Collamat 6600 Release Note

Collamat 6600
Technical handbook
5999.525-01F
HM Collamat AG
Bodenmattstrasse 34
CH-4153 Reinach
Switzerland
Phone [phone]
Fax [phone]
[email protected]
www.collamat.ch

Index page
1 Safety advices ..................................................................... 4.......
1.1 Important Warnings .............................................................. 4.......
1.2 Danger Indications ............................................................... 4.......
1.3 Symbol descriptions .............................................................. 5.......
2 Introduction ........................................................................ 6.......
2.1 General informations ............................................................. 6
.......
2.2 The labeler C6600 ................................................................ 6
.......
2.2.1 Prevention of accidents ......................................................... 7
.......
2.2.2 Noise suppression .............................................................. 7.......
2.2.3 Mechanical stability ............................................................. 7.......
2.3 Assembly parts ................................................................... 8.......
3 Mechanical adjustments ............................................................ 9.......
3.1 Traction unit ...................................................................... 9.......
3.1.1 Threading the labelweb ......................................................... 9.......
3.1.2 Adjustment of rewinder coupling force .......................................... 9.......
3.1.3 Readjustment of paper brake ................................................... 10
......
3.1.4 Longitudinal adjustment on the module rail ...................................... 10
......
3.2 Flap adapter ...................................................................... 11......
3.2.1 Inclination adjustment of flap adapter ........................................... 11......
3.2.2 Adjustment of the pressure roller of the flap adapter ............................ 11......
3.3 Adjustment of the optical label scanner ........................................... 12
......
3.4 Adjustment of the mechanical label scanner ...................................... 13......
4 Technical description ............................................................... 14......
4.1 Dispenser board .................................................................. 14......
4.1.1 Power supply ................................................................... 14
......
4.1.2 Motordriver ..................................................................... 14......
4.1.3 Controller ....................................................................... 14......
4.2 Signals and connection diagrams ................................................. 15......
4.2.1 Inputs .......................................................................... 16......
4.2.2 Outputs ........................................................................ 16
......
4.2.3 Isolated outputs ................................................................ 17......
4.2.4 Open-Collector-outputs ......................................................... 17
......
4.2.5 Currentsource-output ........................................................... 18......
4.3 Connection diagrams BUS X101, X102 ........................................... 19
......
4.4 Transformer wiring ............................................................... 19......
4.5 Connection of the mains input .................................................... 20......
4.6 Grounding of the labeler .......................................................... 20......
4.7 Connection of the mains output ................................................... 21......
4.8 Connection of the frontpanel ...................................................... 21
......
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Index page
4.9 Motor and motorcable ............................................................ 22......
5 Firmware ........................................................................... 23......
5.1 Normalmode ..................................................................... 23......
5.2 DIL-switches ..................................................................... 24......
5.2.1 DIL-switch TEST ............................................................... 24......
5.2.2 DIL-switch DIR ................................................................. 24
......
5.2.3 DIL-switch DEL ................................................................. 25
......
5.2.4 DIL-switch NS .................................................................. 25
......
5.2.5 DIL-switch R1 .................................................................. 25......
5.2.6 DIL-switch R2 .................................................................. 25......
6 Trouble shooting ................................................................... 26......
6.1 Fuses ............................................................................ 26......
6.2 Status LEDs ...................................................................... 26......
7 Peripheral units and sensors ....................................................... 27......
7.1 Optical label scanner ............................................................. 27......
7.2 Goods scanners .................................................................. 27
......
7.2.1 CS measuring IR-scanner ...................................................... 27
......
7.2.2 NPN-Reflective scanner ........................................................ 27......
7.3 Magnet adapter .................................................................. 28......
7.4 Flatprinting unit ................................................................... 29......
7.4.1 Flatprinter board ................................................................ 29
......
8 Control signals for external units .................................................... 30......
8.1 How to connect a goods scanner ................................................. 30......
9 Electrical installation ................................................................ 31......
9.1 Introduction ...................................................................... 31
......
10 Nonstop labelling .................................................................. 33......
10.0.1 Setting up of the Nonstopmode ................................................ 34......
11 Testmode ......................................................................... 35......
11.1 Testprogram .................................................................... 36......
11.1.1 Motortest ...................................................................... 36
......
11.1.2 Motor intervall test ............................................................. 37......
11.1.3 BUS-signal selftest ............................................................ 37
......
11.1.4 Signal display ................................................................. 38......
11.1.5 DIL-switch settings ............................................................ 38
......
11.1.6 Potentiometer settings ........................................................ 38......
11.1.7 EEPROM Data ................................................................ 39......
11.1.8 Version and Serial-No ......................................................... 39......
11.2 Potentiometer parameters ....................................................... 39......
11.3 Incremental encoder programming .............................................. 41
......
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Index page
12 Incremental encoder .............................................................. 43......
13 Control of a hotstamp with the IFEED signal ....................................... 44......
14 Cabling and setting up ............................................................ 45......
14.1 Cabling ......................................................................... 45......
14.2 Setting up ....................................................................... 45......
15 Version numbers .................................................................. 46
......
16 Glossary and terms ............................................................... 46
......
16.1 Short cuts ....................................................................... 46
......
16.2 Signals .......................................................................... 46......
16.3 Terms ........................................................................... 47......
17 Technical data .................................................................... 48......
17.1 Dimensions - systemdesign ..................................................... 50......
18 Trouble shooting .................................................................. 51......
18.1 Trouble shooting Collamat 6600 ................................................. 51......
18.2 Trouble shooting checklist ....................................................... 56......
Appendix spare parts Collamat 6600
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1Safety advices
1.1Important Warnings
Before installing and operating the Collamat 6600 read following safety
instructions:
The labeler C6600 is exclusively determinated for labelling goods.
The installation of a Collamat 6600 has to be done by a trained specialist.
For this you have to consider the national specific regulations of
prevention of accidents
mechanical stability
construction of electrical and mechanical systems
noise suppression
Take notice to the technical data of the Collamat 6600. Especially the environ-
ment conditions must be observed.
The operation of the Collamat 6600 must be done by trained personnel.
In case of non-authorized modification guarantee will fall.
Before connecting non-standard products ask your competent technical
supporter.
1.2Danger Indications
The safety symbols and danger advices on the Collamat 6600 and in this man-
ual must strictly be observed.
Before connecting or disconnecting the labeler to or from the mains, it must be
switched off.
The labeler C6600 may only be opened by authorized personnel.
Before opening the labeler C6600, it must be separated from the mains power.
It exists danger of pinching hairs, jewelry, ties, clothes etc. into the traction unit
It exists danger of injury by cutting fingers in the area of the paper web.
It exists danger of injury in the area of the dancer of the unwinder of the
Collamat 6600.
It exists danger of injury in the area of the paper stockcontroller of the Collamat
6600.
For operation on the Collamat 6600 the operating personnel must keep to a
safely place to prevent injury from the products being labeled.
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1.3Symbol descriptions
ATTENTION
Indicates danger of damaging the Collamat 6600 or other system compo-
nents, with a potential consequential danger of injuries.
DANGER
Indicates an immediate hazard for persons.
DANGER
Shock hazard due to high voltage at component.
DANGER
Hazard due to high temperature component.
ATTENTION
ESD warning (Electro Static Discharge). The PC boards or component may
only be touched in an electrostatically protected environment.
NOTE
Important or additional information to Collamat 6600 or to the
documentation.
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2Introduction
2.1General informations
This technical handbook describes the construction and the function of the Collamat 6600. In addi-
tion to the operating instructions, it contains the necessary tips and adjustments to get optimum
use of the Collamat 6600. The descriptions of each electrical or mechanical device also helps for
quick error analysis and error elimination.
We recommend you to replace the complete electronic boards. Return it to HM Collamat AG or to
its representative for repair. You can then feel sure, that the high quality standard of the Collamat
6600 can also be guaranteed after repair.
2.2The labeler C6600
Special characteristics of the Collamat 6600:
resistant to wear, no clutch/brake-system
robust, stable
easy installation and operation due to the modular construction
quick change-over to other labelling tasks
high performance
high reliability
latest SMD-technology
high precision 2-phase steppermotor
The traction unit as well as the other peripheral assemblies are mounted on a modular rail. The
control electronics of the peripheral units are built in the units. The units are controlled and driven
by signals of the bussystem inside of the modular rail.
The operating elements for dispensing speed, predispensing, position, optical label scanner, data-
hold switch, as well as the mains switch are placed right on the body of the traction unit itself. All
parts are corrosion-proof, the feedroller of the traction unit is provided with a special coating for
permanent nonslip torque transmission onto the paperweb. The rewinding force of the rewinder as
well as the braking power of the paper brake are adjustable at the traction unit from the outside.
The installation of the Collamat 6600 must be done by trained personnel. For this you have to con-
sider the national specific regulations of:
prevention of accidents
noise suppression
mechanical stability
construction of electrical and mechanical systems
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2.2.1Prevention of accidents
While installing and connecting the Collamat 6600 take care that the signal cables and power ca-
bles can't become obstacles. The cables must be placed and installed according to the national
safety requirements. Take care that the signalcables are not placed beneath power cables.
The mains switch and the controll elements must be easily accessible.
2.2.2Noise suppression
The dispenser C6600 is shielded according to the CE directives. Only cables which are certificated
by HM Collamat AG may be used for connecting the dispenser to the peripheral units and the
mains power. Additional peripheral units must be connected to the auxiliary mains terminal of the
dispenser. These assemblies must be certificated by HM Collamat AG.
2.2.3Mechanical stability
If the Collamat 6600 is used on a movable stand, this stand must be capable to be tilt 10° in each
direction. See also following figure 1:
Figure 1: Stability of the stand
10° 10°
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2.3Assembly parts
The assembly parts are mounted and placed on a modular rail. Following figure 2 shows these as-
sembly parts with their names on the modular rail:
Figure 2: Assembly parts
Legend
1. Unwinder dancer 5. Modular rail
2. Unwinder 6. Support
3. Traction unit 7. Adapter (optional with magnet)
4. Paper brake
1 2 34 5 67
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3Mechanical adjustments
3.1Traction unit
3.1.1Threading the labelweb
Figure 3
Thread the labelweb as shown in figure 3 up to the dispensing edge and draw it out by approx. 1m.
Detach the labels from the paperweb at the drawn-out web. Then open the pinchroller by turning
the knob 1, place the paperweb over the dispensing edge and finish threading the paperweb as
shown in figure 3. Close the pinchroller. Adjust the side guides of the paperweb well, leaving 0.5
mm free space to the paperweb's edge.
3.1.2Adjustment of rewinder coupling force
Figure 4
The coupling force of the rewinder is factory-set. Proceed as follows if out of adjustment:
Detach winding spindle 1 after unscrewing the M5-bolt 3. Screw M8-bolt 2 accordingly:
in = harder coupling
out = softer coupling
1
3
2
1
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3.1.3Readjustment of paper brake
Figure 5
The braking force is factory-set to an optimum value. Should it, however, be unadjusted, readjust it
with the M3-bolt 2 in the web-end controlbox of the traction unit, from the outside.
Screw in bolt = higher braking force
Unscrew bolt = lower braking force
3.1.4Longitudinal adjustment on the module rail
Figure 6
Unscrew 4 bolts with special tool (wrench for socket head cap screws 5 mm) one half turn (adapter
only 2 bolts).
Move device, observing scale on module rail. Then tighten bolts equally.
2
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3.2Flap adapter
3.2.1Inclination adjustment of flap adapter
Figure 7
The inclination of the flap adapter can be changed against the module rail: Unscrew nut 1 with two
turns (refer to figure 7), with special hexagonal spanner (included as accessory). Push adapter in
the direction indicated by the arrow 2, turn to desired setting at ring 3. Retighten nut1.
The pressure force of the flap adapter without magnet or of the magnetic flap adapter is variable:
push in button 4in the direction indicated by the arrow, twist for appropriate spring tension and ad-
just until it meets the next stop.
3.2.2Adjustment of the pressure roller of the flap adapter
Figure 8
The pressure roller of the adapter can be adjusted depending on the labels and goods:
Horizontal adjustment with the knurled nut 5
Vertical adjustment with the hexagonal nut 6
12 3 4
5 6
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3.3Adjustment of the optical label scanner
Figure 9
Proceeding of the adjustment of the optical label scanner:
Switch on the Collamat 6600. Set the label scanner potentiometer to zero. Pull the labelweb so that
the gap is located below the marking 1 of the scanner. Turn the potentiometer until the red LED on
the scanner goes off. Continue pulling the labelweb until a label is located below the scanner. Con-
tinue turning the potentiometer until the LED switches off again. The optimum setting is at the cen-
ter position of the two potentiometer settings witch turned the LED off.
Remark:
If the setting of the optical label scanner is faulty, the gap between the la-
bels will not be detected. After the triggering of a labelling operation, the
labeler will stop after approx. 0.75 m of the labelweb.
For transparent labels, please use the mechanical label scanner.
min. 2 mm
LED
1
Gap
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3.4Adjustment of the mechanical label scanner
The mechanical label scanner (not used on magnetic flap adapter) is an alternative to the optical
label scanner and is mainly used for transparent labels.
1. Scanner support
2. Scanning head
3. Nut
Figure 10
Adjustment:
Place the label under the scanning head, the LED on the scanner support must be turned on. If
this is not the case, unscrew the nut on the scanning head and turn it counterclockwise until the
LED turns on.
Turn the scanning head clockwise until the LED turns off.
Turn the scanner one quarter turn forward and retight the nut.
Place the gap between the labels under scanning head, the LED-display must be turned on.
Note:
No adjustment is necessary on the traction unit!
2 - 6 mm
LED
1
2
3
1
2
3
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4Technical description
4.1Dispenser board
All the electronic devices including power transformer, except of the main switch with indicator
lamp, are located on a printed board. The dimensions of the board are approximately 215 x 234
mm. Figure 11 shows the board with all the connectors and terminals.
The description is divided into power supply, motordriver, controller and firmware.
4.1.1Power supply
The power supply unit generates the two regulated voltages +12V/1A and + 5 V/1A for the logic,
as well as an unregulated DC voltage of approx. 70V/3.5A for the steppermotor. The stabilization is
done by linear voltage regulators.
4.1.2Motordriver
The driver board consists of 2 H-bridge circuits to drive the two motor phases. The phase current
is 4 A while running, and 2 A when stopped. To control the current, a chopper circuit with 20 kHz
chopper-frequency is used.
Dependent on the dispensing speed the processor generates a fullstep- or a halfsteppattern. For
speeds faster than 8 m/min, the motor is driven by a fullstep-pattern.
In the case of overheating, short-circuit or malfunction the motordriver is switched off and the red
LED FAULT is illuminated. In this case the labeler must be switched off and on again. If a faulty
condition is detected, the signal ERROR is activated.
4.1.3Controller
The single chip micro-controller H8/532 with external 32 K-Byte EPROM controls the functions of
the labelling process.
All outputs are buffered by photo-couplers.
All the inputs are pulled up to +12V with 2.2 K and are equipped with a low-pass filter.
The A/D-converter scans periodically the value of the settings of the 4 potentiometers
(R101....R104).
The control current of the label scanner is generated by a controlled current source.
The data, stored when DATA-HOLD is activated, are stored in a 256 bit EEPROM.
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Figure 11: Dispenser board
4.2Signals and connection diagrams
All in- and outputs are equipped with filter elements to prevent electromagnetic interference. These
components also prevent interference caused by electrostatic discharge. The interference can lead
to malfunction of the Collamat 6600. Anyway, installing the Collamat 6600 you have to consider the
rules concerning RMI and ESD to prevent these interferences. See also chapter Cabling.
GND
GSC1
+12V
GND
LSC
+12V
TCY
+12V
GND
RDY
FEED
IFD
IFD
+12V
GND
GSC2
+12V
GND
GSC3
NSTPI
NSTPO
GND
ERR
ERR
+12V
X48
a3
a2
a1
L1
N1 X46
96
1
F1
2AT 230V
4AT 115V
N
L
X51
F2
3.15AT
1.6AT
F3
3377
IN
X40 LNPE
X101X102
12V
5V
TEST
DIR
DEL
NS
R1
R2
X104
1
2
RESET
FAULT
X61 X60
1
X103
X106
1
7
605
OUT
X1
X25
SPEED PREDISP POS TCY
X105
X39
X36
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4.2.1Inputs
The inputs are used to connect peripheral units and sensors. The inputs are activated while they
are pulled to GND (0 Volt). The peripheral units from HM Collamat AG have NPN-outputs to 0 Volt.
Figure 12 shows the schematic diagram of the inputs:
On: >4mA (or < 2V)
Off: 0mA (or > 8V)
Vmax: 24V
Figure 12: Signal input
An input is then active, when a current of minimum 4mA is pulled to GND. The following inputs are
available:
GSC1 Goods scanner
GSC2 Incremental encoder input
GSC3 Goods scanner for counting in the Nonstop-mode
LSC Label scanner
READY READY-signal for peripheral units
NSTPI Nonstop-input, (Controlsignal), (equal to RESIN)
4.2.2Outputs
The outputs are used to control peripheral units. There are three different kinds of outputs:
Isolated outputs
Open-Collector-outputs
Currentsource-output
10nF
2k2
+5V
-
+
LM339
10k
10k
+12V+12V
100k
2k2
GND
IN 4k7
1n
H8/532 Input
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4.2.3Isolated outputs
These outputs are completely isolated to the electronic circuit of the labeler. Figure 13 shows the
schematic diagram of the isolated outputs. The following outputs are available:
ERROR Photocoupler, indicates an error condition (ERR)
IFEED Photocoupler, isolated FEED-signal (IFD)
Figure 13: Isolated outputs
4.2.4Open-Collector-outputs
For better resistance against interferences, the Open-Collector-outputs are also equipped with
photocouplers. Figure 14 shows the schematic diagram of the Open-Collector-outputs. The follow-
ing Open-Collector-outputs are available:
FEED Indicated that the motor is turning
CLOCK Steppermotor clock for synchronizing external units
NSTPO Nonstop-output (controlsignal), equal to RESOUT
Figure 14: Open-Collector-outputs
PC355T
+
-
1n 1n
Umax.: 24VDC
Imax: 25 mA
+5V
PC355T
+
1n
Umax.: 24VDC
Imax: 25 mA
+5V
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4.2.5Currentsource-output
For the IR-transmitter of the label scanner TCY, a controlled currentsource is used. Figure 15
shows the schematic diagram of the currentsource:
Figure 15: TCY-currentsource
+12V
TCY
4 IR-LEDs
OP-AMP
10k 100k
100n 10n
BCP54-16
100
LM358
PWM
H8/532
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4.3Connection diagrams BUS X101, X102
The buscable of the peripheral units is connected to the connectors X101 or X102. The cable must
be placed inside of the module rail to prevent interferences. Figure 16 shows the position of the
buscable connectors on the dispenser board:
Figure 16
Connector X102 Connector X101
Pin Signal Pin Signal Pin Signal Pin Signal
1+12V 2+12V 1GND 2GND
3READY 4FEED 3nc. 4nc.
5LSC 6GSC1 5CLOCK 6nc.
7TCY 8GSC2 7GSC2 8TCY
9nc. 10 CLOCK 9GSC1 10 LSC
11 nc. 12 nc. 11 FEED 12 READY
13 GND 14 GND 13 +12V 14 +12V
4.4Transformer wiring
The secondary side of the transformer is connected to the terminals X36...X39. Both violet wires
are connected to the terminals signaled with a 7. Both orange wires are connected to the terminals
signaled with a 3. See also Figure 17:
Figure 17
X102 X101
1
1
1 2
13 14 12
14 13
X39
X36
3 3 77
violet
orange
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