Collamat C9100 Release Note

WWinderinder C9100C9100
Technical handbook
Collamat Stralfors AG CH-4147 Aesch Pfeffingerring 201 Tel [phone] Fax [phone]
5999.554-01A

Index page
1 Safety advices .............................................................. 3......
1.1 Important warnings ........................................................ 3......
1.2 Danger advices ........................................................... 3......
1.3 Symbol descriptions ....................................................... 4......
2 Introduction ................................................................. 5......
2.1 General information ....................................................... 5......
3 The Winder C9100 .......................................................... 5
......
3.1 Prevention of accidents .................................................... 5......
3.2 Noise suppression ........................................................ 5......
3.3 Mechanical stability ....................................................... 6......
3.4 Installation examples ...................................................... 7......
3.5 Rewinder and unwinder ................................................... 8......
3.5.1 General information ..................................................... 8......
3.5.2 Support plate ............................................................ 9......
3.5.3 Drive .................................................................... 9......
3.5.4 Dancer .................................................................. 9......
3.5.5 Winder mandrel ......................................................... 9......
3.5.6 Brake ................................................................... 9......
3.5.7 Winder control .......................................................... 9
......
3.6 Final assembly of the winder .............................................. 10.....
3.6.1 Assembly of the dancer .................................................. 10.....
3.6.2 Assembly of the unwinder/rewinder mandrel ............................. 10.....
3.6.3 Exchange of the dancer spring ........................................... 10.....
3.7 Adjustments ............................................................... 11.....
3.7.1 Spring force of the dancer ............................................... 11.....
3.7.2 Tension direction of the dancer .......................................... 12.....
3.7.3 Direction of action of the dancer ......................................... 12.....
3.7.4 Motor rotation direction ................................................. 12.....
3.7.5 Tension force of the motor ............................................... 12.....
3.8 Arrangement and mechanical adjustment of the rewinder .................. 13.....
3.9 Arrangement and mechanical adjustment of the unwinder .................. 15
.....
3.10 Maintenance ............................................................. 15.....
3.11 Brake .................................................................... 16.....
3.11.1 Adjustment of brake .................................................... 16.....
3.12 Motor brushes ........................................................... 17.....
4 Electrical settings ........................................................... 18.....
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Index page
4.0.1 Direction of action of dancer (DANCER) ................................. 19.....
4.0.2 Motor force (TORQUE) .................................................. 20.....
4.0.3 Winder (WIND) .......................................................... 20.....
4.1 Electrical connection ...................................................... 21.....
4.1 The connector box 9100 ................................................... 21.....
4.1.1 Fuse F1, 5A slow blowing ............................................... 21.....
4.1.2 Pinassignment Monitor Connector DISPENSER .......................... 22
.....
4.2 Cabling ................................................................... 23.....
4.3 Setting up ................................................................. 23.....
5 Technical data .............................................................. 24.....
5.1 Fuses ..................................................................... 24.....
6 Troubleshooting ............................................................. 25.....
6.1 Troubleshooting Collamat 9100 ............................................ 25.....
6.2 Trouble shooting checklist ................................................. 26.....
The information in this handbook reflects
the state of the publication date.
We reserve the right to make design modifications.
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1Safety advices
1.1Important warnings
Before installing and operating the Collamat®9100 read the following
safety instructions.
The Collamat®9100 labeller is exclusively intended for labelling goods. It must
exclusively be controlled and driven by a C9100 monitor.
Install the Collamat®9100 only by a trained specialist considering the national
specific regulations of
prevention of accidents
mechanical stability
construction of electrical and mechanical systems
noise suppression
Take notice of the technical data of the Collamat®9100. Especially the environ-
ment conditions must be observed.
Operate the Collamat®9100 only by trained personnel.
In case of non-authorized modifications the guarantee will become void.
Before connecting non-standard products, ask your competent technical
supporter.
1.2Danger advices
The safety symbols and danger advices on the Collamat®9100 and in this
manual must strictly be observed.
Switch the monitor C9100 off before connecting or disconnecting the labeller
to or from the monitor C9100.
Only authorized personnel may open the monitor and the connector box.
Disconnect the monitor from the mains before opening the connector box.
Danger of pinching hair, jewelry, ties, clothes etc. into the traction unit !
Danger of injury by cutting fingers in the paper zone !
Danger of injury in the dancer roller zone of the Collamat®9100 rewinder and
unwinder !
Danger of injury in the case of non-expert use of the Collamat®9100 paper
stock control !
When operating the labeller, the operating personnel must keep to a safe loca-
tion to prevent injury by the products being labeled.
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1.3Symbol descriptions
ATTENTION
Danger to damage the Collamat®9100 or other system components,
with a potential consequential danger of injuries.
DANGER
Imminent hazard for persons.
DANGER
Shock hazard due to high voltage at component.
DANGER
Hazard of contact injury due to high component temperature.
ATTENTION
ESD (ElectroStatic Discharge) warning. The p.c.boards or other compo-
nents may only be touched in an electrostatically protected envi-
ronment.
NOTE
Important or additional information to Collamat®9100 or its documen-
tation.
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2Introduction
2.1General information
This Technical Manual describes design and function of the Powered Winder C9100. In addition
to the Operating Instructions, it contains the settings and notes necessary to get optimum use of
the Winder C9100. The descriptions of the electrical and mechanical assembly also help for
quick error analysis and trouble-shooting.
We recommend to replace p.c.boards always as complete units returning them to Collamat
Stralfors or its representative for repair to be sure that the high quality standard of the Winder
C9100 can also be guaranteed after any repair.
Special characteristics of the Winder C9100:
resistant to wear
rugged
quick change-over to other labelling tasks
high performance
SMD-technology
3The Winder C9100
The Winder C9100 must be installed by trained personnel considering the following national
specific regulations:
Prevention of accidents
Noise suppression
Construction of electrical and mechanical systems
3.1Prevention of accidents
When installing and connecting the C9100 monitor and labeller pay attention that the signal and
power cables cannot become stumble obstacles. Lay the cables according to the national safety
regulations. Signal cables must not be placed in close proximity to power cables.
3.2Noise suppression
For radio interference suppression the C9100 labeller and monitor are shielded according to the
CE directives. Only cables approved by Collamat Stralfors are allowed to be used to connect the
monitor to labeller and mains. Additional peripherals have to be connected only to the mains
socket of the monitor. These devices must be approved by Collamat Stralfors.
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3.3Mechanical stability
If the Collamat®9100 is used on a movable stand, this stand must be capable to be tilted by 10°
in each direction. See Figure 1:
Figure 1: Mechanical stability of C9100 labeller stand
10° 10°
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3.4Installation examples
Due to the modular design of the Collamat®9100 there is nearly no limit in variations of the
installation. But for best results in labelling, the following figures show installation examples of
constructions which do their work successfully:
Figure 2: 1st example
Figure 3: 2nd example
The threading of the paper web, the adjustment of the paper brake and
adapter are described in the Operating Instructions of the Collamat®
9100 labeller.
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3.5Rewinder and unwinder
3.5.1General information
Rewinder and unwinder (= winder) with motor drive are intended to automatically wind or
unwind the paper web of the COLLAMAT 9100 labellers. The winder is powered with 24 VDC.
A deviation of the dancer roller starts automatically the winder motor. The winding speed is
electronically controlled as a function of the dancer roller position. At the end of the paper web
or upon paper web break, the motor is stopped automatically after some revolutions to prevent
an uncontrolled run-up of the winder. Thickness of the wound roll and direction of action of the
dancer roller can be adapted by plug-in jumpers on the electronic winder system. The direction
of rotation can be switched over from outside. Rewinder and unwinder distinguish themselves
only by dancer roller and winder mandrel.
Design
Legend
1. Unwinder
dancer roller
2. Rewinder dancer
3. Knurled knob for
dancer position
4. Toothed belt
5. Brake
6. Winder mandrel
7. Lateral disk
8. Support plate
9. Clamp
10. Dancer spring
11. DC motor
12. Motor brush
13. Cover
14. Winder control
15. Direction of rotation
toggle switch
16 Spring adjust
Figure 4: Winder
1
2
3
4
5
6
7
8
9
15
13
14
11
12
10
16
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3.5.2Support plate
The assembly is mounted on a rigid support plate 8fixing the winder on the module rail in a
stable way. A cover 13 with rubber sealing protects the winder control 14 from dirt and
humidity.
3.5.3Drive
The winder mandrel 6is driven by a current-controlled DC motor 11 via a toothed belt 4. To
prevent the winding from after-running the winder mandrel is braked with free dancer roller by
brake 5. The DC motor is equipped with exchangeable brushes 12.
3.5.4Dancer
The dancer roller arm has two tasks. On the one hand it represents a paper web stock for rapid
supply or take-up of the paper web, on the other hand it signalizes its position to the winder con-
trol by optical sensors. With adjustable spring force, it stabilizes the tension applied to the paper
web. The cooperation of the dancer roller with the winder control and the winder motor provides
a controlled paper supply or take-up. Two different dancer roller types 1 or 2are available for
rewinders and unwinders, respectively.
3.5.5Winder mandrel
The winder mandrels 6of rewinder and unwinder are also different. The mandrel of the rewinder
is designed to take up a clamping bow which provides a sure but well detachable connection of
the empty paper web with the mandrel.
The winder mandrel can be provided additionally with a clamping core for paper rolls with 3"
core diameter (76.2 mm). The clamping core is intended to correctly transmit the torque to the
paper roll.
On request, also clamping cores with other diameters are available.
3.5.6Brake
The winder mandrel 6is braked by a electromagnetic brake. This brake is activated by the
winder control 14 at the moment when the dancer runs free, after detection of a broken paperweb
or when the motor stands still. The breaking force and breaking time can be adjusted.
3.5.7Winder control
The winder control 14 controls the whole winding process controlling the DC motor 11 as a
function of the dancer position which is optically measured and electrically weighted. The
winder control also controls the electromagnetic brake 5.
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3.6Final assembly of the winder
If the winder is delivered in parts (Dancer and winder mandrel not assembled) all parts must be
finally assembled. Refer to the figure 4.
3.6.1Assembly of the dancer
Remove the knurled knob 3 of its shaft
Put the dancer 1, 2on the dancer shaft and fix it to the desired position using the knurled
knob 3.
3.6.2Assembly of the unwinder/rewinder mandrel
Plug the unwinder/rewinder mandrel 6to the winder shaft and fix it with its fixing screw.
3.6.3Exchange of the dancer spring
The Collamat 9100 winders use three different springs types. To figure out the spring types the
springs are coded with three different colours.
Colour Springwirediameter [mm] Winder
yellow 1,7 Rewinder C9110...C9130
blue 2,25 Unwinder C9110
red 2,5 Unwinder C9120, C9130
Normally the blue springs are used in the unwinder C9110. If you received another kind of
winder the appropriate springs are delivered in the package. It must be exchanged.
Remove the spring adjusting screw 16
Remove the springguide tubeholder at the bottom from the support plate 8
Remove the square springguide tube 10
Remove all three springs together with the spring guides from the pulling bar
Reassemble the attached springs and spring guides in the same manner to the pulling bar
Slightly retighten the fixing screw to fix the system
Lubricate the springs, the spring guides and the quare springguide tube with grease
Reassemble the square springguide tube 10 and fix it with the springguide tubeholder to the
support plate 8
Adjust the spring adjusting screw 16 until the necessary spring force of the dancer is OK
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3.7Adjustments
In the following chapter the various adjustments are described considering the items:
Dancer:Motor: Brake:
Spring force
Tension direction
Direction of action
Direction of rotation
Tension force Airgap
see also chapter Brake
3.7.1Spring force of the dancer
Adjust the spring force of the dancer roller so that the retraction force of the dancer roller is not
higher than required by the dancer roller to reset itself with threaded-in paper web.
1. Dancer
2. Dancer spring
3. Modulel rail
Winder rear view
Figure 5
For adjustment of the spring force, use a 5mm hex screw driver. The dancer spring 2can be
accessed from the bottom of the winder.
To increase the dancer force tighten the dancer spring clockwise
To decrease the dancer force loosen the dancer spring anti clockwise
1
2
3
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3.7.2Tension direction of the dancer
Rewinder and unwinder tension direction are different:
The rewinder provides permanent traction force on the paper web
The unwinder provides permanently a full paper loop
Depending on space, mounting of the winders may differ. In principle the dancer roller has to be
mounted so that the paper web never can be stretched. This applies both for full and empty paper
rolls.
At the rewinder, the direction of rotation of the motor must act against the spring force of the
dancer roller allowing thus a finer adaptation of the dancer roller position with empty winder
mandrel.
At the unwinder the direction of rotation of the motor has to be adjusted according to the label
roll design: whether it is inside or outside wound.
3.7.3Direction of action of the dancer
The direction of action of the dancer roller is set on the C9100 winder control 14 with the
DANCER jumper. As a rule the jumper is already set in factory in the correct direction of ac-
tion. It must be distinguished between rewinder and unwinder:
The rewinder motor must start with free dancer
The unwinder motor must stop with free dancer
ATTENTION:
On the rewinder a free released dancer starts the free-wheel limitation
which stops the winder mandrel after eight revolutions. Therefore either
stop the winder or do not let swing out the dancer completely.
3.7.4Motor rotation direction
The toggle switch 15, placed on the cover 13 of the winder allows to select the direction of rota-
tion of the winder mandrel 6.
3.7.5Tension force of the motor
The tension force of the motor depends of:
The rewinder must not produce high accelerations but provide a constant force on the paper
web.
The unwinder must be capable to rapidly produce high accelerations but after unwinding it
must stop immediately.
The TORQUE and WIND jumper blocks on the C9100 winder control 14 are intended to set the
tension force.
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3.8Arrangement and mechanical adjustment of the rewinder
The rewinder is placed behind the traction unit on the module rail.
Legend
1. Dancer
2. Rewinder mandrel
3. Clamping bow
4. Paper web
5. Direction of rotation
toggle switch
Figure 6
The rewinder is fastened under the module rail.The dancer 1pulls the paper web 4from the
traction unit downwards. The winder mandrel 2turns counterclockwise. The sprinf force of the
dancer is set with the dancer spring so that the force in the upper stop does not become too high.
With high labelling speed, the dancer roller must not impact the paper web. The direction of
action of the dancer 1is the same as that of the spring force, i.e. if the dancer roller moves
downward, the motor must start to rotate. The direction of rotation of the motor is set with the
change-over switch 5on the rear side of the rewinder cover.
For LEFTHAND MACHINES, the above information applies reversely!
ATTENTION:
The upper position of the dancer roller must be so that the paper web is
never fully stretched. Otherwise impacts on the traction unit may occur
which open the closure.
The angle of paper web around the dancer between winder mandrel and
traction unit must be an obtuse angle. See figure 6. In most cases a
stretched paper web will cause faults !
B
A1
2
3
4
5
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Figure 7 shows the second mode to mount a rewinder. Here the rewinder is mounted above the
module rail. But this mounting type should be used only when a mounting according to figure 6
is not possible for space reasons.
Figure 7
Set the spring force of the dancer roller so that the dancer roller can bear the paper web to the
upper stop. The dancer roller must move independently fully upwards (lefthand stop) if there is
no paper web to be wound. The winder mandrel must turn clockwise. Be carefully that the paper
web is never stretched.
For LEFTHAND MACHINES the above information applies reversely !
Righthand stop = clockwise
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3.9Arrangement and mechanical adjustment of the unwinder
The unwinder is placed, as shown in figure 8, on the top of the module rail.
Legend
1. Module rail
2. Traction unit
3. Unwinder
4. Dancer
5. Direction of rotation
toggle switch
6. Deflection rollers
7. Paper web
Figure 8
The unwinder is fastened above the module rail 1. The dancer roller 4pulls the paper web
upwards. If the dancer is moved downwards the motor starts to rotate. The direction of rotation
of the unwinder is set by the toggle switch 5. The resetting force of the dancer should be set as
low as possible. But in operation the dancer roller must never touch the lower stop avoiding thus
impacts to the label web and an inaccurate labelling.
NOTE:
In the case of horizontal mounting position and lateral labelling special
paper web guides are available which prevent that the paper web can
slip down.
3.10 Maintenance
The winder does not need maintenance to a large extent. Remove dirt with a cleaning agent free
of solvents. No cleaning agent or humidity must penetrate into the winder. Otherwise there is the
danger of damages to electrical components or bearings.
The brake of the winder mandrel and the motor brushes are liable to wear depending of use.
They must be exchanged or readjusted depending of use and wear.
123
4
5
7
6
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3.11 Brake
The brake 7must brake the winder mandrel 10 when the dancer 1is released to its rest position.
It must not more be active when the motor 12 is powered. The brake force is controlled by the
winder control 4.
The optimum airgap of the break is 0.2mm when it is released. If the gap is wider (> 0.5mm) the
break must be readjusted. This readjustment is also necessary when the breaking force is not
sufficient.
Legend
1. Dancer
2. Support plate
3. Fixing bolt
4. Winder control
5. Cover
6. Sensor flag
7. Electromagnetic
break
8. Securing nut
9. Wedge
10. Winder mandrel
11. Anchor
12. DC Motor
13. Motor Brush
Figure 9
3.11.1Adjustment of brake
Remove the cover 5. Open the fixing bolts 3and remove the winder control 4. Remove the
sensor flag 6on the winder mandrel 10. Lock the mandrel. Adjust the brake while shifting the
ancor 11 in or out until the gap is 0.2mm again. Fix the securing bolts 8with Loctite.
Reassemble all parts in reverse mode.
ATTENTION:
Do not forget to retighten the powertransistors of the winder control
to the heatsink (2 screws).
While unpowered, the anchor must not touch the break magnet !
(Minimum 0.2mm airgap)
1
2
3
4
5
6
7
8
9
10
11
12
13
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3.12 Motor brushes
In normal operation the brush life is approx. 2500 hours. During occasional maintenance works,
check for abrasion. They should be exchanged only when the motor does not more rotate.
To exchange the motor brush, carefully loosen the brush holder since the brush is under spring
pressure. With removed screw the brush can be removed. After check or exchange the brush can
be reassembled in the holder and fixed with the screw.
ATTENTION:
Only use genuine type brushes. Otherwise there will be the danger of
permanent motor damage.
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4Electrical settings
The winder control C9100 controls the winders motorcurrent and the breakcurrent depending on
the dancers position. This position is sensed without contact in five steps with optical sensors
placed at the rear side of the winder control p.c.board. Six connectors are used to connect the 24
volt supply voltage, the motor and break wires respectively. Figure 10 shows the component side
of the p.c.board:
Figure 10: Winder control
The winder control board carries seven jumper blocks for the motor and break current
adjustment. Three jumpers (WIND, TORQUE and DANCER) are used for the motor currentt.
The following table shows the jumpers and their function.
Motor-jumpers Function
DANCER Direction of action of dancer roller
TORQUE Torque
WIND Rewinder/Unwinder
24V GND MOTOR BREAK
WIND TORQUE DANCER
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4.0.1Direction of action of dancer (DANCER)
The position of the dancer roller is sensed without contact by five optical sensors which are
mounted mechanically in line so that depending to the dancer position the light beam of one or
more sensors is detected.
The output signals of these light sensors are added and represent the signal to control the winder
motor current. Since the same dancer is used for righthand and lefthand type winders, it must be
only possible to switch over the characteristics of the deflection. This is set by means of the
DANCER jumper.
If with righthand stop of the dancer roller the motor should rotate, the DANCER jumper must
be plugged in the left (1) position, for lefthand stop in the right (3). See next figure 11.
Figure 11
WIND TORQUE DANCER
1 3
LR
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