Collamat C4300 Series Release Note

Contents
Technical Handbook
Collamat C4300- / C7300- Series
Doc-ID: TH-C4300-C7300-EN
Release: 1.00/01/2013
This manual is a translated English version. The only mandatory
Technical Handbook for this product is the German version – signed
as the Original-/Reference-Version.
These Operating Instructions and the Technical Handbook have to be read before start up, and before any work
are done on the machine.

2
Translated English version
Lawful direction:
This manual is a translated English
version. The only mandatory
Technical Handbook for this product
is the German version – signed as the
Original-/Reference-Version.
SD: 28.01.2013 16:49
Etikettiersysteme
Bodenmattstrasse 34
4153 Reinach BL / Switzerland
Tel.: [phone] - 28
Fax: [phone] - 29
E-mail: in[email protected]
Internet: www.collamat.ch
Produced by: Collamat AG - ps
Internal message: use revision mode ONLY
while updating the original (german
reference) document (Überprüfen –
Änderungen nachverfolgen) !
2012/11/26 V1.00 Prototype and Zero-Series -ps

Contents
3
Contents
1 General....................................................................................7
1.1 Information to the Technical Handbook.........................7
1.2 Symbols in the instructions ............................................8
1.3 Limitation of liability........................................................9
1.4 Copyright protection.......................................................9
1.5 Replacement parts.......................................................10
1.6 Conditions of warranty .................................................10
1.7 Customer service.........................................................10
1.8 CE Declaration of Conformity ......................................10
2 Safety ....................................................................................11
2.1 Intended use ................................................................11
2.2 Responsibility of the operating company.....................12
2.3 Operating personnel ....................................................13
2.3.1 Requirements ...............................................13
2.3.2 Unauthorized persons ..................................14
2.4 Personal protective equipment ....................................14
2.5 Industrial safety and special hazards ..........................15
2.6 Conduct in emergencies and accidents.......................19
2.7 Safety equipment.........................................................19
2.8 Assure against power on .............................................20
3 Technical specifications .....................................................21
3.1 Dimensions of Collamat C4300-C7300-Series............21
3.2 Condition at delivery ....................................................22
3.2.1 Options .........................................................24
3.3 Technical data..............................................................25
3.4 Weight..........................................................................26
3.5 Emissions.....................................................................26
3.6 Performance values.....................................................26
3.7 Label material ..............................................................26
3.8 Mounting ......................................................................27
3.9 Identification plate ........................................................27
4 Construction and function ..................................................28
4.1 Overview of components .............................................28
4.1.1 Side labeling - optional –..............................28
4.2 Variations .....................................................................29
4.3 Assembly of the unit ....................................................30
4.4 Function .......................................................................30
4.5 Operator panel + indicators .........................................30
5 Transport, packaging and storage .....................................31
5.1 Safety information for transport ...................................31

Contents
4
5.2 Symbols on the packaging...........................................31
5.3 Transport inspection.....................................................32
5.4 Transport......................................................................32
5.5 Packaging ....................................................................33
5.6 Storage.........................................................................33
6 Installation and assembly....................................................34
6.1 Safety ...........................................................................34
6.2 Preparation...................................................................35
6.3 Requirements of the installation location .....................36
6.4 Assembly......................................................................36
6.5 Mounting ......................................................................38
6.6 Electrical connections ..................................................40
6.7 Wiring ...........................................................................41
6.8 Inspection on conclusion of installation work...............41
7 Start-up and operation.........................................................42
7.1 Safety ...........................................................................42
7.2 Adjustments .................................................................43
7.2.1 Thread up the labels.....................................44
7.3 The most important mechanical adjustments ..............44
7.3.1 Force of the paper break ..............................44
7.3.2 Rewinder clutch adjustment .........................45
7.3.3 Modular rail ...................................................45
7.3.4 Pressure roller ..............................................46
7.3.5 Adapter tilt angle...........................................46
7.3.6 Adapter front pressure roller.........................47
7.3.7 Adapter – optical label scanner ....................47
7.3.8 Adapter – alternative label sensors ..............48
7.3.9 Unwinder - adjustments................................49
7.4 Operation .....................................................................50
7.4.1 Adjusting the labeler on the operator panel..50
7.5 Parameter - explanatory notes.....................................51
7.5.1 Labeling parameter - speed..........................51
7.5.2 Labeling parameter - Predispensing ............52
7.5.3 Labeling parameter – label scanner .............52
7.6 Jumper Adjustments ....................................................53
7.6.1 Jumper - Turning direction of the motor .......53
7.6.2 Jumper - IFEED polarity ...............................53
7.6.3 Jumper – Test functions ...............................54
7.7 Placing into operation ..................................................54
7.8 Switching off.................................................................54
8 Connections + buildup [electronic] ....................................55
8.1 Mainboard ....................................................................55

Contents
5
8.1.1 Safety ...........................................................55
8.1.2 Connections „main-connecting terminals“...55
8.1.3 Cable input - Traction unit ............................57
8.1.4 Connection „FUTURE-BUS“........................57
8.1.5 Connection „Programming port“...................58
8.1.6 Connection „external operator panel“...........58
8.1.7 Connection „FEED-key“ ...............................58
8.1.8 Connection „motor controller“.......................58
8.1.9 Connection „Transformer“ ............................59
8.1.10 Connectoion „POWER input line“.................59
8.1.11 Connection „AC-Power output“ ....................59
8.1.12 Connection „Main Power switch“..................60
8.1.13 Connection „FAN-output“ .............................60
8.1.14 „PE“Connection ............................................60
8.2 Motor controller HGD05...............................................61
8.3 Applicator / Adapter .....................................................62
8.3.1 Applicator- / Adapter-Types..........................62
8.3.2 Connection „FUTURE-bus“ ..........................62
8.3.3 Connections „applicator terminals“...............63
8.3.4 Connection „Applicator PE“ ..........................64
8.3.5 Label scanner (explanation).........................64
8.3.6 Cable inputs/outputs.....................................64
9 Software ................................................................................65
9.1 Normal run ...................................................................65
9.2 Test runs......................................................................65
9.2.1 Test run 1 ....................................................66
9.2.2 Test run 2 ....................................................66
9.2.3 Test run 3 ....................................................66
10 Maintenance .........................................................................67
10.1 Safety 67
10.2 Maintenance ................................................................69
10.3 Cleaning 70
11 Faults, repair and maintenance work.................................71
11.1 Safety – Warnings .......................................................71
11.2 Restarting after remedy of faults.................................71
11.3 Check fuses .................................................................71
11.4 Status LED...................................................................72
11.5 Error-output..................................................................73
11.6 Table of faults ..............................................................73
11.7 Maintenance- and Repair- works.................................75
11.8 Taking out of service and disposal ..............................75
12 Abbreviations, signals, terms,… ........................................76

Contents
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12.1 Abbreviations - general ................................................76
12.2 Signal names ...............................................................76
12.3 Terms - explanations....................................................76
13 INDEX.....................................................................................79
14 APPENDIXES ........................................................................81

General
7
1 General
1.1 Information to the Technical Handbook
These operating instructions provide important information about
using the machine. The prerequisite for safe work is the
observation of all the safety information and operating instructions
given here.
In addition, for the use of the machine, the local accident
prevention regulations and the general safety regulations are to be
observed.
These operating instructions must be read carefully before all work!
They are part of the product, and must be kept near to the machine
and accessible to the personnel at all times.
If the machine is passed on to third parties, the operating
instructions must also be passed on.
The illustrations in these instructions serve to provide better a
demonstration of the circumstances. They are not necessarily to
scale, and may be slightly different from the actual machine.
In addition to these operating instructions, the instructions in the
Appendices for the installed components also apply. The
information which they contain – in particular the safety information
– must be observed!

General
8
1.2 Symbols in the instructions
Warnings In these operating instructions, warnings are indicated by symbols.
The warnings are introduced by words which indicate the extent of
the hazard.
Observe the warnings and act carefully, in order to avoid
accidents, personal injury or material damage.
DANGER!
… indicates a dangerous situation, which may
cause death or serious injury if it is not avoided.
WARNING!
… indicates a possibly dangerous situation, which
may cause death or serious injury if it is not
avoided.
ATTENTION!
… indicates a possibly dangerous situation, which
may cause slight injury if it is not avoided.
BEWARE!
… indicates a possibly dangerous situation, which
may cause material damage if it is not avoided.
Hints and recommendations INFORMATION!
… highlights useful hints and recommendations for
the efficient and trouble-free operation of the
machine.

General
9
1.3 Limitation of liability
All statements and information in these operating instructions were
compiled by taking into account the valid standards and
regulations, the stat-of-the-art and our long years of expertise and
experience.
The manufacturer accepts no liability for damages due to:
Not observing these operating instructions
Use of the machine for purposes for which it was not
intended
Employment of untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement and wearing parts
The actual scope of delivery may differ from the explanations and
illustrations described here in the case of special constructions,
additional ordering options, or due to the latest modifications.
As well as this, the obligations agreed in the Supply Contract, the
General Conditions of Business and the manufacturer's conditions
of Supply, and the statutory regulations valid at the time of
conclusion of the contract apply.
Warranty The manufacturer warrants the functionality of the process
methods and the specified performance parameters.
The term of warranty begins at the time of delivery of the machine
to the customer.
Wearing parts Wearing parts are all components which come into direct contact
with the processing material or the material to be processed.
These components are excluded from the warranty and from
claims for defects, insofar as these concern wearing parts.
1.4 Copyright protection
The operating instructions are to be treated as confidential. They
are exclusively intended for personnel involved with the machine.
The transfer of the operating instructions to third parties without the
written permission of the manufacturer is not permitted.
INFORMATION!
The contents, texts, drawings and other illustrations
are protected by copyright and are subject to -
commercial protective rights. Any misuse may be
prosecuted.
Reproduction in any manner or means – even of excerpts – as well
as the utilization and/or communication of the contents without the
written permission of the manufacturer is not permitted. Offences
will attract claims for compensation. We reserve the right to other
claims.

General
10
1.5 Replacement parts
WARNING!
Danger of injury due to incorrect replacement
parts!
Incorrect or faulty replacement parts may cause
damage, faulty function or total breakdown, as well
as impairing safety.
Therefore:
– Only use original replacement parts made by
the manufacturer.
Obtain replacement parts from an authorized dealer or directly
from the manufacturer. For addresses, see page 2.
The Appendix contains a list of replacement and wearing parts.
1.6 Conditions of warranty
The warranty conditions are contained as a separate document in
the sales documents.
1.7 Customer service
Our customer service is available to provide technical information.
Information about the contacts responsible can be obtained at any
time by telephone, fax, e-mail or on the Internet. See the
manufacturer's address on page 2.
In addition, our staff is always interested in receiving new
information and experiences resulting from the application, and
which can be valuable for the improvement of our products.
1.8 CE Declaration of Conformity
Manufacturer's declaration (as per EU Guideline for Machinery
2006/42/EG Appendix II): see Appendix.