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
6
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.

Safety
11
2 Safety
This section gives an overview of all the important safety aspects
for the optimum protection of personnel, and for safe and fault-free
operation.
Considerable hazards may result from the non-observance of the
instructions and safety information listed in these operating
instructions.
2.1 Intended use
The machine is exclusively designed for the intended purpose
described here.
The Collamat C4300/C7300 is a label dispensing unit for the
application of labels, and is usually used in automated packaging
lines for application of adhesive labels.
The machine operates fully automatically.
The working area of the machine should be protected against
unauthorized access.
WARNING!
Danger due to incorrect use!
Any use which exceeds the intended use and/or
different use of the machine, can lead to dangerous
situations.
Therefore:
– The machine should only be used as intended.
– All instructions in the operating instructions
should be strictly observed.
– In particular, do not use the machine for the -
following purposes, as these are considered to
be not intended:
– Use of the machine in unsecured areas.
– Labeling with other than the products stated
above.
– Use of unsuitable labels.
Claims of any kind due to damage caused by incorrect use are
excluded.
The operator is entirely liable for all damage due to incorrect use.

Safety
12
2.2 Responsibility of the operating company
The machine will be used in a commercial area. The company
operating the machine is therefore subject to the statutory
obligations of industrial safety.
In additions to the safety instructions for operation contained in
these operating instructions, the valid regulations for safety,
accident prevention and environmental protection for the area of
use of the machine must be observed. In particular, the operator
must:
Obtain information concerning the valid industrial safety
regulations.
Determine the additional hazards resulting from the special
conditions at the site of operation of operation of the machine,
by means of a risk assessment.
Implement the necessary regulations of conduct as instructions
for the operation of the machine at the particular site.
During the entire period of operation of the machine, examine
whether the operating regulations which he has produced
conform to the current status of the written regulations.
Insofar as necessary adapt the operating regulations to the new
regulations, standards and conditions of use.
Unambiguously regulate the responsibilities for the
installation, operation, maintenance and cleaning of the
machine.
Ensure that all employees involved on or with the machine
have read and understood the operating instructions. In
addition, he must train the personnel in the use of the
machine at regular intervals, and inform them of the possible
hazards.
In addition, the operator is responsible that the machine is
always in a technically perfect condition.
maintained according to the stated service intervals.
all safety features are regularly inspected with regard to -
completeness and functionality

Safety
13
2.3 Operating personnel
2.3.1 Requirements
WARNING!
Danger of injury if insufficiently qualified!
Incorrect use can cause considerable personal
injury and material damage.
Therefore:
– All activities should only be carried out by the
persons designated.
The following qualification requirements for the various areas of
activity are designated in the operating instructions:
Instructed persons
are those instructed by the operating company with regard
to the task with which they are entrusted and the possible
dangers of incorrect conduct.
Specialist personnel
entrusted and to independently recognize possible hazards
due to their specialist training, experience, and knowledge of
the relevant regulations.
Qualified electricians
are in a position to carry out work on electrical equipment
and to independently recognize possible hazards due to
their specialist training, experience, and knowledge of the
relevant standards and regulations.
Qualified electricians are specially trained for the field of
work in which they are active, and have knowledge of the
relevant standards and regulations.
In Germany, a qualified electrician must fulfill the
regulations of the accident prevention regulations BGV
A3 (e.g. master electrical installation craftsman). In other
countries, the corresponding regulations apply.
Only personnel may be employed, who can be expected to carry
out their work in a reliable manner. Persons whose reactions are
impaired, e.g. due to drugs, alcohol or medication are not
permitted.
In addition, the specific regulations regarding age and profession
applicable at the place of use are to be observed in the selection of
personnel.

Safety
14
2.3.2 Unauthorized persons
WARNING! Danger to unauthorized persons!
Unauthorized persons are unaware of the dangers
which may result from the machine.
Therefore:
– Unauthorized persons must be kept away from
the working area.
– In case of doubt, speak to them and instruct
them to leave the work area.
– Interrupt work as long as unauthorized persons
are in the work area.
2.4 Personal protective equipment
For the use of the machine, it is necessary to wear personal -
protective equipment in order to minimize hazards to health.
Therefore:
For all work, correctly put on the stated personal protective
equipment and wear it while working.
In addition, signs in the work area concerning personal
protective equipment must be observed.
To be worn For all work, the following must be worn:
Industrial safety clothing
is closely fitting work clothing with low resistance to tearing, closely
fitting sleeves and with no parts which hang out. This is primarily
for protection against being caught by moving parts of the
machine.
No rings, chains or other jewelers.
Protective gloves
for protection of the hands against contact with substances
hazardous to health, or hot or cold surfaces.
Safety footwear
for protection against falling objects and slipping on slippery
surfaces.
Protective goggles with side protection
to protect against hazardous substances and splashed liquids
coming into contact with the eyes.

Safety
15
2.5 Industrial safety and special hazards
In the following section the residual risks will be stated, which
result from the risk analysis.
Observe the safety information and the warnings in this and other
chapters in order to reduce hazards to health and avoid hazardous
situations.
Warning symbols on the machine
The particular danger areas on the machine are indicated by these
symbols:
DANGER!
Danger of death due to electrical current!
… indicates situations with danger of death due to
electrical current. If the safety information is not
observed, there is danger of death or serious
injury.
The work should only be performed by a
qualified electrician.
WARNING!
Danger of crushing!
During operation, moving components and objects
may cause crushing with very serious injuries and
permanent physical damage.
Therefore:
– Do not enter the danger area while the machine
is in operation.
– Adjustment and maintenance work, as well as -
measures to remedy faults must always be
carried out with particular care and attention
with regard to crushing.
– Personal protective equipment for protection
against crushing must be worn for all work.

Safety
16
Danger symbols in the operating instruction
In the operating instructions the following symbols are used in
connection with safety information:
Electrical current DANGER!
Danger of death due to electrical current!
There is direct danger of death on touching live
components.
Damage to the insulation or individual components
may cause danger of death.
Therefore:
– In case of damage to the insulation, switch off
the power supply immediately, and have repairs
carried out.
– Only have work on electrical equipment carried
out by qualified electricians.
– Switch off the power before undertaking any
work on electrical equipment. Check that no
voltage is present!
– Before carrying out regular maintenance,
cleaning and repair work, switch off the power
supply and secure against switching on again.
– Never bypass fuses or put them out of action.
– Observe the correct current rating when
replacing fuses.
– Keep dampness away from live components, as
this may cause short circuits.
Sharp edges and pointed corners BEWARE!
Danger of injury on edges and corners!
Sharp edges and pointed corners can cause cuts
and grazes to the skin.
Therefore:
– Always take care when working near sharp
edges and pointed corners.
– Wear gloves in case of doubt.

Safety
17
Moving parts WARNING!
Danger of injury due to moving parts!
Driven, rotating or linearly moving components can
cause extremely serious injuries!
Therefore, during operation:
– The presence of persons in the danger area or
the immediate vicinity is strictly forbidden!
– Covers such as flaps, doors, hatches or
maintenance covers must not be removed.
– Safety devices and/or functions must not be put
out of action, made unusable, or bypassed.
– Never operate the machine without the covers
closed or without functioning safety devices.
– Never reach into the moving equipment.
Before entering the danger area:
– Switch off the power supply and secure against
switching on again.
– Wait until moving parts have come to a
standstill.
– Wait for the self-acting reduction and/or
discharge of residual energy.
Pneumatic system WARNING!
Danger of injury due to pneumatic
energy (compressed air)!
Pneumatic energy can cause very serious injuries.
Pneumatically driven components may move
without warning.
In case of damage to individual components, air
may escape under high pressure and e.g. cause
damage to the eyes.
Therefore:
– Only have work on the pneumatic system
carried out by trained specialist personnel.
– Release the pressure before starting work on
the pneumatic equipment. Beware of pressure
reservoirs. These must also be fully
depressurized.
– Do not adjust the pressure beyond the
maximum values.

Safety
18
Sharp paper edges BEWARE!
Danger of injury due to sharp paper edges!
Sharp paper edges can cause slight to moderate
cuts.
Therefore:
– For all work, the prescribed personal protective
equipment must be worn.
– Always perform work with particular care and
attention.
Falling objects WARNING!
Danger of injury due to falling objects!
During operation, objects in the work area may
drop without warning and cause injuries.
Therefore:
– Do not enter the danger area while the machine
is in operation.
– For adjustment and maintenance work, or
remedying faults, personal protective equipment
should be worn.
Dirt and scattered objects BEWARE!
Danger of tripping due to dirt and scattered -
objects
Dirt and scattered objects can be the cause of slips
and trips, which may cause considerable injuries.
Therefore:
– Always keep the work area clean.
– Remove objects which are no longer needed.
– Indicate sources of tripping with yellow - black
warning tape.
Signs WARNING!
Danger of injury due to illegible symbols!
Stickers and signs may get dirty or become illegible
in the course of time.
Therefore:
– Always keep warning and operating signs in a
legible condition.
– Replace damaged or illegible signs and stickers
immediately.

Safety
19
2.6 Conduct in emergencies and accidents
Preventive measures Always be prepared for accidents or fires!
Keep first-aid equipment (first aid box, blankets etc.) and fire
extinguishers so that they can easily be reached.
Familiarize the personnel with first-aid and rescue equip-
ment
Keep access for emergency vehicles clear.
In case of emergency: Act correctly Trigger the emergency stop (if available)
Begin with first-aid measures.
Remove people from the danger area.
Inform those responsible at the site of the emergency.
Call a doctor and/or the fire brigade.
Clear access routes for emergency vehicles.
2.7 Safety equipment
WARNING!
Danger of death due to non-functioning safety
devices!
Safety devices ensure that the operation is as safe
as possible. Even if work processes are made
more complicated by safety devices, under no
circumstances may they be put out of action.
Safety is only ensured by intact safety devices.
Therefore:
– Before starting work, check that the safety devi-
ces are functional and correctly installed
– Safety devices must never be put out of action.
– Do not hinder access to safety devices such as
emergency stop buttons, lanyards etc.
The following safety devices must be installed by the company operating the machine:
Emergency stop button in the vicinity of the labeling device or
the entire machine
Main valve

Safety
20
2.8 Assure against power on
Lock main control switch in position „0“
Lock main control switch
The main switch should be locked with a padlock to avoid an
unwanted (unauthorized) power on - if there is a main switch within
the safety chain.
WARNING!
Danger of life caused by unauthorized power
on!
Only with the mains control switch in position „0“
and locked, individuals are allowed to be in the
area of danger.
A not authorized switching on of a locked mains
control switch can bring individuals into serious
danger of life.
Therefore:
– Never remove a lock without authorization.
– Be sure no individuals are in the area of danger
before removing the lock.
Safety tag 1
Mains switch locked
Date: …….. Time: ……
do NOT switch-on
Permission to remove the padlock is
given to:
Mr. Muster
Switch-on procedure:
Check the area of danger before
switching on the machine!
Protection against unauthorized power on:
1. Switch off mains power.
2. If possible lock mains switch with a padlock and mark the
switch with an eye-catching tag (see left side: Safety tag 1).
3. The key of the padlock has to be kept in a save place by the
person having permission to switch-on the machine.
Safety tag 2
Switched OFF
Date: …….. Time: ……
do NOT switch-on
Permission to switch-on the machine is
given to:
Mr. Muster
Switch-on procedure:
Check the area of danger before
switching on the machine!
4. If there is no possibility to lock the mains switch with a
padlock, mark the switch with an eye-catching tag (see left
side: Safety tag 2).
5. After all work has been done in the area of danger, check the
area of danger again before starting the switch-on procedure.
All individuals have to leave the area of danger!
6. Be sure all safety facilities are installed and are working
properly.
7. Remove the safety tag and switch on the machine.
1
0