MUTOH Unwinder Maintenance Manual

Mutoh’s Roll Systems

Unwinder / Winder 100

Winder 30

Maintenance Manual

MUTOH EUROPE N.V.

AP-74100, Rev : 2.0, 13/01/2005

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AP-74100, Rev. 2.0, 12/01/05

Roll systems – Maintenance Manual

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AP-74100, Rev. 2.0, 12/01/05

COPYRIGHT NOTICE

This document may not be reproduced by any means, in whole or in part, without written permission of the

copyright owner.

This document is furnished to support the Mutoh’s Unwinder / Winder 100, Unwinder 100 / Winder 30. In

consideration of the furnishing of the information contained in this document, the party to whom it is given,

assumes its custody and control and agrees to the following:

The information herein contained is given in confidence, and any part thereof shall not be copied or

reproduced without written consent of Mutoh Europe N.V.

This document or the contents herein under no circumstances shall be used in the manufacture or

reproduction of the article shown and the delivery of this document shall not constitute any right or license to

do so.

January 2005

Published: Mutoh Europe N.V., Archimedesstraat 13, B-8400 Oostende, BELGIUM

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Important Notice

This product has been tested and found to comply with the limits for a Class A digital device, pursuant to Part

15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference

when the product is operated in a commercial environment.

This product generates, uses, and can radiate radio frequency energy and if not installed and used in

accordance with this manual, may cause harmful interference to radio communications. Operation of this

product in a residential area is likely to cause harmful interference in which case the user will be required to

correct the interference at his expense.

1. Radio interfere

Product generates weak radio signals and may interfere with television reception and utilities. If a

product does interfere with radio or TV reception, try following:

¾ Change the direction of your radio and TV reception antenna or feeder.

¾ Change the direction of the product.

¾ Move either the product or the receiving antenna so there is more distance between them.

¾ Be sure the product and the receiving antenna are on separate power lines.

2. Trademark mentioned in this manual.

¾ MUTOH is a registered trademark or product name of MUTOH INDUSTRIES LTD.

¾ Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer

Corporation.

¾ Other company and product names may be registered trademarks or product names.

No part of this product or publication may be reproduced, copied or transmitted in any form or by any means,

except for personal use, without the permission of MUTOH EUROPE N.V.

The product and the contents of this publication may be changed without prior notification.

MUTOH EUROPE N.V. has made the best efforts to keep this publication free from error, but if you find any

uncertainties or misprints, please call us or the shop where you bought this equipment.

MUTOH EUROPE N.V. shall not be liable for any damages or troubles resulting from the use of this

equipment or this manual.

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TABLE OF CONTENTS

1. SAFETY INSTRUCTIONS............................................................................................................................. 9

1.1. INTRODUCTION ......................................................................................................................................... 9

1.2. WARNINGS, CAUTIONS AND NOTE.............................................................................................................. 9

1.3. IMPORTANT SAFETY INSTRUCTIONS............................................................................................................ 9

1.4. WARNING LABELS ................................................................................................................................... 10

2. PRODUCT OVERVIEW................................................................................................................................11

2.1. INTRODUCTION ....................................................................................................................................... 11

2.2. PART NAMES AND FUNCTIONS.................................................................................................................. 11

2.2.1. Unwinder / Winder 100..................................................................................................................................11

2.2.2. Operation panel unwinder/winder 100...........................................................................................................12

2.2.3 Winder 30 .......................................................................................................................................................13

2.2.4. Operation Panel Winder 30 ...........................................................................................................................14

2.2.5. Unwinder 100.................................................................................................................................................15

2.2.6. Operation Panel Unwinder 100......................................................................................................................16

3. PARTS REPLACEMENT ............................................................................................................................ 17

3.1. INTRODUCTION ....................................................................................................................................... 17

3.2. REMOVAL ON THE OPERATION PANEL ....................................................................................................... 18

3.2.1. Replace the operation panel cover................................................................................................................18

3.2.2. Replace the operation panel PCB box...........................................................................................................19

3.2.3. Connecting the PCB board operation panel with the operation panel............................................................20

3.3. REMOVAL OF THE PCB BOX OF THE UNWINDER/WINDER 100..................................................................... 21

3.3.1. How to replace the power supply board.........................................................................................................21

3.3.2. How to replace the PCB board of the PCB box .............................................................................................23

3.3.3. How to replace the power supply connector..................................................................................................24

3.3.4. Connections in the PCB box..........................................................................................................................26

3.4 REMOVAL OF THE PCB BOX OF THE WINDER 30......................................................................................... 27

3.5. REMOVAL ONTO THE TENSIONING SYSTEM................................................................................................ 29

3.5.1 Replacing the sensor assy..............................................................................................................................29

3.5.2 Connecting the sensors..................................................................................................................................31

3.6. REMOVALS ONTO THE ROLL UNIT ............................................................................................................. 32

3.6.1. Replacing the core cone of the roll unit..........................................................................................................32

3.6.2. Replacing the core cone of the motorized roll unit.........................................................................................33

3.6.3. Replacing the motor in the motorized roll unit................................................................................................34

3.6.4. Connecting the motor ....................................................................................................................................35

3.7 REPLACEMENT OF THE SCROLLER ASSEMBLY ............................................................................................ 36

3.7.1. Replacing the scroller R assembly.................................................................................................................36

3.7.2. Replacing the scroller L assembly.................................................................................................................37

4. ADJUSTMENTS.......................................................................................................................................... 39

4.1. SENSOR (TENSION BAR) ADJUSTMENT UNWINDER/WINDER 100.................................................................. 39

(ONLY APPLICALBE FOR SYSTEMS MANUFACTURED BEFORE YEAR 2005)......................................................... 39

4.1.1. Understanding the principles of the sensors..................................................................................................39

4.1.2. Adjust the sensors of the front tensioning bar................................................................................................40

4.1.3. Adjust the sensors of the rear tensioning bar ................................................................................................42

4.1.4. Sensor disc and adjustment direction............................................................................................................45

4.1.5. Angle mark front tensioning system...............................................................................................................46

4.1.6. Stop Sensor Position.....................................................................................................................................46

4.1.7. Start Sensor Position.....................................................................................................................................47

4.2. SENSOR (TENSION BAR) ADJUSTMENT UNWINDER 100 / WINDER 30........................................................... 48

(ONLY APPLICALBE FOR SYSTEMS MANUFACTURED BEFORE YEAR 2005)......................................................... 48

4.2.1. Understanding the principles of the sensors..................................................................................................48

4.2.2. Adjust the sensors of the rear tensioning bar ................................................................................................49

4.2.3. Sensor disc and adjustment direction............................................................................................................51

4.2.4. Stop Sensor Position.....................................................................................................................................51

4.2.5. Start Sensor Position.....................................................................................................................................52

4.3 CALIBRATION OF THE UNWINDER 100 AND WINDER 100.............................................................................. 53

4.3.1 Calibration of the rear tensioning system........................................................................................................53

4.3.2 Calibration of the front and rear roll unit..........................................................................................................56

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5. APPENDIX................................................................................................................................................... 59

5.1. INTRODUCTION ....................................................................................................................................... 59

5.2. WIRING DIAGRAM ................................................................................................................................... 59

5.3. EXPLODED VIEWS................................................................................................................................... 60

5.3.1 Assembling unwinder/winder 100...................................................................................................................61

5.3.2 Assembling unwinder 100/winder 30..............................................................................................................78

5.3.3 Unwinder 30 ...................................................................................................................................................99

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1. SAFETY INSTRUCTIONS

1.1. INTRODUCTION

This chapter explains the meaning of safety terms for personnel who operate this equipment and important

safety instructions.

Important :

• Be sure to follow all instructions and warnings in this manual when using the

equipment.

1.2. WARNINGS, CAUTIONS AND NOTE

Safety terms in this manual and the contents of warning labels attached to the printer are categorized into

the following three types depending on the degree of risk (or the scale of accident).

Read the following explanations carefully, and follow the instructions in this manual.

Safety terms Details

Important Must be followed carefully to avoid death or serious bodily injury.

Caution Must be observed to avoid bodily injury (moderately or lightly) or damage to your

equipment.

Note Contains important information and useful tips on the operation of your printer.

1.3. IMPORTANT SAFETY INSTRUCTIONS

General safety instructions that must be observed to use the equipment safely are explained below.

¾ Do not stand on or place heavy objects on the unit. Doing so may result in the unit tipping or

falling over and causing injury.

¾ Do not attempt to plug in electrical plugs with wet hands. Doing so may result in electrical shock.

¾ Do not use thinner, benzene, alcohol or other active agents. Doing so may result in damage or

paint peeling from the casing.

¾ Be careful not to spill water inside the printer. Doing so may result in a short circuit.

¾ Never open the covers fixed with screws. Doing so may result in electrical shock or a

malfunctioning in the unit.

¾ When setting roll media, place it on top of a desk or other flat surface. Setting roll media with the

scroller standing up may damage them.

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1.4. WARNING LABELS

The handling, attachment locations and types of warning labels are explained below.

Warning labels are attached on areas which require attention. Read and understand the positions and

contents thoroughly before performing your work.

Be sure to note the following when handling the labels.

Notes :

• Make sure that all labels can be recognized. If text or illustrations cannot be seen

clearly, either clean or replace the label.

• When cleaning labels, use a cloth with water or neutral detergent. Do not use a

solvent or gasoline.

• If a warning label is damaged, lost, or cannot be recognized, replace the label.

When replacing warning labels, contact your local MUTOH dealer.

Foot switch label unwinder 100

Roll unit handle label unwinder 100

Rear tensioning label unwinder 100

Front tensioning label unwinder 100

Paper guide label unwinder 100

PCB box label unwinder

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2. PRODUCT OVERVIEW

2.1. INTRODUCTION

This chapter explains the features, part names and functions of the printer.

2.2. PART NAMES AND FUNCTIONS

Part names and functions are explained below.

2.2.1. Unwinder / Winder 100

Part names and functions are explained below.

No. Name Function

1 Roll-Off System This is the device that sets the media when using roll media and feeds it to

the printing position.

2 Rear Tension system Adjust the tension of the media between the roll-off system and the media

feed slot.

3 PCB Box Contains the boards to control the unwinder / winder 100.

4 Rail Assembly Carries the roll units.

5 Motorized roll unit Supports the roll media.

6 Roll unit Supports the roll media.

7 Roll-off foot switch This switch is used to roll-up or roll-off roll media of the unwinder 100.

8 Front Tension System Adjust the tension of the media between the paper guide and the roll-up

system.

9 Roll-Up System This is the device that collects the media when using roll media.

10 Operation Panel This panel is used to set operational conditions, and the status of the product.

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2.2.2. Operation panel unwinder/winder 100

The operation panel is used to set operational conditions.

No. Name Function

A / Part of the operation panel controlling the unwinder 100.

B / Part of the operation panel controlling the winder 100.

1 Print Side Selector

In case you loaded media with printed side on the outside select

‘OUT’, otherwise select ‘IN’.

2 Unwinder 100 power ON Toggle between Manual and Automatic mode.

Manual

3 Unwinder 100 LED

Automatic

LED lights up when pushing one of the buttons

Motor turns: LED flashes.

Motor is off : LED is out.

Outside printing Inside printing

4 Backwards button Roll-off unwinder Roll-up unwinder

5 Forwards button Roll-up unwinder Roll-off unwinder

6 Winder 100 power ON Power ON or OFF the winder 100.

Manual

7 Winder 100 LED

Automatic

LED lights up when pushing one of the buttons

Motor turns: LED flashes

Motor is off: LED is out.

Outside printing Inside printing

8 Backwards button Roll-off winder Roll-off winder

9 Forwards button Roll-up winder Roll-up winder

10 Power LED Lightens up the system is powered ON.

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2.2.3 Winder 30

No. Name Function

1 Winder 30 motorized unit Winds and collects the printed roll media.

2 Media sensor Detects the printed media.

3 Scroller receiver Loads the scroller for the winding unit.

4 Power switch Turn the product ON and OFF.

5 Operation Panel This panel is used to set operational conditions, and the status of the product.

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2.2.4. Operation Panel Winder 30

The operation panel is used to set operational conditions and to check / display the status of the product.

(1) Operation switches

No. Name Function

1 AUTO switch Used to automatically wind the roll media.

→ Forward : When the media sensor detects the media, the

scroller automatically rotates forward. The media is wound with

the printed side at the outside.

→ OFF : Used when operating the MANUAL switch.

→ Backward : When the media sensor detects the media, the

scroller automatically rotates backward. The media is wound with

the printed side at the inside.

2 MANUAL switch The winder system is manually operated.

→ Forward : The scroller rotates forward.

→ Backward : The scroller rotates backward.

(2) Status Lamp

No. Name Status Function

ON The product is ON.

Waiting

Flashing An error has occurred.

3 SENSOR lamp

OFF The product is winding the media.

The product is OFF.

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2.2.5. Unwinder 100

No. Name Function

1 Roll-Off System This is the device that sets the media when using roll media and

feeds it to the printing position.

2 Rear Tension system Adjust the tension of the media between the roll-off system and

the media feed slot.

3 PCB Box Contains the boards to control the unwinder 100.

4 Rail Assembly Carries the roll units.

5 Motorized roll unit Supports the roll media.

6 Roll unit Supports the roll media.

7 Roll-off foot switch This switch is used to roll-up or roll-off roll media of the unwinder

100.

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2.2.6. Operation Panel Unwinder 100

The operation panel is used to set operational conditions.

No. Name Function

1 Print Side Selector

In case you loaded media with printed side on the outside select

‘OUT’, otherwise select ‘IN’.

2 Unwinder 100 power ON Toggle between Manual and Automatic mode.

Manual

3 Unwinder 100 LED

Automatic

LED lights up when pushing one of the buttons

Motor turns: LED flashes.

Motor is off : LED is out.

Outside printing Inside printing

4 Backwards button Roll-off unwinder Roll-up unwinder

5 Forwards button Roll-up unwinder Roll-off unwinder

6 Power LED Lightens up once the system is powered ON

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3. PARTS REPLACEMENT

3.1. INTRODUCTION

This chapter explains the procedures for replacing and removing maintenance parts.

Important :

¾ Before replacing parts, be sure to perform following operations.

 Turn the power off. Make sure the printer is also powered off.

 Remove the electrical cable from the socket. Otherwise, you may

suffer electric shock or the machine’s electric circuits may be

damaged.

 Disconnect all cables from the machine. Not doing so could cause

damage to the printer.

Caution :

¾ Assembling and disassembling the unit are possible only for the parts for which

disassembling procedures are shown in the operation manual.

¾ Do not disassemble any frame parts or parts for which disassembling procedures

are not shown in the manual.

¾ Doing so may cause trouble that cannot be restored, as the unit is originally

assembled in the factory with a high accuracy of 1/100 mm.

Caution :

• In case you have replaced the front and/or rear media guide, always perform a

calibration of the front tensioning system and the roll-up systems. Because the new

media guide can have a slight different shape, thickness…

Notes :

¾ After replacing the parts, perform the adjustment of the unwinder / winder 100 as

described in the User’s Guide.

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3.2. REMOVAL ON THE OPERATION PANEL

3.2.1. Replace the operation panel cover.

Step 1 : Remove the eight screws fixing the operation panel.

Caution :

Be sure not to damage the cables nor the connectors.

Step 2 : Carefully loosen the connectors.

Step 3 : Remove the operation panel.

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3.2.2. Replace the operation panel PCB box

Step 1 : Remove the operation panel.

Step 2 : Loosen the sensor cables.

Step 3 : Remove the parallel connector cable.

Step 4 : Loosen the two screws fixing the parallel connector.

Step 5 : Loosen the four screws fixing the operation panel PCB box.

Step 6 : Remove the operation panel PCB box.

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3.2.3. Connecting the PCB board operation panel with the operation

panel.

Connections at the operation panel are:

Caution :

Be sure not to damage the cables nor the connectors.

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