3 Ba KTB S09 en

EN
OPERATING INSTRUCTIONS
KTB S09
Valid for
Sigma 688 ST
Doc. B|S0131|00001|V0003|EN
Art. No. Komax: 0399204 Kabatec: 10030178 – Version 3
ORIGINAL INSTRUCTIONS
Publisher
Komax Taping GmbH & Co. KG

Am Grubener Weg 15
36151 Burghaun
Germany
Phone +49 6652 79362-0

Customer service +49 6652 79362-260
info.bgh@komaxgroup.com
service.bgh@komaxgroup.com
komaxgroup.com
WEEE-Reg.-Nr. DE 66297243
Reproduction of these instructions or parts of them in whatever form is not permitted without express
written permission from the publisher.
The figures and information in these instructions are subject to technical changes that become neces-
sary to improve the machine.
© October 2022 by Komax Taping GmbH & Co. KG

TABLE OF CONTENTS
1 Introduction 7
1.1 About the product 7
1.1.1 Product description 7
1.1.2 Product identification 7
1.1.3 Technical data 8
1.1.3.1 Tapes approved for use 8
1.2 About these instructions 9
1.2.1 Layout conventions 9
1.2.2 Saving the instructions 9
2 Safety 11
2.1 Explanation of warning notices 11
2.2 General safety instructions 11
2.3 Technical condition of the product 12
2.4 Personnel qualification 12
2.4.1 Trained personnel 13
2.4.2 Qualified personnel 13
2.4.3 Specialized personnel 13
3 Product overview 15
3.1 KTB S09 module 15
3.1.1 Bundling head 20
4 Transport 23
4.1 Safety instructions 23
4.2 Handling symbols 23
4.3 Unpack product 24
4.4 Transport case 24
4.5 Delivery package 24
5 Installation and start-up 27
KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 3 / 70

5.1 Mechanical mounting 27
5.2 Connection 28
6 Operation 29
6.2 Checks prior to operation 29
6.3 Operation 29
6.4 Changing the tape fixture arbor 30
6.5 Inserting the tape 31
6.6 Setting up the module 35
6.7 Setting up the tape 35
7 Maintenance 37
7.2 Tools and equipment 37
7.3 Maintenance table 38
7.4 Preparation 39
7.4.1 Removing the side protective cover 39
7.4.2 Installing the side protective cover 39
7.4.3 Releasing the blade cover 40
7.4.4 Attaching the blade cover 40
7.5 Maintenance work 40
7.5.1 Cleaning the bundling jaws 40
7.5.2 Checking the bundling head springs 42
7.5.3 Inspecting and cleaning the applying rollers 43
7.5.4 Checking the tape pull-off spindle 44
7.5.5 Cleaning the deflection rollers 45
7.5.6 Cleaning the blade 46
7.5.7 Cleaning the tape gripper 48
7.5.8 Checking the drive belt of the bundling head 49
7.5.9 Fill the oil 50
7.5.10 Oiling the bundling head bearing 51
7.5.11 Cleaning and oiling the tape pull-off spindle 52
8 Servicing and repairs 55

8.2 Tools and equipment 55
8.3 Replacement tasks 56
8.3.1 Replacing the blade 56
8.3.2 Replacing the oil felt 57
8.3.3 Replacing the tape pull-off belt 58
8.3.4 Tensioning the drive belt of the bundling head 63
8.3.5 Replacing the drive belt of the bundling head 64
4 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

9 Malfunctions/errors 67
9.1 General malfunctions 67
10 Decommissioning / storage / disposal 69

10.1 Decommissioning 69
10.2 Storage 69
10.3 Disposal 69

TABLE OF CONTENTS

INTRODUCTION
1 INTRODUCTION
1.1 ABOUT THE PRODUCT
1.1.1 Product description

The KTB S09 spot taping module is an expandable, fully automatic module for bundling twisted
wires. The spot taping module is designed for installation in the Komax Sigma 688 ST. No other use
is authorized.
1.1.2 Product identification

The name plate contains the most important in-
formation for identification and the most impor-
tant technical data for connecting the module.
The name plate [1] is located on the tape-roll

side of the module.
Fig. 1

INTRODUCTION
1 Type
2 Article number
3 Machine number
4 Year of manufacture 1 5
5 Operating voltage 2 6
6 Control voltage 3 7
7 Connection power 4 8
8 Max. pneumatic pressure
Fig. 2
1.1.3 Technical data
Control voltage 24 V DC
Connection power 75 W
Operating pressure 6 bar (0.6 MPa / 87 psi)
Bundle diameter 2 mm to 12 mm
Tape width 9 mm
Tape roll core diameter 1.5” (38.1 mm)
3.5'' (76.2 mm)
Maximum outer diameter of tape roll 160 mm
Dimensions (h/d/w) 274 mm / 302 mm / 111 mm
Weight 4.5 kg
Sound pressure level LEX, 8h < 85 dB (A)
LpC, peak < 137 dB (C)
Ambient temperature Min: +5 C (41°F)
Max: +40°C (104°F)
1.1.3.1 Tapes approved for use
TIP
Malfunction during processing of unsuitable tapes
The module is suitable for processing various tapes.
A list of approved tapes can be found on the KOMAX direct information platform:
https://direct.komaxgroup.com.
Once KOMAX has conducted a successful feasibility test, further tapes may also be processed
on the module.

INTRODUCTION
1.2 ABOUT THESE INSTRUCTIONS
1.2.1 Layout conventions

These instructions are laid out as follows:
TIP
Designates user tips and other useful information.
Tip is not a signal word for hazards.
Instructions
Instructions consist of one or more optional requirements, one or more action sequences, and op-
tional results.
Requirements
n This is a requirement for an action.
Procedure
u This is an action sequence.
Ú This is an intermediate result from a single action sequence.

Ú This is the result of a complete set of instructions.
Numbered lists
1. This is a numbered list.
List
n This is a non-numbered list.
– This is a second-level bullet point.
Markup elements
Legend numbers for images are designated as in the following example:
Place setup gauge [1] into guide-tube holder [2].
Software elements are designated as in the following example:
Press OK.
1.2.2 Saving the instructions

These instructions are a component of the product. Keep the instructions at hand so that they are al-
ways readily accessible for any needed information.

INTRODUCTION

SAFETY
2 SAFETY
2.1 EXPLANATION OF WARNING NOTICES
DANGER
Indicates a hazard of high risk.
Death or serious injury will result if it is not prevented.
WARNING
Indicates a hazard of medium risk.
If not prevented, death or serious injury can result.
CAUTION
Indicates a hazard of low risk.
If not prevented, injury can result.
NOTICE
Designates useful information
If not followed, property damage may result. Notice is not a signal word for hazards.
2.2 GENERAL SAFETY INSTRUCTIONS

Personal safety
Personal safety is only ensured for a single operator. Make sure that your actions do not expose any-
one to risk. Any person who initiates a command input automatically becomes an operator and is
thereby responsible for all other persons at the machine.
Personnel qualification
Only persons with the relevant qualifications are allowed to operate, configure, and maintain the
product.

SAFETY
Instructions
These instructions form part of the product. Read the instructions before working with the product.
Observe the safety and warning notices.
Other instructions
Also observe the safety and warning notices in the instructions for the associated products.
2.3 TECHNICAL CONDITION OF THE PRODUCT

Safe operation
If safe operation of the product can no longer be warranted, disconnect the product from the power
supply system and protect against inadvertent activation.
Safety installations
Operate the product only with functioning safety installations. Do not remove, bypass or manipulate
any safety installation.
Maintenance
Service the product within the indicated time intervals. If you do not regularly service the product,
damage may result and smooth operation of the safety installations cannot be ensured.
Replacement parts
Replace defective parts only with original replacement parts. You can obtain original replacement
parts from Komax.
Backfitting
The product must not be backfitted or modified.
Software
The software must not be modified.
2.4 PERSONNEL QUALIFICATION

Komax applies minimum requirements to operating personnel and differentiates between the follow-
ing user groups:
n Trained personnel (e.g. operators)

n Qualified personnel (e.g. setup technicians, maintenance technicians)
n Specialized personnel (e.g. service technicians, shift supervisors)
Overview of tasks
Specialized personnel
Tasks
Qualified personnel
Trained personnel
Positioning, aligning and leveling of machine × ×

SAFETY
Installing and setting up process modules and applications × ×

Carrying out mechanical basic configuration of machine × ×
Setting up and configuring the machine × ×
Preparing machine for production × × ×
Loading and charging ready for production × × ×
Safely operating machine during production × × ×
Performing daily maintenance × × ×
Maintaining and servicing the machine × ×
Carrying out trouble-shooting, malfunction diagnosis, and fault correction ×
Correct selection of replacement parts ×
Storage and disposal ×
2.4.1 Trained personnel
Requirements
n Technical knowledge
n Read and write (national language)
Product knowledge
n Technical data and intended use
n Sources of danger and safety installations
n User interface and its functions (normal operation)
n Proper action in the case of malfunctions
2.4.2 Qualified personnel
Requirements
n Requirements and product knowledge corresponding to “trained personnel”
n Mechanical training
n Electrotechnical knowledge
n General knowledge of wire processing
Product knowledge
n In-depth knowledge of user interfaces and their functions (special operation)
n Knowledge of areas of application and processing options
n In-depth knowledge of components (mechanical, electrical, pneumatic) and their function, set-
tings and maintenance
2.4.3 Specialized personnel
Requirements
n Requirements and product knowledge corresponding to “trained personnel” and “qualified per-
sonnel”

SAFETY
n Knowledge of spoken and written English

n Electrotechnical continuing education/training
n In-depth knowledge of wire processing
Product knowledge
n Reading and interpreting of wiring diagrams, I/O list and pneumatic diagram
n In-depth knowledge of PC hardware, operating system (Windows), periphery and applications
n In-depth knowledge of process options (applications and Q tools)
n Systematic approach for troubleshooting and fault diagnosis

PRODUCT OVERVIEW
3 PRODUCT OVERVIEW
3.1 KTB S09 MODULE
3
1
5
4
Fig. 3: View with cover closed
1 Flanged wheel 2 Tape fixture arbor

PRODUCT OVERVIEW
3 Protective enclosure 4 Protective cover
5 Blade cover
Flanged wheel
The flanged wheel presses laterally against the tape and prevents the tape on the roll from arching
outward. The flanged wheel is monitored by the material change detection of the basic machine.
Tape fixture arbor

The tape roll is pressed onto the tape fixture arbor. The 1.5” tape fixture arbor is permanently
mounted. The 3” tape fixture arbor is pressed onto the 1.5” arbor.
Protective enclosure
The protective enclosure prevents the operator from reaching into the drive belt of the bundling head
during operation, and protects the drive belts and the motor from damage.
Protective cover
The protective cover prevents the operator from reaching into the moving machine parts while the
machine is in operation.
Blade cover
Die blade cover prevents the operator from reaching into the operating area of the blade.

PRODUCT OVERVIEW
2
11
10
3 4 5 6 7 8
Fig. 4: View with cover open
1 Oil peep hole 2 Deflection roller
3 Tape pull-off 4 Take-up roller
5 Tape pre-pull-off 6 Free-wheel roller
7 Bundling head 8 Oil-felt holder
9 Tape holder 10 Blade
11 Tape gripper
Oil peep hole

The current fill level of the oil container can be seen through the oil peep hole.
Deflection roller
The deflection roller deflects the tape and guides it. The non-adhesive side of the tape is placed
around these rollers.
Tape pull-off
The tape pull-off guides the tape gripper and pulls the tape from the inserted tape roll over it.

PRODUCT OVERVIEW
Take-up roller
The take-up roller prevents the tape from falling down.
Tape pre-pull-off
The tape pre-pull-off governs the amount of tape extracted. When retracting (in direction of tape fix-
ture arbor) the tape is pulled off the roll. This reduces the tape pull-off forces.
Free-wheel roller
The free-wheel roller deflects the tape and guides it. The adhesive side of the tape is placed around
this roller. The profile of the roller prevents the tape from sticking to the roller.
Bundling head
The bundling head wraps the dispensed and cut tape around the bundled goods.
Oil-felt holder
The oil felt is in the oil-felt holder. The oil felt oils and cleans the blade at every cutting procedure.
Tape holder
The tape holder clamps and holds the tape. This prevents the tape from running back.
Blade
The blade cuts the tape.
Tape gripper
The tape gripper pulls off the tape and holds the tape until the tape is cut.

PRODUCT OVERVIEW
3
2
Fig. 5
1 Locking bolt 2 Compressed-air connection
3 Input/output signal connection 4 Encoder signal connection
5 Power connection, motors 6 Oil reservoir screw plug
Locking bolt
The locking bolt fixes the spot taping module in the holder in the basic machine.
Compressed-air connection
The compressed-air supply for the spot taping module is connected to the compressed-air connec-
tion .
Input/output signal connection

The basic machine uses this connection to control the actuators and import the sensor states of the
spot taping module. The connection is color coded with a yellow ring.
Encoder signal connection

The basic machine uses this connection to receive the encoder signals. The connection is color
coded with a red ring.

PRODUCT OVERVIEW
Power connection, motors

The power supply for the motors is connected here. The connection is color coded with a blue ring.
Oil reservoir screw plug

To fill up the oil supply, the screw plug of the oil reservoir must be opened. The oil is used to oil the
oil felt.
3.1.1 Bundling head
1 2
Fig. 6
1 Bundling jaw springs 2 Applying roller springs
3 Bundling jaws 4 Applying rollers
Bundling jaw springs

The pre-tensioned bundling jaw springs apply pressure to the bundling jaws.
Applying roller springs

The pre-tensioned applying roller springs apply pressure to the arms of the applying rollers.

PRODUCT OVERVIEW
Bundling jaws
The bundling jaws press the tape onto the wire while the bundling head is rotating.
Applying rollers
The applying rollers press the tape onto the wire as they move in. As they move away, the applying
rollers press the tail end of the tape onto the wire. The profile of these rollers prevents the tape from
sticking to them.

PRODUCT OVERVIEW

TRANSPORT
4 TRANSPORT
4.1 SAFETY INSTRUCTIONS
Personal safety
Make sure that your actions do not expose anyone to danger.
Only Komax service technicians or transport specialists may transport the module.
More information: («Personnel qualification», p. 12)
Handling symbols
Observe the handling symbols on the packaging.
More information: («Handling symbols», p. 23)
Transport case
The product is delivered in a shock-resistant transport case.
The transport case can be transported by hand due to its light weight. Make sure you do not drop the
case.
The unpacked machine can also be transported by hand.
Observe the applicable accident prevention regulations during transport and comply with these regu-
lations.
4.2 HANDLING SYMBOLS

Do not use hand-hooks. Center of gravity not in the cen-
Weight ter.
is not in
balance
Sensitive electronic components Do not use forklift at this spot.

TRANSPORT
This side up. Keep dry.
Do not place weight on lid. Store in a dry place at below

0
40° 40° C and above -20° C.
-20°
Fragile Do not expose to direct sunlight.
4.3 UNPACK PRODUCT

Procedure
u Place the transport case on a level surface.
u Open the clasps [1] at the front of the case.
u Open the case.
u Remove contents.
Fig. 7
4.4 TRANSPORT CASE

Procedure
u Use the transport case to store the product.
u Use the transport case to return the product to Komax if any repair work is required.
The transport case is the property of the recipient.
4.5 DELIVERY PACKAGE

Procedure
u Check the delivery for completeness.
u Upon delivery, immediately check the product for transport damage.

TRANSPORT
TIP
Immediately notify Komax AG or the nearest representative if there are any missing or defec-
tive parts.
1 2
5 4 3
Fig. 8
1 KTB S09 module 2 Locking bolt
3 3 inch (3”) tape fixture arbor 4 Plastic tweezers
5 Accompanying documents:
n Translation of original operating instruc-
tions
n Declaration of incorporation
n Test certificate from functional check

TRANSPORT

INSTALLATION AND START-UP
5 INSTALLATION AND START-UP

5.1 MECHANICAL MOUNTING
Procedure
u Press the button of the locking bolt [1] and 2
pull out the bolt.
u Insert the module into the holder [2] of the 1
basic machine. 3
The holder studs must be inserted into the
two mounting holes [3] of the module.
Fig. 9
u Press the button of the locking bolt [1].
u Slide the locking bolt back into the module.
u Move the lever [2] to secure the module.
u To remove the module, carry out the steps in 2

the opposite order.
Fig. 10

INSTALLATION AND START-UP
5.2 CONNECTION
The module must be connected to the basic machine via the defined interfaces. The compressed-air
supply must be 6 bar (0.6 MPa/87 psi). The module must be operated only with filtered, oil-free com-
pressed air.
Procedure
u Connect the compressed-air supply of the
basic machine to the module's compressed-
1
air connection [1].
u Insert the motor cable connection into the
blue-coded connection socket [2]. 2
The plug pin must be in the designated notch
of the socket. 3
u Insert the encoder signal connection plug into
4
the red-coded connection socket [3].
of the socket.
u Insert the input/output signal connection plug
into the yellow-coded connection socket [4].
Fig. 11
of the socket.

OPERATION
6 OPERATION
Only persons with the relevant qualifications are allowed to mount the product.
Personal safety
Make sure that your actions do not expose anyone to risk.
Technical condition of the product

Only operate the product if it is in perfect technical condition.
6.2 CHECKS PRIOR TO OPERATION

Check the following points prior to each operation:
Electrical connections
u Check that all cables are correctly plugged in and not damaged. Replace defective cables.
Pneumatic connections
u Check that all compressed-air hoses are correctly connected and not damaged. Replace defec-
tive hoses.
u Check whether the operating pressure is set correctly according to the technical data.
6.3 OPERATION
The module is operated via the Sigma 688 ST basic machine.

OPERATION
6.4 CHANGING THE TAPE FIXTURE ARBOR

Procedure
u Turn the flanged wheel [1] counterclockwise
(arrow).
u Pull off the flanged wheel [1].
u Remove the inserted tape.
Fig. 12
u Slide the 3" tape fixture arbor [1] onto the
1.5" tape fixture arbor [2].
Make sure that the pins on the outer diame-
ter of the 1.5” tape fixture arbor [2] sit in the
slots of the inner diameter of the 3" tape fix- 1
ture arbor [1].
Fig. 13
u To secure the 3" tape fixture arbor [1], screw
in the threaded pin [2].
The threaded pin [2] must be firmly seated on
the 1.5" tape fixture arbor [3]. 2 3
Fig. 14

OPERATION
u Slide the tape roll [1] onto the 3" tape fixture
arbor [2].
u Fit the flanged wheel [3].
1
u Press the flanged wheel [3] firmly onto the
1.5" tape fixture arbor.
u Turn the flanged wheel [3] clockwise (arrow)
until the bayonet lock engages. 2
Fig. 15
6.5 INSERTING THE TAPE

Procedure
u Push away the protective cover [1] at the side
of the module.
The protective cover will release under light
pressure.
Fig. 16

OPERATION
u Turn the flanged wheel [1] counterclockwise

(arrow) and remove it.
Fig. 17
u Slide a roll of approved tape [1] onto the tape
fixture arbor [2].
u Pull the tape off.
The non-adhesive side must be facing in the 1

direction of the deflection roller [3].
The adhesive side must face the connec-
tions [4]. 2
Fig. 18
u Guide the non-adhesive side of the tape
around the deflection rollers [1].
Fig. 19

OPERATION
u Guide the adhesive side of the tape around

the upper free-wheel roller [1]. 1

around the deflection roller [2].
Do not guide the tape around the take-up
roller.
u Guide the adhesive side of the tape around
the lower free-wheel roller [3].
4
around the deflection roller [4].
2 3
Fig. 20
WARNING
Cutting hazard
There is a cutting hazard in the area around the blades.
u Prior to working on the blades, disconnect the machine from the power supply and take mea-
sures to prevent inadvertent activation.
u Turn off the compressed air using the manual shut-off valve.
u Do not reach between the blades.
u Pull the tape through the tape holder [1].
u Adhere the tape to the housing.
If the tape is correctly inserted and not 2

twisted, the adhesive side of the tape is fac-
ing outward. The non-adhesive side faces the 1
applying rollers [2].
Fig. 21

OPERATION
u Place the flanged wheel [1] on the tape fixture

arbor.
u Turn the flanged wheel clockwise (arrow) until
the bayonet lock engages.
Fig. 22
u Fit the protective cover [1] in place at the
side.
u Press the protective cover against the mod-
ule until it engages in the module.
Fig. 23
u Trigger the cutting process on the basic ma-
chine.
Ú The tape holder clamps the tape.
Ú The blade cuts the tape off, straight.
Ú The tape gripper grips the start segment.
u Remove the cut tape from the machine.
u Confirm the operation on the basic machine.
u Start the home position run.
Fig. 24

OPERATION
6.6 SETTING UP THE MODULE
TIP
Setup work
All set-up work can be carried out while the module is installed in the basic machine.
u The tape change function must be activated on the basic machine.
6.7 SETTING UP THE TAPE
TIP
If the module with inserted tape is not used for a period of one day or longer, proper spot tap-
ing of the wire can no longer be ensured.
u To restart the module, manually pull off a length of tape measuring at least 700 mm and set up
the tape.
TIP
To set up the tape, the spot taping module must be installed in the basic machine.
TIP
Individual elements have been removed from the illustrations for illustrative purposes. All pro-
tective covers must be installed for operation.
Procedure
of the module.
The protective cover will release under light
pressure.
Fig. 25

OPERATION
u Pull the tape through the tape holder [1].
u Adhere the tape to the housing.
If the tape is correctly inserted and not 2

twisted, the adhesive side of the tape is fac-
ing outward. The non-adhesive side faces the 1
applying rollers [2].
Fig. 26
u Fit the protective cover [1] in place at the
side.
ule until it engages in the module.
Fig. 27
u Trigger the cutting process on the basic ma-
chine.
Ú The tape holder clamps the tape.
Ú The blade cuts the tape off, straight.
Ú The tape gripper grips the start segment.
u Remove the cut tape from the machine.
u Confirm the operation on the basic machine.
u Start the home position run.
Fig. 28

MAINTENANCE
7 MAINTENANCE
Daily maintenance work may be conducted by instructed personnel. The work carried out at other
maintenance intervals may only be conducted by qualified personnel.
More information: Personnel qualification
Personal safety
Prior to carrying out maintenance in the hazardous zone of moving and energized electric parts, dis-
connect the machine from the power supply system and take measures to prevent inadvertent
switching on.
Switch off the compressed air supply at the shut-off cock and secure it against inadvertent switch-
ing-on.
Maintenance issues
Please turn to your local Komax representative when maintenance issues arise which you are unable
to resolve.
7.2 TOOLS AND EQUIPMENT

The following auxiliary materials are required for the work described.
Daily
n Soft, lint-free cleaning cloth
n White spirits
n Allen key set
n Cotton swabs
Weekly
n None
n White spirits

MAINTENANCE
n Opta Cut 2000
Monthly
n Allen key set
n Opta Cut 2000
Semi-annually
n Frequency measuring device
n Screwdriver set
Every 1 million cycles

n Klüber Isoflex Topas NCA52
n Allen key set
n White spirits
7.3 MAINTENANCE TABLE
Every 1 million cycles
Maintenance dura-
Semi-annually
Monthly
Weekly
Daily
tion
7.5.1 Cleaning the bundling jaws 1 5 minutes
7.5.3 Inspecting and cleaning the applying rollers 1 2 minutes
7.5.6 Cleaning the blade 1 5 minutes
7.5.7 Cleaning the tape gripper 1 2 minutes
7.5.2 Checking the bundling head springs 1 2 minutes
7.5.5 Cleaning the deflection rollers 1 2 minutes
7.5.10 Oiling the bundling head bearing 1 2 minutes
7.5.4 Checking the tape pull-off spindle 1 5 minutes
7.5.9 Fill the oil 1 5 minutes
7.5.8 Checking the drive belt of the bundling head 1 5 minutes
7.5.11 Cleaning and oiling the tape pull-off spindle 1 5 minutes
1 - Maintenance personnel

MAINTENANCE
7.4 PREPARATION
7.4.1 Removing the side protective cover

The side protective cover [1] must be removed
before maintenance work.
Procedure
of the module.
Ú The protective cover will release under light
1
pressure.
Fig. 29
7.4.2 Installing the side protective cover

After maintenance work, the side protective
cover [1] must be re-installed.
Procedure
u Fit the side protective cover [1].

ule until it engages.
1
Fig. 30

MAINTENANCE
7.4.3 Releasing the blade cover

Procedure
u To release the blade cover [1], loosen the re-
taining screws [2].
Ú The blade cover [1] swings downwards.
1 2
Fig. 31
7.4.4 Attaching the blade cover

Procedure
u To attach the blade cover [1], swing the blade 2
cover [1] upwards.
u Tighten the retaining screws [2].
Fig. 32
7.5 MAINTENANCE WORK
7.5.1 Cleaning the bundling jaws
Maintenance interval Daily
Maintenance personnel Maintenance personnel
Maintenance duration 5 minutes
Tools n Soft, lint-free cleaning cloth

n White spirits

MAINTENANCE
Requirements
n The module is installed in the basic machine.
Procedure
u Clean the bundling jaws [1].
u Remove all tape and adhesive remains.

1
Fig. 33

MAINTENANCE
7.5.2 Checking the bundling head springs
Maintenance interval Weekly
Tools n None
Requirements
Procedure
u Check the bundling jaw springs [1] for dam-
age and firm hold.
1 2
If one or more bundling jaw springs [1] are
damaged, replace them immediately.
u Check the applying roller springs [2] for dam-
age and firm hold.
If one or more applying roller springs [2] are
damaged, replace them immediately.
Fig. 34

MAINTENANCE
7.5.3 Inspecting and cleaning the applying rollers
Tools n White spirits

Requirements
Procedure
u Clean the applying rollers [1].
u Check the applying rollers [1] for free move-

ment. 1
Fig. 35

MAINTENANCE
7.5.4 Checking the tape pull-off spindle
Maintenance interval Monthly
Tools n Allen key set
Requirements
n The module is removed from the basic ma-
chine.
Procedure
u Release the threaded pin [1].
1
Fig. 36
u Pull the sleeve [3] towards the bundling head.
u Check the spindle [2] for dirt, foreign objects

and sufficient lubricant.
1 2 3
u Clean and oil if necessary («Cleaning and oil-
ing the tape pull-off spindle», p. 52).
u Slide the sleeve [3] back to the housing [1].
Align the bevel of the sleeve vertically.

u Secure the sleeve [3] with a threaded pin [1].
Fig. 37

MAINTENANCE
7.5.5 Cleaning the deflection rollers
Tools n White spirits

Requirements
2
Procedure
u Clean the deflection rollers [1] and profiled
deflection rollers [2].
u Check rollers for free movement.
TIP Roller rotation

The profiled rollers only turn in one direction
by freewheeling.
Fig. 38

MAINTENANCE
7.5.6 Cleaning the blade
Tools n Allen key set

n White spirits
WARNING
Cutting hazard
Requirements
chine.
Procedure
u Release the blade cover [1](«Releasing the
blade cover», p. 40).
Fig. 39

MAINTENANCE
u Pull the blade lever [1] forwards (in the direc-

tion of the oil felt).
u Clean the blade [2].
If the blade [2] is blunt or damaged, replace

the blade.
u Attach the blade cover («Attaching the blade
cover», p. 40). 2
Fig. 40

MAINTENANCE
7.5.7 Cleaning the tape gripper
Tools n Cotton swabs

n White spirits
Requirements
n The module is disconnected from com-

pressed-air supply.
Procedure
u Clean the contact surfaces of the tape grip-
per [1].
Fig. 41

MAINTENANCE
7.5.8 Checking the drive belt of the bundling head
Maintenance interval Semi-annually
Tools n Frequency measuring device

n Screwdriver set
Requirements
chine.
Procedure
u Release the screws [1].
u Remove the protective enclosure [2].

1
Fig. 42
u Check the drive belt [1] for wear and damage.
If the belt is damaged or worn, replace the

belt («Replacing the drive belt of the bundling
head», p. 64).
u To check the tension of the drive belt, posi- 1
tion the frequency measuring device at the
marked position (arrow).
The belt tension frequency must be between
110 and 115 Hz.
If the belt tension is outside the specified
range, tighten the belt («Tensioning the drive
belt of the bundling head», p. 63).
u After checking, fit the protective enclosure.
u Secure the protective enclosure with the re-

taining screws. Fig. 43

MAINTENANCE
7.5.9 Fill the oil
Maintenance interval Monthly
Tools n Opta Cut 2000
Requirements
chine («Mechanical mounting», p. 27).
Procedure 1
u Hold the spot taping module vertically.
The screw plug [1] must be pointing upwards.

u Remove the screw plug [1] from the oil reser-
voir.
u Refill the oil.
Fill quantity: approx. 10 ml if the oil reservoir

is empty
u Close the oil reservoir with the screw plug [1].
u Install the spot taping module («Mechanical Fig. 44

mounting», p. 27).

MAINTENANCE
7.5.10 Oiling the bundling head bearing
Tools n Soft, lint-free cleaning cloth

n Opta Cut 2000
Requirements
n The module is installed in the basic machine
Procedure
u Turn the bundling head [1] by hand (arrow)
until the bearing [2] becomes visible.
1
Fig. 45
u Oil the bearing [1].
u Turn the bundling head by hand.
Ú The rotation distributes the oil in the bundling

head.
u Wipe off excess oil.
Fig. 46

MAINTENANCE
7.5.11 Cleaning and oiling the tape pull-off spindle
Maintenance interval Every 1 million cycles
Tools n Klüber Isoflex Topas NCA52

n Allen key set
n White spirits
Requirements
chine.
Procedure
1
Fig. 47
u Pull the sleeve [1] towards the bundling head.
u Clean the spindle [2].
u Apply oil evenly to the spindle [2].
Fig. 48

MAINTENANCE
u Slide the sleeve [1] back to the housing [2].
Align the bevel of the sleeve vertically.

u Secure the sleeve [1] with a threaded pin [3].
1
2
Fig. 49

MAINTENANCE

SERVICING AND REPAIRS
8 SERVICING AND REPAIRS

Only qualified personnel are permitted to perform repair and maintenance work.
More information: («Personnel qualification», p. 12)
Personnel safety
Prior to carrying out repair work, disconnect the machine from the power supply system and take
measures to prevent inadvertent activation.
For tasks controlled via the user interface, switch the machine on.
Make sure that your actions do not pose a hazard to other persons.
Wear protective goggles for all set-up and maintenance work.
8.2 TOOLS AND EQUIPMENT

The following auxiliary materials are required for the work described.
n Allen key set

n Wrench set
n Screwdriver set
n Frequency measuring device

8.3 REPLACEMENT TASKS
8.3.1 Replacing the blade
WARNING
Cutting hazard
Requirements
chine.
Procedure
u Release the blade cover [1](«Releasing the
blade cover», p. 40).
Fig. 50
u Push back the blade lever [1].
Ú The screw [2] can be accessed.

u Loosen the screw [2]. 3
u Remove the old blade [3].
u Install the new blade.

2
u Secure the blade with a screw [2].
u Attach the blade cover («Attaching the blade 1

cover», p. 40).
Fig. 51

8.3.2 Replacing the oil felt
WARNING
Cutting hazard
NOTICE
After one or two oiling processes, the new oil felt is saturated with oil.
Requirements
1
Procedure
u Remove the side protective cover («Remov-
ing the side protective cover», p. 39).
u Loosen the screw [1].
u Remove the oil felt holder [2]. 2
Fig. 52
u Pull out the old oil felt [2].
u Insert the new oil felt.

2
u Screw in the threaded pin [1]. 1
u Insert the oil felt holder [3].
u Secure the oil felt holder [3] with the

3
screw [4].
Fig. 53

u Oil the oil felt with a precision oiler in the

marked area [1].
u Attach the protective cover («Installing the
side protective cover», p. 39).
Fig. 54
8.3.3 Replacing the tape pull-off belt

Requirements
chine.
Procedure

1
Fig. 55

u Remove the side protective cover («Remov-

ing the side protective cover», p. 39). 1
u Remove the counter bearing [2].
u Remove the hose clip [3]. 2

u Loosen the axle [4].
Fig. 56
u Pull the plug connection [1] off the tape pull-
off.
Ú The connection to the electrical components
is disconnected.
Fig. 57
u Remove the tape pull-off.
Fig. 58

u Loosen the screws [1] of the motor [2].
2 1
Fig. 59
u Release the counternut [1] on the belt ten-
sioning screw [2]. 2 1
u Release the belt tensioning screw [2].
Fig. 60
u Remove the spindle connection [2].
1 2
Fig. 61

u Push the motor [1] in the direction of the belt

pulley [3] (arrow).
1 2
u Remove the belt [2].
u Pull on the new belt.
The teeth of the belt and the teeth of both

belt pulleys [3] and [4] must interlock.
4 3
Fig. 62
u Adjust the belt tension of the new belt using
the belt tensioning screw [1].
Ú The deflection in area a must be 1.5 mm.
a = 1,5 mm
u Tighten the counternut [2].
1 2
Fig. 63
u Position the spindle connection [2].
u Fasten the spindle connection [2] with the

screws [1].
1 2
Fig. 64

u Loosely tighten the screws [1].
u Tighten the screws [1] in a criss-cross se-

2 1
quence.
Fig. 65
u Return the tape pull-off to its old position.
u Reconnect the plug connections [1].
Fig. 66
u Fit the axle [4] and tighten loosely.
u Insert the counter bearing [2] and insert the

1
hose holder [3].
u Insert and tighten the screws [1].
u Securely tighten the axle [4] . 2

u Fit the protective cover («Installing the side
protective cover», p. 39).
3
u Fit the protective enclosure. Fasten with
screws.
Fig. 67

8.3.4 Tensioning the drive belt of the bundling head

Requirements
chine.
Procedure

1
Fig. 68
u Use the adjustment [2] to tighten the drive

belt [3]. 3
Fig. 69
u To tighten the tension on the drive belt, turn
the threaded pin [1] with hex nut clockwise
(white arrow).
u To loosen the tension on the drive belt, turn
the threaded pin [1] with hex nut counter-
clockwise (black arrow).
1
u Check the belt tension («Checking the drive
u After tensioning, lock the threaded pin [1]
with the hex nut [2].
2
Fig. 70

u Tighten the screws [1] of the motor flange.
u Fit the protective enclosure. Fasten with

screws.
Fig. 71
8.3.5 Replacing the drive belt of the bundling head

Requirements
chine.
Procedure

1
Fig. 72

u Release the tension on the drive belt [2] with

the adjustment [3]. 3
Fig. 73
u To loosen the drive belt, turn the threaded
pin [1] counterclockwise (black arrow).
Fig. 74
u Remove the screws [1].
u Remove the motor [2].
u Pull off the old drive belt [3].
u Pull on the new belt.

1
2
Fig. 75

u Guide the belt around both deflection

rollers [1], [4] .
The teeth of the new belt and the teeth of the
bundling head [3] must interlock.
The teeth of the new belt and the teeth of the
deflection rollers [1], [4] must interlock. 1
u Reinstall the motor. 3
The teeth of the new belt and the teeth of the 4
motor belt pulley [2] must interlock.
2
Fig. 76
u Fasten the motor flange with screws [1].
u Tighten the new belt («Tensioning the drive

Fig. 77

MALFUNCTIONS/ERRORS
9 MALFUNCTIONS/ERRORS
9.1 GENERAL MALFUNCTIONS
The following table lists malfunctions which may affect the module, possible causes of these prob-
lems, and information and cross-references on resolving them.
Malfunction Possible cause Remedy
Bundling head blocked Lack of lubrication «Oiling the bundling head

bearing» (p. 51)
Module does not respond Plug incorrectly inserted Insert plug correctly
Terminals soiled Clean the terminals
Broken wire Replace the wire in question
Tape is not cut correctly or not Blade is soiled «Cleaning the blade» (p. 46)
cut at all.
The blade is blunt «Replacing the blade» (p. 56)
Tape not gripped Gripper soiled or oily «Cleaning the tape
gripper» (p. 48)
Start of tape lost «Setting up the tape » (p. 35)
Tape is not pulled off Deflection rollers soiled «Cleaning the deflection
rollers» (p. 45)
Blade not being oiled Worn oil felt «Replacing the oil felt» (p. 57)
Oil reservoir empty «Fill the oil» (p. 50)
Air bubbles in oil circulation Trigger two to three automatic
oiling procedures

MALFUNCTIONS/ERRORS

DECOMMISSIONING / STORAGE / DISPOSAL
10 DECOMMISSIONING /
STORAGE / DISPOSAL
10.1 DECOMMISSIONING
Procedure
u Disconnect the module from the power and compressed-air supply.
u Remove the inserted tape from the module.
u Remove the module from the basic machine.
u Empty the oil reservoir.
u Perform complete maintenance and cleaning.
u Use the parts list to check whether all components are on the module.
10.2 STORAGE
Procedure
u Shut down and decommission the module.
u Select a suitable storage place. The same requirements as for the place of installation apply to the
storage place (floor conditions, space requirements and ambient conditions).
u Protect the module from soiling.
u Protect the module from corrosion (keep in dry rooms with no direct sunlight).
10.3 DISPOSAL
TIP
Legal provisions
It is the responsibility of the operator to ensure that the module and operating materials are
disposed of in an environmentally sound and appropriate manner.
u Observe all national and local legal regulations and provisions.

DECOMMISSIONING / STORAGE / DISPOSAL
Most of the materials used (metals, plastics) can be recycled.
Procedure
u Shut down and decommission the module.
u Disassemble the module, sort the parts according to material and dispose of the materials at the
appropriate recycling facility.
u Electric and electronic components, in particular PCBs, monitors etc., must be disposed of in an
environmentally-friendly way.
u It is recommended to bring in specialized companies.

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EN

Komax Taping GmbH & Co. KG

Phone +49 6652 79362-0

© October 2022 by Komax Taping GmbH & Co. KG

5 Installation and start-up 27

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 3 / 70

8 Servicing and repairs 55

4 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

10 Decommissioning / storage / disposal 69

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 5 / 70

6 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

1.1.1 Product description

1.1.2 Product identification

The name plate [1] is located on the tape-roll

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 7 / 70

8 Max. pneumatic pressure

1.1.3 Technical data

1.1.3.1 Tapes approved for use

8 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

1.2 ABOUT THESE INSTRUCTIONS

1.2.1 Layout conventions

Ú This is an intermediate result from a single action sequence.

Place setup gauge [1] into guide-tube holder [2].

Software elements are designated as in the following example:

1.2.2 Saving the instructions

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 9 / 70

10 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

2.2 GENERAL SAFETY INSTRUCTIONS

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 11 / 70

2.3 TECHNICAL CONDITION OF THE PRODUCT

2.4 PERSONNEL QUALIFICATION

n Trained personnel (e.g. operators)

Positioning, aligning and leveling of machine × ×

12 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

Installing and setting up process modules and applications × ×

2.4.1 Trained personnel

2.4.2 Qualified personnel

2.4.3 Specialized personnel

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 13 / 70

n Knowledge of spoken and written English

14 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

Fig. 3: View with cover closed

1 Flanged wheel 2 Tape fixture arbor

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 15 / 70

3 Protective enclosure 4 Protective cover

Tape fixture arbor

16 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

Fig. 4: View with cover open

1 Oil peep hole 2 Deflection roller

3 Tape pull-off 4 Take-up roller

5 Tape pre-pull-off 6 Free-wheel roller

7 Bundling head 8 Oil-felt holder

9 Tape holder 10 Blade

Oil peep hole

KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN 17 / 70

18 / 70 KTB S09 – Komax: 0399204 Kabatec: 10030178 – Version 3 – EN

1 Locking bolt 2 Compressed-air connection