Collamat 8600 User manual

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

Index page
1 Safety advices ......................................................................4.......
1.1 Important warnings ................................................................4.......
1.2 Danger notes .....................................................................4.......
1.3 Symbol description ................................................................5.......
2 General information .................................................................6.......
2.1 Special characteristics of the Collamat 8600/9100 monitor ........................6.......
3 The monitor .........................................................................7.......
3.1 The controls of the monitor ........................................................8.......
3.1.1 LCD display .....................................................................9.......
3.1.2 Function keys ...................................................................9.......
3.1.3 RUN/STOP key (6) .............................................................9.......
3.1.4 Numerical keyboard (10) ........................................................9.......
3.1.5 ENTER key (12) ................................................................9.......
3.1.6 ESC key (9) ....................................................................10 ......
3.1.7 UP (13) and DOWN (14) keys ..................................................10 ......
3.1.8 LABELLING MODE function key (2) ............................................10 ......
3.1.9 PROGRAMMING function key (3) ..............................................10 ......
3.1.10 CONFIGURATION function key (4) ............................................10 ......
3.1.11 SERVICE DISPLAY function key (5) ...........................................10 ......
3.2 Entering data with the keyboard ....................................................11 ......
3.3 Selecting a branch in the function tree .............................................12 ......
4 The 'labelling mode' menu tree ......................................................13 ......
4.1 Label jog ..........................................................................13 ......
4.2 Select program ...................................................................13 ......
4.3 Information display ................................................................14 ......
4.4 Reset counter ....................................................................14 ......
4.5 Preset counter ....................................................................14 ......
4.6 Select counter ....................................................................15 ......
4.7 Nonstop ..........................................................................15 ......
4.7.1 Nonstop display .................................................................15 ......
4.7.2 Nonstop Reset ..................................................................16 ......
5 The 'PROGRAMMING' menu tree ..................................................17 ......
5.1 Change program ..................................................................18 ......
5.2 Label scanner sensitivity ..........................................................18 ......
5.2.1 Auto adjust ......................................................................19 ......
5.2.2 Manual adjust ...................................................................19 ......
5.3 Label length .......................................................................20 ......
5999.530-01E 14.01.2004 CSWM 41

Index page
5.3.1 Auto adjust ......................................................................20 ......
5.3.2 Manual adjust ...................................................................20 ......
5.4 Label suppression (suppression of label scanner) ..................................21 ......
5.5 Predispensing ....................................................................21 ......
5.6 Position ...........................................................................22 ......
5.7 Speed and type of measurement ..................................................23 ......
5.7.1 Fixed speed ....................................................................23 ......
5.7.2 Inkremental encoder and measuring light barrier .................................23 ......
5.8 Maximum Speed ..................................................................24 ......
5.9 Good suppression ................................................................24 ......
5.10 Labelling mode ..................................................................24 ......
5.10.1 Normal Mode ..................................................................24 ......
5.10.2 Multiple labelling mode .........................................................25 ......
5.10.3 Delayed Predispensing ........................................................26 ......
5.11 Profiling .........................................................................27 ......
5.12 Store program ...................................................................28 ......
5.13 Program name ...................................................................28 ......
5.14 Program presets (Setting default values of program) ..............................29 ......
6 The 'CONFIGURATION' menu tree .................................................30 ......
6.1 User Menu .......................................................................31 ......
6.2 Language .........................................................................31 ......
6.3 User level .........................................................................32 ......
6.3.1 Change level ....................................................................32 ......
6.3.2 Change password ...............................................................33 ......
6.4 Error handling .....................................................................34 ......
6.5 Nonstop mode ....................................................................35 ......
6.6 Adapter magnet (only Collamat 9100) ..............................................36 ......
6.7 Motor direction ....................................................................36 ......
6.8 Polarity IFEED ....................................................................36 ......
7 The 'SERVICE FUNCTIONS' menu tree .............................................37 ......
7.1 Software-Version .................................................................37 ......
7.2 Error sequence ...................................................................38 ......
7.3 Self-test ..........................................................................38 ......
7.3.1 Test RAM .......................................................................38 ......
7.3.2 Test EEPROM ..................................................................39 ......
7.3.3 Test keyboard ..................................................................39 ......
7.3.4 Test LED .......................................................................39 ......
7.3.5 Test LCD .......................................................................39 ......
5999.530-01E 14.01.2004 CSWM 42

Index page
7.3.6 Test Illumination .................................................................40 ......
7.3.7 Test IO Controller ...............................................................40 ......
7.3.8 Test IO Monitor .................................................................40 ......
7.3.9 Test drive .......................................................................41 ......
7.4 Remote Control ...................................................................41 ......
7.5 Working time .....................................................................41 ......
7.6 Motor running .....................................................................41 ......
8 Technical appendix .................................................................42 ......
8.1 Adjusting the predispensing ........................................................42 ......
8.2 Adjusting the label position .........................................................43 ......
8.3 Adjusting the Profiling .............................................................44 ......
8.4 Error messages ..................................................................45 ......
8.5 Error diagnosis ...................................................................46 ......
8.5.1 Operating warnings ..............................................................49
8.6 Nonstop - Configuration and setup ................................................49 ......
8.6.1 Error handling configuration of a Nonstop-installation .............................50 ......
8.7 Value table ........................................................................51 ......
9 Maintenance ........................................................................52 ......
9.1 Cleaning ..........................................................................52 ......
9.2 Fuses ............................................................................52 ......
9.3 Repairs ...........................................................................53 ......
9.4 Packing ...........................................................................53 ......
9.5 Technical data of monitor .........................................................54 ......
10 Trouble shooting checklist .........................................................55 ......
5999.530-01E 14.01.2004 CSWM 43

1General information
The entire electronic operating and control system is installed in a modern, elegant monitor. 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 moni-
tor. A microprocessor controls all labeller functions. To facilitate entering values in noisy environ-
ment, the foil keyboard is provided with action point contacts. There are no potentiometers or con-
trollers 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 star-
ted or stopped by a signal from outside. The operating mode is displayed to the outside by relay
contacts.
1.1Special characteristics of the Collamat 8600/9100 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
5999.530-01E 14.01.2004 CSWM 44

2Safety advices
2.1Important warnings
Before installing and operating the Collamat 8600/9100read 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
national 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
environment 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.
2.2Danger 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 monitor
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.
5999.530-01E 14.01.2004 CSWM 45

2.3Symbol 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 components may only
be touched in an electrostatically protected environment.
NOTE
Important or additional information to Collamat 8600/9100 or to the
documentation.
This documentation or parts of the documentation may not be copied, duplicated or pu-
blished in any form without a written permission of Collamat Stralfors AG.
The information in this documentation reflects the state at the publication date.
Subject to technical alterations.
5999.530-01E 14.01.2004 CSWM 46

3The 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 A and a rear view B of the monitor.
Figure 1: Monitor
Legend
1. Heatsink 4. Mains switch
2. Front panel 5. Sockets
3. Cover 6. Back panel
1 2 3 4 56
AB
5999.530-01E 14.01.2004 CSWM 47

3.1The 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 sta-
tes 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 in-
puts in a noisy environment. The controls of the monitor 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
0
ESC ENTER
7 8 9
4 5 6
1 2 3
1 2 3 4 5 67 8
9 10 11 12 14 13
Collamat
STRALFORS AG
5999.530-01E 14.01.2004 CSWM 48

3.1.1LCD 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 arrows on the border of the LCD help to
pass through the function trees and to select menu items.
3.1.2Function 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.
3.1.3RUN/STOP key (6)
The RUN/STOP key is used to start (RUN) or stop (STOP) the Collamat . The RUN sta-
te 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 la-
belling. But in STOP state all functions can be changed.
3.1.4Numerical keyboard (10)
With the numerical keys 0...9 all numerical data can be directly entered via the keyboard.
A decimal point ',' can be entered by key (11).
3.1.5ENTER key (12)
With the ENTER key the inputs are terminated. The ENTER key is also used to select
the menu item, on which the cursor is actually positioned.
0...9
ENTER
5999.530-01E 14.01.2004 CSWM 49

3.1.6ESC key (9)
The ESC key is used to abort the input of data and to jump back to theprevious
branch of the function tree.
3.1.7UP (13) and DOWN (14) keys
These two keys are used to select a function within a function tree. When entering da-
ta the indicated value can be increased (up key) or reduced (down key) with these
keys.
3.1.8LABELLING MODE function key (2)
This key is used to select the labelling mode function. When depressed, theLED
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 (pa-
ge 11) shows the function tree of the labelling mode.
3.1.9PROGRAMMING function key (3)
This key is used to select the programming function. When depressed, the LED
placed above lights up and indicates that the monitor is in programming mode. The pa-
rameters of labeller and labelling are entered in the programming mode. The Figure
"PROGRAMMING menu tree" (page 14) shows the function tree of the programming
mode.
3.1.10 CONFIGURATION function key (4)
This key is used to select the configuration function.When depressed, 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 "CONFIGURATI-
ON menu tree" (page 25) shows the function tree of the configuration mode.
3.1.11 SERVICE DISPLAY function key (5)
This key is used to select the service displayfunction. When depressed, 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
5999.530-01E 14.01.2004 CSWM 410

3.2Entering data with the keyboard
The numerical keys of the keyboard (10) are used to enter data. If the value to be entered is a deci-
mal, 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 indica-
ted for a short time and the original value does not change.
Warning Warning
Exceeding value Short falling value
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.
Note:
All minimum and maximum values of the functions are shown in the value ta-
bles of the Technical Appendix.
5999.530-01E 14.01.2004 CSWM 411

3.3Selecting 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 litt-
le 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 little direction (arrow) (2) informs, whether it is possible to
move further up or down.
1. Cursor FUNCTIONTREE
Functionbranch 1
Functionbranch 2 2. Direction arrows
Functionbranch 3
NOTE:
Not all functions can be changed in the labelling mode. In the description of the
function is noted, which one is only changeable in start or stop state of the la-
beller.
Not all functions can be selected in the operating mode. In the description 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 con-
sidered function are permitted.
5999.530-01E 14.01.2004 CSWM 412

4The 'LABELING 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)
Nonstop
Nonstop display
Nonstop Reset
4.1Label jog
With this function a label can be dispensed for test purposes by the keyboard. The dispensing speed
corresponds to the set fixed speed. The label is dispensed by depressing the ENTER key when the
cursor is placed on this line:
LABELLING MODE
Label Jog
Select program
Information display
Note:
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 become
asynchronous.
4.2Select 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:
5999.530-01E 14.01.2004 CSWM 413

4.3Information display
This function allows to indicate the most important labelling parameters on the LCD-display. The pro-
gram number, the actual dispensing speed, the count and the label position 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 la-
bel key terminates this indication mode:
Program 1 RUN
Speed 3.0m/Min
Counter 000000
Position 10.0 mm
4.4Reset counter
This function allows to reset the counter to zero. ENTER resets the counter.
Counter cleared !
4.5Preset counter
This function allows to activate and set the preset counter. Entering a value greater than zero activa-
tes the preset counter. After entering return to the counter menu by depressing 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:
5999.530-01E 14.01.2004 CSWM 414

4.6Select counter
This function allows to select what should be counted by the counter. The counter input can distin-
guish 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
4.7Nonstop
The nonstop function is used to superwise the nonstop labeling in a nonstop environment - it also
keeps track of the number of products between the Master- and the Slave-goodscanner to ensure a
perfect switching from Master to Slave and vice versa. The function is different for the Master and
Slave.
4.7.1Nonstop display
The nonstop display is used to display the nonstop status. The major display in a nonstop configurati-
on is the display of the Master. The Master is the first Collamat in the product flow direction. It shows
the actual running settings of the master, the slave and of the nonstopcounter.
The Master shows the following display:
NONSTOP MASTER
GSC2-3: 1
Activ: MASTER
Change over [.]
The first line indicates a Master labeler
The second line shows the nonstop counter GSC2-3: whereas the value represents the amount of
goods between the goodscanner of the Master and the Slave
The thirt line indicates the status of the nonstop function. (Master or Slave active)
The fourth line shows the switch over key command (' ' key of the monitor keyboard). This key is
used to switch from the active labeler (Master) to the passive labeler (Slave)
The nonstopdisplay of the Slave is different to the display of the Master. Because GSC2-3 counting
is only done in the Master, the line GSC2-3 will not be shown in the Slave nonstopdisplay:
programmer/operator
STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
5999.530-01E 14.01.2004 CSWM 415

The Slave shows the following display:
NONSTOP MASTER
SLAVE: passive
Change over [.]
The ' ' key can be used to force a switch over to the momentary passive labeler
NONSTOP SLAVE
Labeler-change....
SLAVE: passive
Change over [.]
The first line of the slave-display indicates a Slave labeler. The second labeler in a nonstop-con-
figuration is always the Slave
Line three of the slave-display represents the status of the slave only
Line four of the Slave display shows the switch over key command (' ' key of the monitor keybo-
ard). This keycommand is used to switch from the active labeler Slave to the passive labeler Ma-
ster. As soon as the dot-key is pressed the Slave display indicates this special mode with the
message Labeler-change... on line two of the display, until the Master has switched over the la-
beling mode (Master is active, Slave is passive)
4.7.2Nonstop Reset
The Nonstop Reset is used to reset the internal nonstop counter when in nonstop mode. In case
that at the moment of start there are products between the master and the slave the counter can be
set to the appropriate quantity. (This function helps a lot in case of labeling endless products like for-
mulars or foils or when the conveyor cannot be emptied)
Nonstop Reset has to be called up when a fault has occurred in nonstop mode to guarantee a per-
fect labelling of the goods. The Nonstop Reset is called up with ENTER. The following indication
confirms the execution of the reset.
NONSTOP RESET
Goods between
Master-Slave: 0
Note:
This function can be selected only in switched on nonstop mode.
The Nonstop reset can only be done on a Master Collamat.
programmer/operator
RUN/STOP
User level:
Operating mode:
programmer/operator
RUN/STOP
User level:
Operating mode:
5999.530-01E 14.01.2004 CSWM 416

5The '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
Speed Fixed 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:
5999.530-01E 14.01.2004 CSWM 417

5.1Change program
The Change programfunction is used to branch in an additional menu by calling up further parame-
ters to be changed:
CHANGE PROGRAM
Labelscanner Sens.
Label Length
Label Suppression
Predispensing
Position
Speed
Max. Speed
Good Suppression
Labelling Mode
Profiling
5.2Label scanner sensitivity
The Label scanner sensitivityfunction 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
User level: programmer/operator
RUN/STOP
Operating mode:
5999.530-01E 14.01.2004 CSWM 418

5.2.1Auto 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. After 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
5.2.2Manual adjust
When adjusting the sensitivity manually, the value is entered by hand. Entering can be aborted by de-
pressing the ESC key. This function will especially be used above all for the adjustment of labels ma-
de of 'difficult' material.
LABEL SCANNER SENS.
TCY-Value 50 %
Gap
Label
Dispensing edge
Mark
Labelscanner
programmer
STOP
User level:
Operating mode:
5999.530-01E 14.01.2004 CSWM 419