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Collamat 9100 Technical Handbook

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C C ollamat
ollamat
9100
9100
®
Technical handbook
Collamat Stralfors AG CH-4147 Aesch Pfeffingerring 201 Tel +41 61 756 28 28 Fax +41 61 756 29 29

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  • Page 1 C C ollamat ollamat 9100 9100 ® Technical handbook Collamat Stralfors AG CH-4147 Aesch Pfeffingerring 201 Tel +41 61 756 28 28 Fax +41 61 756 29 29...

  • Page 2: Table Of Contents

    The back panel The mains filter p.c.board The interface p.c.board The power supply Fuses Terminals and connectors The motor driver The connector box 9100 Fuse F1, 5A slow blowing Control signals for external units Page 1 / 64 5999.555-01A 20.08.98 WM...
  • Page 3 Index Page Signals and connector pin assignments Inputs Photocoupler inputs Comparator inputs Functional description of inputs Outputs Isolated outputs Open collector outputs Description of output function Connection of a signalisation to the monitor Monitor C9100 pin assignment Connector X3, LABELLER Connector X5, GSC Connector X7, CONTROL SIGNALS How to connect the goods scanner...

  • Page 4: Important Warnings

    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.
  • Page 5 Symbol 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.

  • Page 6: Introduction

    Introduction General 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.
  • Page 7 The controller p.c.board combines front panel and controller in one component. The software ® The controlling software of the Collamat 9100 is stored in the EPROM (firmware) and has the following features: Modern user guidance 6 digits preselection and batch counter...

  • Page 8: Prevention Of Accidents

    Guhl & Scheibler. Mechanical stability ® If the Collamat 9100 is used on a movable stand, this stand must be capable to be til- ted by 10° in each direction. See Figure 1: 10° 10° Figure 1: Mechanical stability of C9100 labeller stand Page 7 / 64 5999.555-01A 20.08.98 WM...

  • Page 9: The Labeller

    Assemblies In the following the various assemblies, their adjustment and maintenance are descri- bed. First an overall view of the labeller. The assemblies are mounted on a module rail. Figure 2 shows these assemblies with their designations on the module rail: Figure 2: Assemblies Legend for assemblies 1.

  • Page 10: Installation Examples

    Installation examples ® Due to the modular design of the Collamat 9100 there is nearly no limit in variations of the installation. But for best results in labelling, the following figures show installation examples of constructions which do their work successfully:...

  • Page 11: Traction Unit

    Traction unit General information The traction unit can be used both for right- and left-hand versions of the labeller. Figure 6: Traction unit Legend for traction unit 1. Paper break 2. Pinch roller 3. Traction roller 4. Stepper motor 5. Paper web guide 6.

  • Page 12: Pinch Roller

    Pinchroller Direction of tension force The direction of the tension force of the left- and right-hand version are opposite to each other. If the direction of the tension force is not correct, hits of the rewinder to the paper web may open the traction unit. Procedure Slacken locking screw (2), remove, turn, reengage and screw down knurled washer (1).
  • Page 13 Exchange of pinch roller The pinch roller is a part subject to wear. Its wearing time is stress-dependent. It is good practice to select a paper web wider than the pinch roller to avoid wear when the pinch roller runs directly on the traction roller. Procedure Disassemble and remove front panel (1) together with eccentric pinch roller shaft (2).
  • Page 14 Parallel adjustment of pinch roller The parallelism of the pinch roller with the traction roller is decisive for the stability of the paper transport. If the rollers are not in parallel the paper web will be transported obliquely through the traction unit resulting in a lateral force on the paper web which for- ces the web to shift on the dispensing edge and the labels to be dispensed obliquely.

  • Page 15: Traction Roller

    Traction roller Replacement of traction roller and damping disk Procedure Remove front panel (1) together with pinch roller (9). Unscrew stud bolt (7) and remove traction roller (3) from stepper motor-shaft (5). Remove securing ring (8). Remove tracti- on roller (3) from roller shaft (4) and replace the damping disk (6). Reassemble the traction unit in reverse order.

  • Page 16: Rewinder And Unwinder

    Rewinder and unwinder General information The motor driven rewinder and unwinder (= winders) are intended to automatically rewind and unwind the backing paper web. Each winder is supplied with a DC voltage of 18..30 Volt. Any deviation of the dancer roller starts the motor automatically. De- pending on the dancer roller position the electronic system controls the motor current and thus the rewinding speed.
  • Page 17 Due to the adjustable spring force, the paper web tension ® can be kept constant (adjustment of the spring force, see Collamat 9100 Operating In- structions ). The cooperation of dancer roller and electronic control guarantees constant paper tension for both the unwinder and rewinder.
  • Page 18 This can generally be noticed after ® a few dancer roller deviations. For further information see Collamat 9100 Operating Instructions.

  • Page 19: Arrangement And Mechanical Adjustment Of Rewinder

    Adjust the dancer roller with the ® spring so that the force in top position does not become too high. (See Collamat 9100 Operating Instructions.) The dancer roller must not hit the paper web when labelling with high speed.
  • Page 20 ATTENTION: Adjust dancer roller into top position so that the paper web is never completely stretched. Otherwise hits on the paper web may open the traction unit. Best results are obtained when the angle between winder mandrel and traction unit is an obtuse one. See also Figure 12. A straight / stretched paper web will cause problems ! Figure 13 shows a second version to mount the rewinder.
  • Page 21 (5). The ® restoring force of the dancer roller (adjustment according to Collamat 9100 Operating Instructions ) should be adjusted as low as possible. During operation, however, the dancer roller must never touch the lower stop.

  • Page 22: Electrical Settings

    Electrical settings The winder p.c. board GS125 comprises two jumpers J1 and J2 to set the motor torque and the direction of dancer roller action. The direction of dancer roller action is set by J1, the motor torque by J2. Figure 15 shows the view of the p.c.board from the compo- nent side: Dancer roller seen from the front side:...
  • Page 23 If the motor should turn at the right stop of the dancer roller, jumper J1 has to be set to the 'R' position. See also Figure 16. For left stop version, set jumper J1 to position 'L'. See also Figure 17. Figure 16 Figure 17 Motor torque...

  • Page 24: Midi-Unwinder

    ® If the Collamat 9100 is not pushed to its maximum capacity the non-driven midi-unwin- der may be used. As a simple rule the maximum labelling speed should not exceed 2/3 of the maximum labelling speed as defined in the data sheet.

  • Page 25: Flap Adapter

    Flap adapter The flap adapter is used to dispense the labels. It peels the labels from the paperweb when the paperweb is pulled around the peeling edge. Figure 21 shows an overall view of the flap adapter: Legend 1. Support 2.

  • Page 26: Flap

    Flap The whole flap is made of corrosion resistant material. The label scanner is placed on two guiding shafts. The optical label scanner operates with reflecting IR-light. Reliable operation of the label scanner is only guaranteed if the mirror is not scratched or dirty. The mechanical label scanner uses an exchangeable stainless strip.
  • Page 27 Exchange of the mirror Remove the six cylindrical head screws (7) under the dispensing plate. Remove and exchange mirror (3). Reassemble all components in reverse order. Figure 23 Legend 1. Adapter lever plate 6. Guiding shaft 2. Dispensing plate 7. Cylindrical head screws 3.

  • Page 28: Roller Dispenser Edge (Option)

    Roller dispenser edge (option) For wide paper webs and high labelling speed we recommend to mount a roller dispen- ser edge to reduce the torque of the traction unit motor. To fix the roller dispenser edge, first remove the fixed dispenser edge cylindrical head screw (5) and replace it by the roller dispenser edge.

  • Page 29: Optical Label Scanner

    Optical label scanner The optical label scanner is made of corrosion resistant material. It can be shifted or re- moved by releasing the knurled screw (3). By screwing in or out the ball catcher (7) ad- just the scanner catching force. Adjust the ball scatcher so that it exactly fits to the guiding also with released knurled screw.

  • Page 30: Construction

    THE C9100 MONITOR Before opening the monitor unplug the mains plug. Charged capacitors inside the monitor may lead to shock hazard. After unplugging wait at least 10 seconds before opening the monitor. Construction The electronics control of the C9100 labeller is built in a stable, elegant steel cabinet containing no adjustable controls.

  • Page 31: The Control Panel

    ® All settings of the Collamat 9100 are programmed and handled in this unit and stored in the control panel even if the power is turned off. The monitor and control panel can be mounted in two different positions (see figure 27).

  • Page 32: Construction

    Construction The control panel contains ESD sensitive components. When opening the control panel observe the ESD safety precautions. If a control panel component is defective it must be exchanged. For any repair not made by Guhl & Scheibler the guarantee will become void. Control panel and front panel are a constructive unit connected with a 50 conductor flat cable to the interface p.c.board.

  • Page 33: The Lcd-Display

    ® The IC6 program memory is programmed with the firmware of the two Collamat types 8600 and 9100. The firmware detects automatically the monitor by a specific code of the interface p.c.board. ATTENTION: If the EPROM is extracted with an incorrect tool, the socket may be destroyed.

  • Page 34: The Back Panel

    The signal relay contacts (7) only may be used to signalize operation conditions of the ® Collamat . These contacts must not be used to switch self-powered or dangerous units. The connector diagrams of the labeller connection (1), the goods scanners (6) and the signal relay (7) are shown in the chapter 'C9100 monitor pin assignment'.

  • Page 35: The Mains Filter P.c.board

    The mains filter p.c.board The mains filter p.c. board is used to supply a filtered mains voltage to the transformer. The p.c.board is mounted on the back panel and contains components on both sides. The mains filter p.c. board comprises a high-performance mains filter, the voltage selec- tor, the mains plug and socket for the transformer and the mains fuses.

  • Page 36: The Interface P.c.board

    Figure 32: Wiring of the mains filter board ATTENTION: After exchange of the mains filter p.c.board, the voltage selector must ® be set to the correct mains voltage to which the Collamat has to be connected. The interface p.c.board The interface p.c.board is used to connect the labeller and its peripherals to the moni- tor.

  • Page 37: Fuses

    The supply voltage for the logic, the sensors and the winders is connected to terminal X12. Fuse F2 protects this voltage from overload. LED LD2 indicates the presence of 24V. The voltages 12V and 5V are generated from the 24V using switching controllers. LED LD3 indicates the 12V, LED LD4 indicates the 5V.

  • Page 38: Terminals And Connectors

    Connector X7 makes floating potential relay contacts available allowing to control exter- nal units such as signal lamps or SPCs. Also an external signal input, to Start or Stop ® the Collamat is provided. Connector X9 is used to connect a additional key switch. Jumper J1 indicates the presence of the Key switch to the procesor.

  • Page 39: The Motor Driver

    The motor driver The motor p.c.board is an assembly developed and produced by a well-known manu- facturer of stepper motor controls. The motor driver p.c. board is adjusted, tested and built into the monitor by Guhl & Scheibler. Do not change any setting ! Do not change the mo- tor phase current ! ATTENTION: Do not change any switch or jumper position under volta- ge !

  • Page 40: The Connector Box 9100

    When assembling pay attention that no dirt is between cooling plate and heatsink. The connector box 9100 The signals of the C9100 monitor are fed in one cable to the connector box on the la- beller.

  • Page 41: Fuse F1, 5A Slow Blowing

    Fuse F1, 5A slow blowing Fuse F1 protects the 24V power supply of the winders from short-circuit and overload. If one or both winders are dead, first check this fuse. Control signals for external units The FEED, FLAP and READY signals are used to control external units. FEED The FEED signal indicates that the labeller is dispensing, i.e.

  • Page 42: Signals And Connector Pin Assignments

    All inputs and outputs are equipped with filter elements to protect from electromagnetic interferences. These components also prevent interferences caused by electrostatic di- ® scharges. The interference may cause a malfunction of the Collamat 9100. Anyway, when installing the labeller observe the rules concerning RMI and ESD to prevent such interferences.

  • Page 43: Comparator Inputs

    The inputs are protected against wrong polarity and they are active when GND (0V, gro- und) potential is applied. (The peripheral units of Collamat Stralfors AG have NPN-out- puts towards 0V.) Figure 38 shows the input diagram of the comparator inputs:...
  • Page 44 The STOP input is used to stop or start the Collamat . It has the same function like the ® RUN/STOP key on the control panel. If the signal is activated while the Collamat ® stopped the Collamat will be started (RUN) and vice versa.

  • Page 45: Outputs

    LLO (Label LOw) RWF (ReWinder Full) The two signals LLO and RWF are used to observe the diameter of the winders. The standard sensors of Collamat Stralfors AG are equipped with NPN-outputs and are con- nected to the connector box. Outputs...

  • Page 46: Open Collector Outputs

    47n 100E Relais Umax: 250VAC Imax: 1A 47n 100E Umax.: 24VDC Imax: 25 mA Z39V SFH6156-3 Figure 40: Floating outputs The following outputs are floating: Relais output indicates RUN mode Relais output indicates a WARNING message ERROR Relais output indicates an ERROR message IFEED Photocoupler, isolated FEED-signal Open-Collector outputs...

  • Page 47: Connection Of A Signalisation To The Monitor

    The RUN relais output indicates the RUN or Stop mode of the labeler. The output is ® ® activated while the Collamat is in the labelling mode. If the Collamat is stopped the re- lais output is not activated. The output RUN can be used to activate a green lamp.
  • Page 48 The signal CLOCK can be used to synchronize an external device (e.g.. Ink-Jet or Thermal Transfer printer) with the steppermotor. Control output NSTPO (NonSToP Out) ® The signal NSTPO is used to link two Collamat 9100 for the Nonstop mode. The wiring diagram is shown in the chapter Nonstop. Page 47 / 64...
  • Page 49 Monitor C9100 Connector layouts Connector X3, DISPENSER To this connector the control cable to the connector box is attached. The signals of this connector are used especially to control the dispenser and its units. D I S P E N S E R Type: 25 pole, D-Sub, female Name In/Out...

  • Page 50: Connector X5, Gsc

    Connector X5, GSC To this connector the signals of the goods scanners and the nonstop wiring is con- nected. For the prevention of electromagnetic interferences (RMI) shielded cables should be used. Type: 15 pole, D-Sub, female Name In/Out Name In/Out Name In/Out GSC1-...
  • Page 51 How to connect a goods scanner The goods scanners and incremental encoders are connected to the GSC connector. As described in the chapter Inputs NPN- or PNP-sensors may be connected. Figure 43 shows the connection of the standard Collamat Stralfors AG goods scanner: wht/ws GSC1-...

  • Page 52: Nonstop Labelling

    Nonstop labelling ® When using two Collamat 9100 it is possible to label goods with no down time. For this purpose the two monitors must be connected together by an electrical link. The ® necessary links are shown in figure 47. The placement of the two Collamat to each other is shown in figure 48.
  • Page 53 Collamat . In the display of the control panel it is possible to display the goods count of ® the goods between the two GSC2 scanners of the two Collamat . If an error occurs ® which causes both Collamat to stop all goods in between of the both GSC2 scanners must be removed.

  • Page 54: Incremental Encoder

    Incremental encoder The electrical connection of an incremental encoder is described in the chapter Con- nection of the goods scanners. If the speedmeasuring is done by an incremental en- coder, on the control panel the step width must be programmed so that the speed measuring is made correctly.

  • Page 55: Motor And Motor Cable

    Motor and motorcable Attention: The motor never must be dismantled ! For safety reasons and in order to guarantee interference suppressi- on, the motor has to be connected to a ground conductor ! Steppermotors heat up during operation ! When connecting or disconnecting the motor, the monitor must be switched off ! When working on the motor the monitor must be disconnected from mains !
  • Page 56 Control of a Hotstamp with the IFEED signal The connection of a hotstamp printer to the IFEED signal is described below. On the CONTROL SIGNALS connector the IFEED signal can be attached. It can be connected with two different types (NPN or PNP) of hotstamp inputs. Figure 54 shows the con- nection of different hotstamps.
  • Page 57 Connecting a relais, a free wheeling diode must be provided. If this is not made electromagnetic interferences can cause malfunction to the ® Collamat . Keep care to the polarity of the diode ! The FLAP signal can be adjusted in the configuration menu of the monitor. The signal can be switched on or off.
  • Page 58 + 1 2 V N S T P I + Figure 57: Diagnostic connector Cabling and setting up ® For a troublefree operation of the Collamat 9100 following items must be observed: Trained personnel Ambient temperature Dirt and dust Splashing water Installation and setting up of the installation ®...
  • Page 59 Do the winder turn the right way ? Turn off the monitor and unplug it from mains ® Connect the remaining units to the connector box of the Collamat Connect the monitor to the mains voltage and turn it on Do the peripheral units work OK ?

  • Page 60: Fuses

    Light Emitting Diode not connected RS232 Standard serial data exchange protocol Signals ® ERROR Errorsignal caused by any error of the Collamat FEED Signal indicating the labelling process GrouND Goods SCanner IFEED Isolated FEED signal Label LOw signal indicating the end of the label stock...
  • Page 61 Rewinder: Device that takes the empty paperweb from the traction unit and rewinds it CE-Mark: Certification for the European market, means: Conformité Européenne ® Collamat : Brand name for a labeler built by Collamat Stralfors. C9100: Labeler type C9100 GSC: Goods SCanner Flap adapter: Adapter which moves to the product during the labelling...

  • Page 62: Technical Data

    Technical data Dispenser general data (standard values) System Units C9110 C9120 C9130 Version right/left Dispensing speed m/min 0.5-80 0.5-60 0.5-40 Min. label width Max. width of the paperweb Min. label length Min. label length @ max. dispensing speed Stop accuracy @ 40 m/min ±...
  • Page 63 Midi-unwinder Diameter of the roll core 42 mm Max. outside diameter of roll 350 mm Max. weight of roll 20 kg Empty weight 4.2 kg Spring dancer with automatic brake Motor driven rewinder and unwinder System Rewinder Unwinder Diameter of roll core 42 mm Max.
  • Page 64 Label scanner Optical label scanner Mechanical label scanner Black mark reader (optional) Monitor System C9100 Mains voltage 110/120V AC, 220/230/240V AC, ±10% Power consumption 480 VA Main fuse 110V : 10 AT, 230V : 5 AT Display LCD, 4 lines, 20 characters each Dimensions (LWH in mm) 375 * 305 * 155 mm Ambient temperature...

  • Page 65: Trouble Shooting Checklist

    Trouble shooting checklist Ser.No. Monitor: Ser.No. Labeler: Machine-Type: Ser.No Control panel: Software-Version: Ser.No. Motordriver: Ser.No. Interfaceboard: Mains voltage: Frequency Hz: Temperature °C: Environment Interference level Interference level ESD Humidity % (Static): (Burst) Width: Length: Gap: Labels Thickness: Transparency: Material: Width: Thickness: Transparency: Paperweb...

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