Collamat S Series Release Note

Inhalt
Technical Handbook
Collamat S Series
Doc. ID: TH-CO-S-EN
Release: V1.15/11/2013
The German-language version of this Technical Handbook is the only
official original version. Any Technical Handbook translated into other
languages (or excerpts of it) are only references to this original
version.
Read the Technical Handbook before performing any work on the machine!

2 Release: V1.15/05/2013
Technical Handbook
Translation of the Original Edition
SD: 28.11.2013 14:33
© Collamat AG
Etikettiersysteme
Bodenmattstrasse 34
4153 Reinach BL
Switzerland
Tel.: [phone] - 28
Fax: [phone] - 29
E-Mail: [email protected]
Internet: www.collamat.ch
Created by:
ps - Collamat AG
20-04-2010 V1.00 Draft for field testing devices - ps
10-05-2010 V1.01 Correction after translation – ps
20-09-2010 V1.02 Better pictures - ps
22-09-2010 V1.03 Update of chapter 6 - ps
25-09-2010 V1.04 Directory formatted - ps
27-09-2010 V1.05 Cable and Assembly – ps
14-01-2011 V1.06 Firmware updates and Debug – ps
03-02-2011 V1.08 Nonstop – ps
10-03-2011 V1.09 Firmware updates and read PIC Reg –ps
23-03-2011 V1.10 Cable + PCB (Index H) – ps
29-08-2011 V1.11 Set Output / Read Input for AVA changed - ps
22-11-2011 V1.12 Register J added - ps
22-12-2011 V1.13 Translations & corrections - ps
23-12-2011 V1.14 Translations & corrections – ps
27-11-2013 V1.15 Translation of nonstop part – Collamat S - ps

Collamat S Series
General
Release: V1.15/05/2013 3
1 General.......................................................................................................................................................6
1.1 Information about the Technical Handbook.........................................................................................6
2 Technology................................................................................................................................................7
2.1 Software/Firmware...............................................................................................................................7
2.2 The traction unit ...................................................................................................................................8
2.3 Components.........................................................................................................................................9
2.3.1 Front view .....................................................................................................................................9
2.3.2 Rear view....................................................................................................................................10
2.3.3 Front view traction unit................................................................................................................11
2.4 Assembly examples...........................................................................................................................12
2.4.1 General information’s to IP54 version ........................................................................................14
3 Components ............................................................................................................................................15
3.1 Construction.......................................................................................................................................15
3.2 Electronics - Control unit....................................................................................................................17
3.2.1 Details for the main control unit..................................................................................................20
3.2.2 Changing the main control unit...................................................................................................23
3.2.3 FIRMWARE versions..................................................................................................................24
3.4 The side connection plate “SIGNALS”...............................................................................................25
3.4.1 The „GSC“ M8-plug ....................................................................................................................27
3.4.2 The „PLC“ M8-plug .....................................................................................................................27
3.4.3 The „TACHO“ M12-plug.............................................................................................................27
3.5 Operator panel...................................................................................................................................28
3.6 The NDC06 motor controller (MC).....................................................................................................30
3.6.1 Changing the MC........................................................................................................................30
3.6.2 Settings for the MC.....................................................................................................................31
3.6.3 Status LED for the MC................................................................................................................32
3.6.4 Jumpers, LED, DIP and plugs of the MC....................................................................................32
3.7 FEED..................................................................................................................................................33
3.8 Controlling external devices...............................................................................................................34
3.9 Incremental encoder (optional) ..........................................................................................................37
3.9.1 Speed measurement ..................................................................................................................37
3.9.2 Hardware data for the incremental encoder...............................................................................38
3.10 Etikettierung - Theorie....................................................................................................................40
3.11 Electrical rewinder..........................................................................................................................44
3.11.1 Short description.........................................................................................................................44
3.11.2 Status LEDs on the MC ..............................................................................................................45
3.11.3 Electrical connections.................................................................................................................45
3.11.4 Voltage supply ............................................................................................................................47
3.11.5 Mechanics...................................................................................................................................47
3.1 Non-stop labeling...............................................................................................................................48
3.1.1 Short description.........................................................................................................................48
3.1.2 Assembly ....................................................................................................................................49

Collamat S Series
General
4 Release: V1.15/05/2013
3.1.3 Setup.......................................................................................................................................... 50
3.1.4 Nonstop Control-Table............................................................................................................... 51
3.1.5 Nonstop cabeling ....................................................................................................................... 52
4 Inputs + Outputs..................................................................................................................................... 53
4.1 Inputs + Outputs (Electronic)............................................................................................................. 53
4.1.1 Inputs ......................................................................................................................................... 53
4.1.2 Label sensor – inputs................................................................................................................. 56
4.1.3 Outputs....................................................................................................................................... 58
4.2 Inputs + Outputs (description)........................................................................................................... 61
4.2.1 Input details................................................................................................................................ 61
4.2.2 Output details............................................................................................................................. 64
5 Maintenance............................................................................................................................................ 66
5.1 Safety ................................................................................................................................................ 66
5.2 Maintenance schedule ...................................................................................................................... 68
5.3 Cleaning ............................................................................................................................................ 69
6 Faults, repair and maintenance work................................................................................................... 70
6.1 Safety ................................................................................................................................................ 70
6.2 Restarting after remediation of faults................................................................................................72
6.3 Table of faults.................................................................................................................................... 73
6.4 Performing maintenance and repair work.........................................................................................74
6.4.1 Replacing the pressure roller..................................................................................................... 75
6.4.2 Changing the traction cylinder ...................................................................................................76
6.4.3 Setting the belt tension (traction)...............................................................................................77
6.4.4 Changing the timing belt (traction).............................................................................................78
6.4.5 Changing the OOL spring ..........................................................................................................78
6.4.6 Changing the drive motor (traction) ...........................................................................................79
6.4.7 Ligth tube / Sender board replacement......................................................................................80
6.4.8 Adjusting the rewinder pendulum (RW active + passive)..........................................................81
6.4.9 Setting the belt tension (RW passive)........................................................................................82
6.4.10 Changing the timing belt (RW passive)......................................................................................83
6.4.11 Adjusting the friction clutch (RW passive)..................................................................................84
6.4.12 Reconditioning the clutch disks (RW passive)...........................................................................85
6.4.13 Setting the belt tension (RW active)...........................................................................................86
6.4.14 Changing the drive belt (RW active)..........................................................................................86
6.4.15 Changing the rewinder board (RW active).................................................................................87
6.4.16 Replacing Rewinder-Sensor-Board ersetzen (RW activ)...........................................................88
6.4.17 Changing the rewinder motor (RW active).................................................................................89
6.4.18 Replacing the mainboard (HMC0601) .......................................................................................90
6.4.19 Replacing the master controller (RCM4010) .............................................................................90
6.4.20 Firmware Update – Master-Controller (RCM4010)....................................................................91
6.4.21 Firmware Update – Slave-Controller (dsPIC) ...........................................................................92
6.4.22 Details to Menu - Service - Read PIC reg 0-63 .........................................................................96
6.4.23 Details to Menu - Service - Inputs..............................................................................................99
6.4.24 Details to Menu - Service – Read Outputs............................................................................... 100

Collamat S Series
General
Release: V1.15/05/2013 5
6.4.25 Details to Menu - Service - Set Outputs ...................................................................................101
6.4.26 Directions to naming of inputs/outputs .....................................................................................101
7 Index.......................................................................................................................................................102
8 Index of documents in the Appendix..................................................................................................103

Collamat S Series
General
6 Release: V1.15/05/2013
1 General
1.1 Information about the Technical Handbook
This Technical Handbook is a technically-detailed addendum to
the operating instructions for the Collamat S. All safety, warning
and caution notices in the Collamat S operating instructions are
also valid in this handbook with no restrictions.
The Collamat S Technical Handbook (abbreviated as TH in this
document) is considered the technical element of the operating
instructions. The TH should help you to use the Collamat S to its
fullest. The description of the individual mechanical and electrical
components also helps for rapid troubleshooting and problem
solving in case of faults. Any defective electronics modules
(printed circuit boards) are to be replaced as entire units and the
defective modules are to be sent to the Collamat AG company or
their representatives for repair or exchange. This is the only way
to ensure that the high level of quality of your Collamat S is
maintained after repairs.
The special features of the Collamat S include the following:
low-wear mechanics
minimal abrasive wear with the rewinder version
with friction clutch
robust, reliable and precise
simple handling with a modular structure
easy-to-adjust label brake
multiple options for installation (clamping pieces) in upright
or horizontal position
user-friendly thanks to modern, menu-based
programming
quickly configured to perform other labeling tasks
maximum labeling power
unwinder unit with a brake mechanism for 300 mm
or 400 mm diameter label rolls – optional with double
dancer
highly modern SMD technology
for 230 VAC / 115 VAC network current (adjustable
on the outside of the machine)
2-phase stepper motor with micro step resolution
for the greatest precision
various adapters for up to 3 cylinders (standard and
customer-specific)optional electrical rewinder
(for dispensing speeds > 50 m/min or for wide labels)
- DC motor with 4Q-MC and single- / double dancer control
optional external connection box / connection module
optional sensors for monitoring label
supply / rewinder volumes, ....
optional warning lamps (ready - error - maintenance)
optional Ethernet connection (standard / customer-specific)
customer-specific interface

Collamat S Series
Technology
Release: V1.15/05/2013 7
2 Technology
2.1 Software/Firmware
The control program for the Collamat S has the following
features:
dual processor hardware allows for rapid parallel
processing for communication and
drive control
modern user interface
preset and print run counter
impulse suppression for path-dependent suppression of the
label scanning for applications such as printed or
transparentlabels
impulse suppression for path-dependent suppression of the
goods scanning after labeling process
programmable settings for label position
programmable settings for pre-dispensing
multiple labeling with electronic adjustment of label offset
automatic adjustment of dispensing speed with
measurement of goods speed using an incremental encoder
storage of 99 labeling programs
password protection with multiple access levels
monitoring of almost empty label supply (LLO - optional) and
of out of label situation (OOL),
open counter-pressure roller in traction unit (TUO), rewinder
full (RWF - optional),
motordriver OK, ...
non-stop operation with 2 Collamat S systems = interruption-
free labeling
multilingual user interface
automatic setup of optical label sensor
all operational steps possible during labeling
control of all peripheral devices from the program - without
potentiometers, switches, etc .....
motorized (optional) rewinder unit for labeling
speeds > 40 - 50 m/min
infinitely adjustable paper brake
error / warning management - every exception status (input)
that could influence labeling can be configured
from the operator panel as an error, warning, or as a
situation to be ignored.

Collamat S Series
Technology
8 Release: V1.15/05/2013
2.2 The traction unit
Description The traction unit system is either attached directly using a
clamping piece connection or using a module rail on an adjustable
unit.
The corresponding peripheral devices are installed on the module
rail and / or on one of the many flanges on the housing.
All mechanical parts are surface-treated against corrosion.
The traction cylinder of the system is treated with a special coating
for permanent, slip-free drive transmission to the carrier paper.
The braking force of the label strip break is infinitely adjustable.
The traction cylinder can be easily turned by hand when the
dispenser is powered down (power OFF) to simplify setup of the
dispenser.
The rewinder drive system can be easily turned by hand to simplify
setup of the dispenser.
The pressure roller that holds the carrier paper on the traction
cylinder can be easily lifted (opened) using a turning knob for easy
setup of the dispenser.
When the pressure roller is open, this is displayed on the operator
panel (TUO - Error - corresponding warning message).
Uninterruptible labeling can be setup by installing the so called
Nonstop-Cabling-Set (two Collamat S are used – only one
incremental encoder will be used in speed mode: TACHO).
Several helpful options are available to increase the performance
and comfort of a Collamat S. These are the most important
options:
- Electrical rewinder unit (ERW)
- Indicator light column (red-green-orange) (SIG)
- Label volume (empty) observation (LLO)
- Rewinder volume (full) observation (RWF)
- Connection-Box (CBO)
- Connection-Module (CMO)
- Incremental-Encoder (TACHO)
- Magnet Flap Adapter (MFA)
- External Operator Panel (EOP)
- Double Dancer Rewinder
- Double Dancer Unwinder
- Lying Down Set
- Ø400mm Unwinder Disks
- div. clamps, modular rails adjusting units
- div. stands
- etc.

Collamat S Series
Technology
Release: V1.15/05/2013 9
2.3 Components
Description The individual components with their setup options and
maintenance are described here. This section begins with a
general overview of the dispenser.
The components are mounted on a module rail. Figure x shows
these components and their names mounted on the module rail:
2.3.1 Front view
Fig. 2-1
1 Pressure roller adapter
2 Dispensing edge adapter
3 Housing adapter
4 Clamping piece, 40 x 40 module rail
5 Side connection plate, "SIGNALS"
6 Pressure roller for traction cylinder
7 Paper brake opener
8 Operator Panel (keyboard and LCD)
9 Pendulum, feed roller unit
10 Unwinder unit
11 Unwinder front plate (adjustable)
12 Module rail
13 Traction cylinder
14 Rewinder pendulum
15 Rewinder cylinder
16 Side connection plate, "power"
1 3 5 7 6 8 9
2 4 12 13 14 15 16 10 11

Collamat S Series
Technology
10 Release: V1.15/05/2013
2.3.2 Rear view
Fig. 2-2
1 Pressure roller adapter
2 Dispensing edge adapter
3 Clamping piece module rail 40/40 x 50
4 Side connection plate, "SIGNALS"
8 Operator panel (keyboard and LCD)
9 Pendulum, feed roller unit
10 Unwinder unit
11 Unwinder front plate
16 Side connection plate, "power"
17 Adjustment wheel, dispenser applicator
18 Unwinder rear plate (fixed)
19 Dispenser edge angle adjustment (+ opt. spring
tension)
20 Unwinder pendulum spring tension adjustment
21 Traction unit housing
11 18 9
8 21 4 3 19 2 1
10 20 16