Collamat 8600 User manual

CollamatCollamat®8600/91008600/9100
Operating instructions
Monitor
Collamat Stralfors AG CH-4147 Aesch Pfeffingerring 201 Tel [phone] Fax [phone]
5999.530-01B

Index Page
Index 1
Important warnings 3
Danger notes 3
Symbol description 4
General information 5
The monitor 6
The controls of the monitor 7
LCD display 8
Function keys 8
RUN/STOP key 8
Keyboard 8
ENTER key 8
ESC key 9
UP and DOWN key 9
LABELLING MODE function key 9
PROGRAMMING function key 9
CONFIGURATION function key 9
SERVICE DISPLAY function key 9
Entering data with the keyboard 10
Selecting a branch in the function tree 10
LABELLING MODE function key 11
Label jog 11
Select program 11
Information display 12
Reset counter 12
Preset counter 12
Select counter 13
Reset nonstop 13
The PROGRAMMING menu tree 14
Change program 15
Label scanner sensitivity 15
Auto adjust 16
Manual adjust 16
Label length 17
Auto adjust 17
Manual adjust 17
Suppression of label scanner 18
Predispensing 18
Position 19
Speed and type of measurement 20
Maximum speed 21
Good suppression 21
Labelling mode 21
Multiple labelling mode 22
Delayed predispensing 23
Profiling 24
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Index Page
Store program 25
Program name 25
Program presets 26
The 'CONFIGURATION' menu tree 27
User menu 28
Language 28
User level 29
Change level 29
Change password 29
Error handling 30
Nonstop mode 30
Adapter magnet 31
Motor direction 31
Polarity IFEED 31
The 'SERVICE FUNCTIONS' menu tree 32
Software-Version 32
Error sequence 33
Self-test 33
Test RAM 33
Test EEPROM 34
Test keyboard 34
Test LED 34
Test LCD 34
Test illumination 35
Test I/O Controller 35
Test I/O Monitor 35
Test drive 36
Remote Control 36
Working time 36
Motor running 36
Technical appendix 37
Adjusting the predispensing 37
Adjusting the label position 38
Adjusting the profiling 39
Error messages 40
Error diagnosis 41
Value table 44
Maintenance 45
Cleaning 45
Fuses 45
Repairs 46
Packing 46
Technical data monitor 47
Trouble shooting checklist 48
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Important warnings
Before installing and operating the Collamat®8600/9100
read the following safety instructions.
The monitor C8600/C9100 is exclusively intended to control the labeller
C8600/C9100.
Install the labeller C8600/C9100 only by a trained specialist considering the na-
tional specific regulations of
prevention of accidents
construction of electrical and mechanical systems
noise suppression (RMI)
Take notice of the technical data of the Collamat®8600/9100. Especially the en-
vironment conditions must be observed.
Install the Collamat®8600/9100 at a dry location, protected from splashing
water.
Operate the Collamat®8600/9100 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.
Peripherals to the Collamat®8600/9100 must only be connected to the mains
socket of the monitor. These devices must be approved by Collamat Stralfors
AG. The specifications of the mains socket are specified in the Technical
Appendix.
Danger notes
The safety symbols and the danger advices on the Collamat®8600/9100 and in
this manual must strictly be observed.
The Collamat®8600/9100 must only be set up in switched off condition.
Before connecting or disconnecting the labeller C8600/9100 to or from the moni-
tor switch off the monitor.
Monitor and distribution box are only allowed to be opened by authorized
personnel.
Danger of pinching hair, jewellery, ties, clothes etc. into the traction unit !
Danger of injury by cutting fingers in the paper web zone !
Danger of injury in the dancer roller zone of the Collamat®8600/9100 rewinder
and unwinder !
Danger of injury in the case of non-expert use of the Collamat®8600/9100 in the
paper stock control zone.
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Symbol description
ATTENTION
Indicates danger of damaging the Collamat®8600/9100 or other
system components, 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 (ElectroStatic Discharge). The PC boards or com-
ponents may only be touched in an electrostatically protected
environment.
NOTE
Important or additional information to Collamat®8600/9100 or to
the documentation.
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General information
Theentire electronic operating and control system is installed in a modern, elegant mo-
nitor. Its SMD-design guarantees high operation safety. The monitor can be operated in
all installation positions, because the front panel can be mounted reversibly. Monitor
and labeller are connected with two cables. One cable feeds the stepper motor, the
other connects the labeller peripherals with the monitor. A microprocessor controls all
labeller functions. To facilitate entering values in noisy environment, the foil keyboard is
provided with action point contacts. There are no potentiometers or controllers inside
the monitor. All parameters can be set via keyboard. (The stepper control was develo-
ped and produced by a well-known manufacturer of stepper motor drives.) The monitor
can be started or stopped by a signal from outside. The operating mode is displayed to
the outside by relay contacts.
Special characteristics of the Collamat®C8600/9100 monitor
Modern menu-driver operation
No controller or potentiometer
All important parameters can be set during labelling
32 program memories
All values and parameters can be stored
Two user levels
Modern design
Variable installation in systems
Due to amply dimensioned heatsink no fan is necessary
Connection to labeller with only two cables
Modern fail-safe electronics
Electric modular design with SMD-components
Variable labelling speed by incremental encoder or measuring light barrier
Nonstop operation with two Collamat®
Remote control possible by SPC
Relay contacts for operating state indication
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The monitor
The monitor may only be opened by trained personnel. It contains no
parts to be handled by the operator.
The monitor contains live parts. Hazard of contact due to high voltages
of the assemblies.
The monitor contains electrostatic (ESD) sensitive assemblies. Unsafe
contact may destroy these assemblies.
The monitor consists of a solid metal housing. Its front panel contains the controls. The
mains switch is installed on the back panel and is intended to connect the labeller and
power. The following figure is a front view Aand a rear view B of the monitor.
Figure 1: Monitor
Legend
1.Heatsink
2.Front panel
3.Cover
4.Mains switch
5.Sockets
6.Back panel
1 2 3 4 56
AB
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The controls of the monitor
The mains switch of the monitor is installed on the back panel. Before
switching on check labeller and system signals for correct connection.
All functions and data of the labeller are entered via the controls of the monitor. Monitor
data and states are indicated by a background lighted LCD-display with four lines with
20 characters each. A foil keyboard is used to enter data. The keys have a well sensible
action point allowing also correct inputs in a noisy environment. The controls of the mo-
nitor are shown on the following figure:
Legend
1. 4 line LCD 8. RUN LED
2. Labeling mode key 9. ESC key
3. Programming key 10. Keyboard 0...9
4. Configuration key 11. ' ' Key
5. Service indication key 12. ENTER key
6. RUN/STOP key 13. UP key
7. STOP LED 14. DOWN key
COLLAMAT 0
ESC ENTER
7 8 9
4 5 6
1 2 3
1 2 3 4 567 8
9 10 11 12 14 13
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LCD display
The LCD-display is used to enter and indicate data and operating states of the monitor
and labeller. The background illumination increases the legibility and shows at the same
time, that the monitor is on. A cursor helps to select and enter data. Orientation ar-
rows on the border of the LCD help to pass through the function trees and to select
menu items.
Function keys
The monitor is operated by five function keys. A LED function display is assigned to
each function key showing that the operator is moving in an assigned function tree. In
a function tree it is possible to access to particular function through branches.
If changing from one function tree to another, the actual branch, in which the operator
works, will be temporarily memorized, so that upon a call of the previous function tree
he is in the previous branch. The particular function keys and the parameters which
can be selected by each function key are described below.
RUN/STOP key (6)
The RUN/STOP key is used to start (RUN) or stop (STOP) the
Collamat®. The RUN state is indicated by a green LED (8). The STOP
state is indicated by a red LED (7). In RUN state it is not possible to
change all functions, because faults could occur during labelling. But in
STOP state all functions can be changed.
Numerical keyboard (10)
With the numerical keys 0...9 all numerical data can be directly ente-
red via the keyboard. A decimal point ',' can be entered by key (11).
ENTER key (12)
With the ENTER key the inputs are terminated. The ENTER key is al-
so used to select the menu item, on which the cursor is actually
positioned.
0...9
ENTER
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ESC key (9)
The ESC key is used to abort the input of data and to jump back to
the previous branch of the function tree.
UP (13) and DOWN (14) keys
These two keys are used to select a function within a function tree.
When entering data the indicated value can be increased (up key) or
reduced (down key) with these keys.
LABELLING MODE function key (2)
This key is used to select the labelling mode function. When depres-
sed, the LED placed above lights up and indicates that the monitor is
in labelling mode. The Collamat®parameters are entered in this mode.
The Figure "LABELLING MODE" menu tree (page 11) shows the
function tree of the labelling mode.
PROGRAMMING function key (3)
This key is used to select the programming function. When depres-
sed, the LED placed above lights up and indicates that the monitor is in
programming mode. The parameters of labeller and labelling are ente-
red in the programming mode. The Figure "PROGRAMMING menu
tree" (page 14) shows the function tree of the programming mode.
CONFIGURATION function key (4)
This key is used to select the configuration function.When depres-
sed, the LED placed above lights up and indicates that the monitor is
in configuration mode. In this mode the Collamat®is adapted to the
customer's requirements. The "CONFIGURATION menu tree" (page
25) shows the function tree of the configuration mode.
SERVICE DISPLAY function key (5)
This key is used to select the service display function. When depres-
sed, the LED placed above lights up and indicates that the monitor is in
service mode. The "SERVICE FUNCTIONS menu tree" (page 30)
shows the function tree of the service mode.
ESC
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Entering data with the keyboard
The numerical keys of the keyboard (10) are used to enter data. If the value to be ente-
red is a decimal, enter the decimal point with the key ' ' (11).
Confirm the input with the ENTER key (12) to validate it. If the data range is exceeded,
this is indicated for a short time and the original value does not change. Now entering
can be continued. The next permissible value of the decimal place is calculated and
indicated.
The indicated data can also be increased or reduced step by step with the arrow keys
up (13) and down (14). The change of data with these keys has to be terminated by
depressing the ESC key (9). Then the last indicated data are taken. Here takes place a
continuous control of the data range, so that unacceptable data can be avoided.
The ESC key (9) allows to abandon entering data by keyboard. Then the original value,
valid before the change will be indicated.
The ESC key (9) is used to jump back to the previous branch after having entered a
value.
All minimum and maximum values of the functions are shown in the
value tables of the Technical Appendix.
Selecting a branch in the function tree
Use the up (13) and down (14) keys to select a branch of the function tree. With these
two keys a little cursor (1) can be moved up and down on the left of the LCD-display.
The line, where the cursor is positioned, points at the branch of the function tree, which
can be selected as next with the ENTER key. On the right side of the LCD-display a litt-
le direction (arrow) (2) informs, whether it is possible to move further up or down.
FUNCTIONTREE 1. Cursor
Functionbranch 1
Functionbranch 2 2. Direction arrows
Functionbranch 3
Not all functions can be changed in the labelling mode. In the descripti-
on of the function is noted, which one is only changeable in start or
stop state of the labeller.
Not all functions can be selected in the operating mode. In the descrip-
tion of the function is noted, which one is changeable in the operating
mode or in the programming mode.
In the value table in the Technical Appendix is shown, which modes in
the considered function are permitted.
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The 'LABELLING MODE' menu tree
The functions necessary for the labelling mode can be called up and operated in the
'LABELLING MODE' menu tree. The 'LABELLING MODE' menu tree comprises the
following functions:
LABELLING MODE
Label Jog
Select program
Information Display
Reset Counter
Preset Counter
Select Counter (Labels / Goods / External)
Reset Nonstop
Label jog
With this function a label can be dispensed for test purposes by the keyboard. The dis-
pensing speed corresponds to the set fixed speed. The label is dispensed by depres-
sing the ENTER key when the cursor is placed on this line:
LABELLING MODE
Label Jog
Select program
Information display
When setting up in nonstop mode the labels have to be triggered with
this function so that the nonstop counter of the master does not be-
come asynchronous.
Select program
This function allows to select one labelling program out of 32 possible programs:
SELECT PROGRAM
Number 1
Name 50x80x3
programmer/operator
RUN/PASSIVE
User level:
Operating mode:
programmer/operator
STOP
User level:
Operating mode:
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Information display
This function allows to indicate the most important labelling parameters on the LCD-dis-
play. The program number, the actual dispensing speed, the count and the label positi-
on on the good are shown here. It is not possible to change any data. They are only
indicated and updated. The arrangement of the information display is made in the User
Menu in the CONFIGURATION menu tree. The ESC label key terminates this indication
mode:
Program 1 RUN
Speed 3.0m/Min
Counter 000000
Position 10.0 mm
Reset counter
This function allows to reset the counter to zero. ENTER resets the counter.
Counter cleared !
Preset counter
This function allows to activate and set the preset counter. Entering a value greater
than zero activates the preset counter. After entering return to the counter menu by de-
pressing the ESC key.
ENTER PRESET
Value : 123456
programmer/operator
RUN/STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
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Select counter
This function allows to select what should be counted by the counter. The counter input
can distinguish between three different input signals:
Products (goods) (GSC2)
Labels (LSC)
External signal (GSC3)
The selection can be done by the arrow key and terminated by ESC.
SELECT COUNTER
Choice: Products
Reset nonstop
This function resets internal counters and monitoring states during the nonstop mode.
This function has to be called up when a fault has occurred in nonstop mode to guaran-
tee a perfect labelling of the goods. The Nonstop Reset is called up with ENTER. The
following indication confirms the execution of the reset.
Nonstop-mode
is initialized !
Note:
This function can be selected only in switched on nonstop mode.
Before starting this function, all products between both labelers must
been removed.
programmer
STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
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The 'PROGRAMMING' menu tree
The 'PROGRAMMING' menu tree is used to call up and operate the functions
necessary for programming.
PROGRAMMING
Change program
Label scanner Sensitivity
Auto adjust
Manual adjust
Label Length
Auto adjust
Manual adjust
Label Suppression
Predispensing
Position
SpeedFixed Speed
Incremental Encoder
Measuring Scanner
Maximum Speed
Good Suppression
Labelling mode
Normal Labelling
Multiple Labelling
Delayed Predispensing
Profiling
Store Program
Program name
Program presets
The 'PROGRAMMING' menu tree has the following indication:
PROGRAMMING
Change Program
Store Program
Program name
Program Preset
programmer/operator
RUN/STOP
User level:
Operating mode:
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Change program
The Change program function is used to branch in an additional menu by calling up
further parameters to be changed:
CHANGE PROGRAM
Labelscanner Sens.
Label Length
Label Suppression
Predispensing
Position
Speed
Max. Speed
Good Suppression
Labelling Mode
Profiling
Label scanner sensitivity
The Label scanner sensitivity function is used to adjust the label scanner sensitivity
manually or automatically. This function is not necessary for mechanical label scanning.
LABEL SCANNER SENS.
Auto adjust
Manual adjust
programmer/operator
RUN/STOP
User level:
Operating mode:
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Auto adjust
When adjusting the sensitivity automatically, the paper web has to be pulled forward by
depressing the up key, until the label scanner is positioned over the gap. A lateral mark
on the scanner head shows the position of the label scanner. The automatic adjustment
is started by depressing the ENTER key or abandoned by depressing the ESC key. Af-
ter adjustment the found value is indicated. If the scanner can not be adjusted on the
paper web, an error message will be issued.
AUTO ADJUST AUTO ADJUST DONE
Move Label with
to the Gap and then TCY-Value 50 %
press [ENTER] Key
User level: programmer/operator
Operating Mode: STOP
Manual adjust
When adjusting the sensitivity manually, the value is entered by hand. Entering can be
aborted by depressing the ESC key. This function will especially be used above all for
the adjustment of labels made of 'difficult' material.
LABEL SCANNER SENS.
TCY-Value 50 %
Gap
Label
Dispensing edge
Mark
Labelscanner
programmer
STOP
User level:
Operating mode:
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Label length
The Label length function is used to adjust the length of the label manually or
automatically.
LABEL LENGTH
Auto adjust
Manual adjust
Auto adjust
When adjusting the label length automatically, the measuring has to be started by the
ENTER key. The adjustment can be aborted by depressing the ESC key. After starting
the adjustment, the paper web is pulled forward by 2 gaps to measure the label length.
If no gap is detected, an error message appears and the label length is set to 100 mm.
AUTO ADJUST LABEL LENGTH
Auto adjust done
Adjust Label length Length : 100 mm
with [ENTER] Key
User level: programmer
Operating Mode: STOP
Note:
The measured label length should only be considered as an approxima-
te value. When using this value a fault message may appear, because
due to mechanical slippage the traction roller may cover a distance
exceeding the label length.When the labeller stops are exceeded an
error message appears.
Normally after automatic measurement the double or triple label length
is entered by hand. The advantage is that the labels not existing on the
backing paper are compensated.
Manual adjust
When adjusting the label length manually, the value is entered by hand. Entering can
be aborted by depressing the ESC key. This function is advantageously used after the
auto automatic length measurement. (The label length should be entered twice or three
times longer than the actual label length. Thus labels missed on the backing paper web
can be compensated.)
LABEL LENGTHSCANNER
Length : 100 mm
programmer
STOP
User level:
Operating mode:
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Label suppression (suppression of label scanner)
This function is used to enter the length forcing the label scanner to suppress the si-
gnals from the backing paper web and the label after having detected the leading edge
of the label. Entering can be aborted by the ESC key. This function is used above all
when relatively transparent labels are used, for which the optical label scanner is distur-
bed by the print on the labels. This function also allows to suppress the rebounding si-
gnals of mechanical label scanners.
SUPPRESSION OF THE
LABEL SCANNER
Length : 10 mm
Predispensing
The Predispensing function is used to adjust the predispensing length of the label.
This length specifies the distance by which the leading edge of the label is pulled for-
ward after scanning.
PREDISPENSING
Value : 25.4 mm
If a predispensing length exceeding the label length is entered, a mal-
function of the labeller may occur because the label gap is scanned at
the wrong time. See diagram 'Predispensing' in the Technical
Appendix.
programmer
STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
Dispensing edge
Label
Labelscanner
Paperweb
Predispensing
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Position
The Position function is used to set a speed dependent labelling delay. This delay 2
causes a speed-independent positioning of the label 3on the good 5in feed direction 4.
With this function it is not necessary to shift the goods scanner 1to obtain a change of
the label position on the goods.
POSITION
Value : 10 mm
Note:
If the value of the position adjustment exceeds the goods distance, a
malfunction will occur, because not each good is labelled.
Predispensing and position influence the placement of the label on the
goods. For a good result, first adjust the predispensing and then the
position of the labels. (If afterwards the predispensing is changed, the
position of the goods will also be changed.)
Attention:
Die position setting must not be used to compensate long distances.
Otherwise goods will not be labeled correctly if the goods distance is
shorter than the position setting.
The position value is speed-independent. If with high speed the calcula-
ted position value is too small this will be indicated as an error.See
diagram 'Position' in the Technical Appendix.
1
2
3
4
5
programmer/operator
RUN/STOP
User level:
Operating mode:
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