENS (Lower) when the
Lower Roll is running.
The sensors have built-in L.E.D.s for troubleshooting. Both sensors may also be checked at the
P.L.C., one at a time. Select the Upper Roll as the Running Roll to check 5SENS. Select the Lower
Roll as the Running Roll to check 6SENS.
CALIBRATION: The gap (space) between the sensor and the end of the threaded rod should be set
to approximately 0.015” [0.38 mm].
The Sensor is adjustable (in and out) in its’ bracket, and the bracket allows for some up and down
adjustment.

SETTING THE AUTO-SPLICE DIAMETER.

Create a roll of the desired Auto-Splice Diameter, by any convenient method.
Such As: stripping a previously used roll down to the correct diameter.
OR
Wrap an empty core with some type of material.
Install the sample roll in the splicer, and lower the Roll Drive Module onto the roll.
Adjust the “trigger” arm, as described on the preceding page, to turn on the L.E.D. in the sensor body.
This setting will be the Auto-Splice Initiation Point. During operation, the Roll Drive Module will pivot
down, toward the Roll shaft, as the roll gets smaller. When the correct diameter is reached, the signal
from the Auto-Splice Sensor will start the Splice Cycle.
THE AUTO-SPLICE DIAMETER MAY BE RESET AT ANY TIME. REMEMBER TO CHECK
THE SETTING IF THE ROLL CORE
DIAMETER IS CHANGED.

Splice Imminent Alarm

A “FLAG” is mounted on the rod/split collar assembly. The Splice Imminent Alarm Sensor is
mounted further out of the bracket than the Auto-Splice Diameter Sensor. The Splice Imminent
Alarm Sensor should be set to trigger, at a roll diameter that is larger than the Auto-Splice
Diameter. Actuation of this sensor will provide a 3-second signal, out of the Butler Controls, to
whatever alarm device is attached.

3 4

Rod, flag & 2 sensors

1. Threaded Rod.
2. Splice imminent flag.
3. auto-splice sensor.
4. splice imminent sensor.

The figure shows the “FLAG” on the rod that is used to trigger the Splice Imminent and
autosplice Sensors.
The angle of the splice imminent flag 2 Rotate the Flag, to actuate the Splice Imminent Sensor,
before the Auto-Splice Diameter is triggered.

SPECIAL OPTIONS:
On request, Butler Automatic Inc. can supply some SPECIAL, OPTIONAL features as original
equipment or as retrofit packages.

Stack Lights
Splicer equipped with a three (3) color stack light. Lights are controlled by splicer PLC and
powered from 24VDC power supply. The stack light will be located with the bottom light at a
minimum height of six feet. The color code for stack lights will conform to the following:

Color Light Function

Red On Solid E-Stop, Fault/Alarm, Not
Ready to Run

Flashing Red Low Materials Splice

Imminent and Splice Not
Prepared

Amber On Solid Splice Prepared

Flashing Splice Imminent

Green On Solid Ready To Run

Ethernet/IP interface

Splicer enclosure will have an external GFCI convenience receptacle and PLC Programming port
(Ethernet/IP) for Programming of the PLC without requiring that the door be opened. This GFCI will
be protected by a circuit breaker. Communication interface module Allen Bradley 1761-NET-ENI
will be installed in the electrical enclosure to allow Ethernet/IP communication to the Micrologix
1500 PLC.

Adjustable Force Vacuum

Vacuum for holding the web in the SP1 Splicer may be supplied by different sources.
Standard Vacuum on an SP1 Splicer is created by applying compressed air to a Vacuum Venturi
Valve.
The splicer may also be connected to a central source of Vacuum, in the plant.
Vacuum Pumps may be used to create Vacuum, at the splicer.
Among the available SPECIAL OPTIONS, is an Adjustable Force Vacuum Pump.
If high vacuum force is applied to light webs, the web could become distorted on the Splice
Preparation Bar, causing sealing problems.
The ability to adjust the force of the vacuum that is applied to the new web, during Splice
Preparation, may be an advantage, on very light or very flexible webs.
VACUUM PUMP ON SP1 SPLICER
The SPECIAL OPTION Adjustable Vacuum Pump is located on the Operator Side of the SP1
Splicer.

PUMP CONTROL BOX

The box below the SP1 Control Cabinet contains the motor controls for the Rotary-Vane Vacuum
Pump.
VACUUM PUMP
The Rotary-Vane Vacuum Pump is connected to the Vacuum Select Solenoid Valve, through
plastic tubing.
The Vacuum Select Solenoid Valve is used to deliver vacuum to the section of the splicing Head
opposite the running roll.

VACUUM ADJUSTMENT KNOB

If you cannot hold the web, in the Splicing Head, turn the Adjustment Knob CLOCKWISE, to
increase the Vacuum Force.
If the web in the Splicing Head is badly distorted when it is on the Splice Preparation Bar, turn the
Adjustment Knob COUNTER-CLOCKWISE, to decrease the Vacuum Force.
The MAXIMUM Vacuum Force that is available from the Rotary-Vane Vacuum Pump is –0.86
bar/25 Inches Water Column.
DO NOT LUBRICATE THE VACUUM PUMP!
There is a decal on the motor, which contains service instructions. Follow the instructions to clean
the filter, periodically.

Low Air Pressure Switch

This switch is a passive system which signals the splicer should the input air pressure ever drop
below 60 PSI. If the air pressure drops below 60 PSI, the blue low air pressure indicator light will
flash in the stack light.
SYSTEM FAULTS

ADDITIONAL L.E.D. INFORMATION.

In addition to the normal ON/OFF status of the L.E.D.s on the Operators’ Panel, some of the
L.E.D.s will FLASH, to alert the operator to some unusual conditions.

SYSTEM FAULT INDICATOR

System Fault Indicator Lamp

The System Fault Indicator (RED L.E.D.) is located above and to the left of the Butler Logo.
IF THE “FAULT” INDICATOR IS OFF, THE MACHINE STATUS IS NORMAL.
Under normal conditions, the System Fault Indicator will be OFF.
“FAULT” Indicator FLASHING.
STATUS – ALARM.

The System Fault Indicator will be flashing ON/OFF at ½ Second Intervals, when an abnormal
condition has been detected.
At the same time, the indicator starts flashing, the “Splicer is OK.” Signal, to the Press/Process
Line, will drop out.
When the OK. Signal drops out, the line should stop.

FAULT CONDITIONS

A Fault is reported when:

a). There is an alarm signal from the Roll Drive Motor Controller to the P.L.C.
WHAT TO DO: CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE.
b). A Web Break has been detected. If the web breaks, the Dancer will drop to the bottom
and the Dancer “B” Sensor will send a signal to the P.L.C.
WHAT TO DO: RE-WEB THE SPLICER AND START AGAIN.
c). The Dancer is near the top of its’ travel. The “Dancer Empty” Sensor will send a signal
to the P.L.C.
If the roll cannot turn easily, the web cannot unwind properly. The Dancer will be pulled up and the
“Dancer Empty” Sensor will switch states.
WHAT TO DO: Fix : CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE. Resolve
reason for fault and press reset button.
The operator interface will also give an output of the actual fault the splicer is experiencing. The
following fault messages will output from the Operator interface.

ALARM / FAULT States:

The red fault indicator light will flash if the splicer is in a fault state.

Drive Not Ready: Indicates that the motor drive has a fault which must be corrected. Press Reset
to clear. If it does not immediately clear, press E-Stop wait 20 seconds and then remove E-Stop
and press reset.

Dancer Empty: Signals that the accumulator is empty and has reached its top stop. Release the
running roll drive and let enough film unwind so that the dancer drops below the top of travel
sensor, return the roll drive onto the roll surface, press reset. The splicer will refill and be ready to
run.

Web Break : The web has broken, causing the dancer to drop to the bottom stops. Web up the
machine and press reset to put the splicer back into the ready state.

E-STOP: The E-Stop button has been pressed, triggering the E-Stop of the machine. Disengage
the E-Stop switch and press reset. The splicer is then back in the ready state.

Register Mark Fault : This fault shows that the splicer is not properly reading the register marks
on the film when register splice has been selected. The splice ready light on the operator touch
panel will now flash until the fault is corrected. If the fault is not corrected at autosplice diameter,
the splicer will actuate a splice after it has timed out during the splice cycle search mode. The fault
must be corrected (verify eye is correctly positioned, printed register marks are OK, eye is clean,
or reset register eye) This fault automatically clears when the register eye starts working again.
Splice not ready: This signals that the splice head is open or has not been opened at all and that
the preset splice diameter has been reached. The splicer ready signal is removed causing the
process to stop. The splice must now be prepared in the splice head and reset must be pressed.
When the process is restarted an Automatic splice will be made.

first. If this clears the other faults, they will go away. If not each fault will be cleared in sequence.
List of Checks and Periodic Maintenance

The following presents the different precautions, verifications and checks required to keep your
splicer in good running condition. Upon verification and cleaning and maintenance of the
production line, particular attention should be paid to the following points:

Cleaning : Due to the open nature of the machine design, it is normal that a certain amount of
dust may accumulate. A periodic cleaning of the machine is therefore required. Particular attention
should be paid to vacuum each of the four zones within the splicer, including the upper and lower
roll enclosures, register sensor zone and festoon zone. This cleaning must be done after each 50
– 100 hours of operation.

VERIFICATION :

-Splice Head : (Every ~200 hours) Visual control of the splicer nips (condition of nips and
adhesion of silicone rubber pads), inspection of two knives for upper and lower cut, verify free
movement of knife carriage assembly, verify movement and return of knife pivot assemblies. It is
necessary to change the knives after approximately 1500 hours of operation depending on
material, or if the knife fails to cut.

Verification of good function of all pneumatic circuits is required after 500 hours. Verification
includes air leaks, function of valves, function of cylinders, and good function of vacuum system.
At the same time function of the mechanical pivot rollers at the front of the splice head, free
movement of the two halves of the splice head and visual inspection for lose or misaligned items
should be performed.

- Register sensor : At the start of each shift, the proper position of the register sensor and the
cleanliness of the lenses should be checked.

- Festoon : (Every 200 hours) Block the web into the festoon and pull the web to raise and lower
the dancer rollers, verifying free movement of the dancer system. If the dancer is not free moving,
the pulleys and bearings may be adjusted. The level is adjusted through the connection of the
belts to the dancer. Verify (every 500 hours) the condition of the idler rollers and free rotation of the
roller bearings.

- Roll shafts : (Every 200 hours) Verify proper function and verification that the core adapters do
not have excess wear.

- Electrical Enclosure : (Every 1000 hours) Visual control of all electronic Components.
Frequency of Control and Cleaning Operations

Shift 100 h 200 h 500 h 1000 h

General Cleaning / X

Splice Head Checks X

-Nip bars X
- Knife support assembly X
- Knife clinder X
- Change knives X
- Pneumatic functions X
- Mechanical functions X

Register Sensor Checks

- Position and cleanliness X

Festoon Checks
- Guides and dancer movement X
- Idler rollers and bearings X

Check Roll Shaft

- Pivot and lift assembly X
- Core Adapters for wear X

Check Electrical Enclosure

- Inspect all components X
APPENDIX A- GENERIC SPLICER TERMS GLOSSARY
While using this manual or discussing Butler products with technical support, you may see
some terms or part names that are not familiar to you, or some of the terms may be used in a
different manner than you are accustomed to. Most definitions reflect their usage within the
Butler Automatic Inc. Splicers. Definitions enclosed in quotation marks are dictionary
definitions.

ACCELERATOR SYSTEM: The control, drive, motor, and rollers that are used to pull on the
Web to get the New Roll up to speed. This system is typically used in large roll over roll zero
speed splicers.
ACCUMULATOR: This refers to the material buffer which feeds the process during the splice
cycle. This system is made from web running over fixed rollers to the moveable dancer rollers.
The system is also referred to as the festoon.
AUTO-SPLICE: When the Control calculates that the Running Roll has unwound down to a
pre-determined size, an Auto-Splice command is issued to start the Splice cycle.
BRAKE SYSTEM: The group of controls and components used to apply Braking Torque to
the roll. The Butler brake system is a dual disc ventilated brake oversized for the application
and thus very reliable for many years of trouble free service.
BRAKING TORQUE: The force applied to the roll of material to control its speed in order to
apply tension to the web and control unwind velocity.
BUTT ROLL: A term used to describe a roll of material usually smaller than 10 in diameter.
BUTT SPLICE: A term used to describe a splice made with tape on one side without any
overlap of the material being joined.
CORE ADAPTER: This term refers to the Delran adapters used on the SP-1 splicer to support
the unwinding roll on the roll support shaft.
CORE SHAFT: This term refers to the pneumatic shaft or arbor used to support the roll of
unwinding material.
CORE SPLICE: Refers to the system added to enable the splicer to actuate a splice when the
last wrap of film on the unwinding roll is reached.
DANCER: The vertically movable carriage containing a number of rollers that are used with
the Fixed Fingers to form the Festoon (accumulation).
DANCER NESTED: The term used in a 1000 style splicer when the dancer is nested in the
festoon and ready to have a new web passed through.
DANCER OSCILLATION: Random, apparently uncontrolled movement of the Dancer during
a normal run is called Oscillation.
DANCER RUNNING POSITION: The position which the machine commands the dancer to
run at during normal unwinding and running of a roll.
DECELERATION BRAKE: The amount of Braking Torque applied to the Running Roll,
during the Splice Cycle, to bring the roll to Zero Speed in order to make the Splice.
EXPIRED ROLL: The roll of material that has just been cut off by the Splicing Head.
FESTOON: The ribbons of web that are formed when the Dancer moves away from the Fixed
Fingers. This web storage is used to keep the press running at normal speed during the Splice
Cycle. Festoon, a string or garland hung in a loop between two points. The festoon is another
name for the entire system which makes up the accumulator.
FIXED FINGERS: The NON-movable section of rollers that are used with the Dancer to form
the Festoon.
HOLDING BRAKE: The amount of brake force applied to the Standby Roll.
IDLER ROLLER: The passage rollers used in the system to pass the web through. These are
typically very light low inertia idlers with special low break away force characteristics.
INCOMING ROLL: See New Roll.
INERTIA: 1. Physics. The tendency of a body to resist acceleration, as the tendency of a body
at rest to remain at rest or of a body in motion to stay in motion in a straight line unless
disturbed by an external force. 2. Resistance to change or motion.
L.E.D. (Light Emitting Diode): An electronic component designed to illuminate when power is
applied to it. As used in the Butler Splicer, a single circular lamp or an array of lamps arranged
in a line. By energizing some or all of the arrays in a pattern, a recognizable letter or number
will be displayed.
LIFT AND LOAD: The pneumatic device used to lower the upper shaft position on an SP-1
splicer down to an ergonomic loading and unloading height.
MANUAL SPLICE: When the operator wishes to splice out of the Running Roll, before an
Auto-Splice command is issued, DATAMAT has the ability to accept a Manual Splice
Command.
M.I.S. (Management Information System): This term is used to describe the information about
roll usage, roll running times, roll weights and numbers as reported by
NEW ROLL: The roll of material that is waiting to be spliced into the Running Roll during the
Splice Cycle.
OLD ROLL: The roll of material that is no longer connected to the press. (See Expired Roll,
Butt Roll).
PLC: Programmable Logic Controller- Refers to the purchased computer which runs the
splicer. Typically either a Siemens or Allen Bradley Device.
POWER SUPPLY: A component used to convert standard 120 Volt A.C. electricity to some
lower voltage D.C. level.
REWINDER: Refers to a machine made to rewind material to create rolls which can then be
unwound into secondary processes.
ROLL DRIVE SYSTEM: This refers to the motor and drive system and integral air shaft
which serve as the fixed connection with the unwinding roll as well as the drive which turns
the roll for unwind.
ROLL SENSOR: An electronic switch, used by DATAMAT to count the revolutions of the
Running Roll, for calculations of Running Roll Size.
ROLL SHAFT: The shaft through the roll of material that is used to support the roll while in
the splicer. The Roll shaft grips the inside of the Core that the material is wound around so that
motor power may be transmitted to the roll of material. The Roll shaft may be supplied by
various manufacturers and may operate differently as designed by the manufacturer.
ROLL SHAFT COUPLING: The device at the end of the Brake shaft that couples or connects
the Roll shaft to the Brake shaft.
ROLL SHAFT SUPPORTS: The area of the machine that the Roll shaft rests on while it is in
the machine.
ROLL SHAFT HOLDDOWNS: The devices used to keep the Roll shaft secure on the Roll
shaft Supports.
RUNNING BRAKE: The Braking Torque applied to the Running Roll.
RUNNING ROLL: The roll of material that is presently connected to, and supplying web to,
the press.
SIDELAY: The action of moving the position of the roll across the centerline of the press for
web positioning.
SIDELAY SYSTEM: The group of controls and components that are used to move the roll of
material across the press centerline for positioning the web.
SPEED MATCH: Any time that the Running Roll is unwinding at the same linear speed as
web is being drawn out of the Festoon. Also, during the Splice Cycle, the time when the New
Roll has been accelerated up to Speed Match and the Dancer stops falling. Speed match can
also refer to a turret style splicer which makes a splice at speed without an accumulator by
matching the speed of the new roll with the old roll and making an on the fly transfer to the
new web which has adhesive applied.
SPLICE: The action of sealing the running web to the leading edge of the New Roll and cutting
off, or severing, what has become the old web.
SPLICE CYCLE: The sequence of events that makes the Splice happen.
SPLICING HEAD: The portion of the machine that seals the leading edge of the new,
incoming roll to the old, running roll and cuts off (severs) the old web when required. This is
where the operator prepares the new roll leading edge for splicing.
STANDBY ROLL: See New Roll.
REWINDER: This is a splicer used to rewind paper and make splices. Also called an automatic
turret rewinder.
TRAM (TRAMMING): Aligning parts to precise parallel measurements.
TRANSDUCER: A device that converts one type of energy to another type. As used in the
Butler Splicer, a Transducer converts an Electronic signal to Pneumatic pressure for use by the
Brake System and Dancer Control System.
VACUUM SYSTEM: As used in the Butler Splicer, the High Volume, Low Pressure Blower
and associated tubing and valve that applies Vacuum to the Splice Preparation Bars in order to
hold the leading edge of the New Roll in place for splicing.
VERTICAL FORM FILL SEAL: The name for the type of packaging machine which has the
web fed through it and then down a forming tube to be filled and cut into sealed bags.
W.I.F. SENSOR: The W.I.F. (Web Into Festoon) Sensor is an electronic switch used by
PLC controls to count the pulses per revolution of an idler roll turned by the web as it enters
the Festoon. This information along with the Roll Sensor information, is used by the control to
calculate the size of the Running Roll and other calculations.
WEB GUIDE: Refers to the system used to keep the running web in alignment with a fixed
reference point.
ZERO SPEED SPLICER Refers to an automatic splicer which performs the roll change while
the web is brought to a stop and the process is fed from an integrated accumulator. The process
never is stopped for this type of splice, only the actual splice joint is made at zero speed for
excellent reliability and consistency of splicing.