Collamat 9100 Release Note

CCollamatollamat®91009100
Technical handbook
Collamat Stralfors AG CH-4147 Aesch Pfeffingerring 201 Tel [phone] Fax [phone]
5999.557-01A

Index page
1 Safety advices .............................................................. 6......
1.1 Important warnings ........................................................ 6......
1.2 Danger advices ............................................................ 6......
1.3 Symbol descriptions ....................................................... 7......
2 Introduction ................................................................. 8......
2.1 General information ....................................................... 8......
2.2 The Monitor ............................................................... 8......
2.3 The software .............................................................. 9......
2.4 The Dispenser ............................................................. 9......
3 The Collamat® 9100 Labeller ................................................ 10.....
3.1 Prevention of accidents .................................................... 10.....
3.2 Noise suppression ......................................................... 10.....
3.3 Mechanical stability ........................................................ 10.....
4 Assemblies .................................................................. 11.....
4.1 Installation examples ...................................................... 12.....
5 Traction unit ................................................................. 13.....
5.1 General information ....................................................... 13.....
5.2 Pinchroller ................................................................. 14.....
5.2.1 Direction of tension force ................................................ 14.....
5.2.2 Exchange of pinch roller ................................................. 15.....
5.2.3 Parallel adjustment of pinch roller ........................................ 16.....
5.3 Traction roller ............................................................. 17.....
5.3.1 Replacement of traction roller and damping disk ......................... 17.....
5.4 Rewinder and unwinder ................................................... 18.....
5.4.1 General information ..................................................... 18.....
5.4.2 Support plate ............................................................ 19.....
5.4.3 Drive .................................................................... 19.....
5.4.4 Dancer .................................................................. 19.....
5.4.5 Winder mandrel ......................................................... 19.....
5.4.6 Brake ................................................................... 19.....
5.4.7 Winder control ........................................................... 19.....
5.5 Final assembly of the winder ............................................... 20.....
5.5.1 Assembly of the dancer .................................................. 20.....
5.5.2 Assembly of the unwinder/rewinder mandrel ............................. 20.....
5.5.3 Exchange of the dancer spring ........................................... 20.....
5.6 Adjustments ............................................................... 21.....
5.6.1 Spring force of the dancer ............................................... 21.....
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Index page
5.6.2 Tension direction of the dancer .......................................... 21.....
5.6.3 Direction of action of the dancer ......................................... 22.....
5.6.4 Motor rotation direction .................................................. 22.....
5.6.5 Tension force of the motor ............................................... 22.....
5.6.6 Breaking force and time ................................................. 22.....
5.7 Arrangement and mechanical adjustment of the rewinder .................. 23.....
5.8 Arrangement and mechanical adjustment of the unwinder .................. 25.....
5.8.1 Maintenance ............................................................ 25.....
5.9 Brake ..................................................................... 26.....
5.9.1 Adjustment of brake ..................................................... 26.....
5.10 Motor brushes ............................................................ 27.....
5.11 Electrical settings ........................................................ 27.....
5.11.1 Direction of action of dancer (DANCER) ................................ 28.....
5.11.2 Motor force (TORQUE) ................................................. 29.....
5.11.3 Winder (WIND) ......................................................... 29.....
5.11.4 Adjustment of the break current ........................................ 30.....
5.11.5 TIME ................................................................... 30.....
5.11.6 BREAK ................................................................ 31.....
5.11.7 ATTN .................................................................. 31.....
5.11.8 DELAY ................................................................. 31.....
5.12 Midi-unwinder ............................................................ 32.....
5.12.1 General information .................................................... 32.....
5.12.2 Installation position and mechanical adjustment ........................ 32.....
5.13 Flap adapter ............................................................. 33.....
5.14 Support .................................................................. 33.....
5.15 Flap ...................................................................... 34.....
5.15.1 Exchange of the mirror ................................................. 35.....
5.15.2 Exchange of peeling edge .............................................. 35.....
5.15.3 Roller dispenser edge (option) .......................................... 36.....
5.16 Optical label scanner ..................................................... 37.....
5.16.1 Replacement of the sensor p.c.board ................................... 37.....
6 THE C9100 MONITOR ...................................................... 38.....
6.1 Construction ............................................................... 38.....
6.2 The control panel .......................................................... 39.....
6.3 Construction ............................................................... 40.....
6.4 Hardware ................................................................. 40.....
6.4.1 IC6 program memory, EPROM 128 Kbytes .............................. 41.....
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Index page
6.4.2 The LCD display ......................................................... 41.....
6.4.3 Adjusting the contrast .................................................... 41.....
6.4.4 Exchanging a defective LCD ............................................. 41.....
6.5 The back panel ............................................................ 42.....
6.6 The mains filter p.c.board .................................................. 43.....
6.6.1 Exchange of mains filter p.c.board ....................................... 43.....
6.7 The interface p.c.board .................................................... 44.....
6.7.1 The power supply ....................................................... 44.....
6.7.2 Fuses ................................................................... 45.....
6.7.3 Exchanging the interface p.c.board ...................................... 46.....
6.7.4 Terminals and connectors ............................................... 46.....
6.7.5 Particularities ............................................................ 46.....
6.8 The motor driver ........................................................... 47.....
6.8.1 Settings ................................................................. 47.....
6.8.2 Status indicators ......................................................... 47.....
6.8.3 Exchanging the motor driver ............................................. 48.....
6.9 The connector box 9100 ................................................... 48.....
6.9.1 Fuse F1, 5A slow blowing ................................................ 49.....
6.10 Control signals for external units .......................................... 49.....
6.10.1 FEED .................................................................. 49.....
6.10.2 FLAP .................................................................. 49.....
7 Signals and connector pin assignments ...................................... 50.....
7.1 Inputs ..................................................................... 50.....
7.1.1 Photocoupler inputs ..................................................... 50.....
7.1.2 Comparator inputs ....................................................... 51.....
7.2 Functional description of inputs ............................................ 51.....
7.2.1 Goods scanners GSC1 and GSC2 (Good SCanner) ..................... 51.....
7.2.2 Goods scanner GSC3 ................................................... 52.....
7.2.3 Control input NSTPI (NonSToP In) ....................................... 52.....
7.2.4 Control input STOP ...................................................... 52.....
7.2.5 LSC (Label SCanner) .................................................... 53.....
7.2.6 TUNIT (Traction UNIT) .................................................. 53.....
7.2.7 READY .................................................................. 53.....
7.2.8 LLO (Label LOw) ........................................................ 53.....
7.2.9 RWF (ReWinder Full) .................................................... 53.....
7.3 Outputs ................................................................... 53.....
7.3.1 Isolated outputs ......................................................... 53.....
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Index page
7.3.2 Open-Collector outputs .................................................. 54.....
7.4 Functional description of the outputs ....................................... 55.....
7.4.1 Mode indicator RUN ..................................................... 55.....
7.4.2 Warning signal NOK (Not OK) ........................................... 55.....
7.4.3 Error signal ERROR ..................................................... 55.....
7.4.4 Connection of a signalisation to the monitor .............................. 55.....
7.4.5 Signal FEED, IFEED .................................................... 56.....
7.4.6 Flap adapter signal FLAP ................................................ 56.....
7.4.7 Steppermotor clock CLOCK ............................................. 56.....
7.4.8 Control output NSTPO (NonSToP Out) .................................. 56.....
7.5 Monitor C9100 Connector layouts ......................................... 57.....
7.5.1 Connector X3, DISPENSER ............................................. 57.....
7.5.2 Connector X5, GSC ..................................................... 58.....
7.5.3 Connector X7, CONTROL SIGNALS ..................................... 58.....
7.6 How to connect a goods scanner .......................................... 59.....
8 Nonstop labelling ............................................................ 60.....
8.1 Setting up of the Nonstop mode ........................................... 61.....
9 Speed measuring ........................................................... 62.....
9.1 Incremental encoder ....................................................... 62.....
9.2 Measuring goods scanner ................................................. 62.....
10 Motor and motorcable ...................................................... 63.....
10.1 Motorcable ............................................................... 63.....
10.2 Motor wiring .............................................................. 63.....
11 Control signals for external devices ......................................... 64.....
11.1 Control of a Hotstamp with the IFEED signal .............................. 64.....
11.2 Control of the flap adapter ................................................ 65.....
12 Testing the monitor with the diagnostic connector ........................... 66.....
13 Cabling and setting up ..................................................... 66.....
13.1 Cabling .................................................................. 67.....
13.2 Setting up ................................................................ 67.....
14 Password .................................................................. 68.....
14.1 By keyboard ............................................................. 68.....
14.2 By keyswitch ............................................................. 68.....
15 Fuses ...................................................................... 69.....
16 Glossary ................................................................... 69.....
16.1 Short cuts ................................................................ 69.....
16.2 Signals ................................................................... 69.....
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Index page
16.3 Terms .................................................................... 70.....
17 Technical data ............................................................. 71.....
18 Trouble shooting checklist .................................................. 74.....
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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 man-
ual 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 compo-
nents, 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
components may only be touched in an electrostatically pro-
tected environment.
NOTE
Important or additional information to Collamat®9100 or its
documentation.
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2Introduction
2.1General information
This Technical Manual describes design and function of the Collamat®9100. In addition
to the Operating Instructions, it contains the settings and notes necessary to get opti-
mum use of the Collamat®9100. The descriptions of each electrical or mechanical as-
sembly also help for quick error analysis and trouble-shooting.
We recommend to replace p.c.boards always as complete units returning them to Colla-
mat Stralfors or its representative for repair to be sure that the high quality standard of
the Collamat®9100 can also be guaranteed after any repair.
Special characteristics of the Collamat®9100:
resistant to wear, no clutch/brake-system
rugged
easy installation and operation due to modular design
easy to operate due to up-to-date menu operated software
quick change-over to other labelling tasks
high performance
high reliability and accuracy
latest SMD-technology
high precision 3-phase steppermotor
2.2The Monitor
The power supply and the electronic control are built into a stable metal casing. All pe-
ripherals are connected to a connector box connected to the monitor back panel by one
single D-sub-connector. A large heatsink allows to operate the monitor without addi-
tional fan. The control (monitor) can be mounted in various positions.
The monitor contains the following assemblies:
Noise filter with voltage selector
The noise filter keeps EMI outside to prevent any interference with the electronic
control and also prevents EMI to be transmitted to the mains supply. The voltage se-
lector allows versatile adaptation of the power supply to different mains voltages.
Transformer
Supplies the power for all components of the Collamat®9100.
Interface p.c.board
The interface p.c.board connects the motor driver to the power supply and to the
controller. The electronic part of the power supply is also installed on the interface
p.c.board which shapes all input and output signals to and from the controller.
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Motor Driver
The 3-phase motor driver is a standard assembly of a leading stepper motor. It ener-
gizes the stepper motor. The step rate is adjustable from 200 up to 1000 steps per
revolution. Standard setting is 500 steps per revolution.
Controller p.c.board
The controller p.c.board comprises a Hitachi H8/532 microcontroller, EPROM with
software, LC-display and short-stroke keyboard. The controller p.c.board controls all
labelling sequences, the LC-display, the keyboard and the nonvolatile memory.
The LC-display has four lines with 20 characters each and a background illumination.
The controller p.c.board combines front panel and controller in one component.
2.3The software
The controlling software of the Collamat®9100 is stored in the EPROM (firmware) and
has the following features:
Modern user interface
6 digits preset and batch counter
Adjustable label length dependent suppression of label scanner signal to detect
transparent or preprinted labels
Adjustable goods speed and length dependent scanner signal suppression after
labelling
Programmable adjustment of labelling position on the goods
Programmable adjustment of predispensing
Multiple labelling with electronic setting of gap between labels
Automatic adaptation of dispensing speed by measuring the goods speed by light
barrier or incremental encoder
Storage of 32 labelling programs
Memory protection by access password
Two user levels
Monitoring of label stock and out-of-label, end of paper web, open roller in traction
unit, motor driver OK-signal
Nonstop mode with two Collamat®9100 systems
Multilingual user display
Automatic label scanner adjustment
Full operability during labelling
All peripherals program-controlled - no potentiometers and switches necessary
2.4The Dispenser
The traction unit as well as the other peripherals are mounted on a module rail. All parts
are surface treated to protect from corrosion. The special coating of the traction unit
roller affords permanent torque transmission to the paper web without slip. The force of
the paper web brake is adjustable. The traction roller can be easily turned by hand dur-
ing Power OFF for easy threading and installing the paper web.
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