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12 Cabling and setting up

For a trouble free operation of the Collamat 3600 following items must be observed:

Trained personnel
Ambient temperature
Absence of dirt and dust
Absence of splashing water
Installation and setting up of the installation
Installation and setting up of the Collamat 3600
Electromagnetic interferences
Safety regulations and safety requirements

12.1 Cabling

Electromagnetic interferences can lead to non repeatable and not obvious errors while label-
ling. Most times misplaced layout of the cabling, RMI and ESD interferences disturb the label-
ling. Because of this, the following rules must be observed for the cabling:

Separated mains and signal cables
Use shielded cables
All units must be grounded
Connect only devices which meet the RMI standards
Use power filters in interfered environments and interfered mains supplies

12.2 Setting up

The setting up must be done carefully by trained personnel. The following items must be
observed:

Visual check of the labeler unit

Are all electrical and mechanical units correctly attached ?
Are all connectors accessible ?

Connect the labeler to the mains and switch it on

Is the power switch illuminated ?

Turn off the labeler and unplug it
Set up the DIL-switches according to the desired mode. Motor turning direction.
Attach the goods scanner signals to the labeler
Connect the remaining units to the labeler
Connect the labeler to the mains and switch it on

Do the peripheral units work OK ?

Thread the paperweb and adjust the label scanner
Dispense a label. Is it dispensed correctly ?

5999.515-01E 12.06.2007 WM

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Summary of Contents for 3600

Page 1: ...Collamat 3600 Technical handbook 5999 515 01E HM Collamat AG Bodenmattstrasse 34 CH 4153 Reinach Switzerland Phone 41 61 756 28 28 Fax 41 61 756 29 29 contact collamat ch www collamat ch ...

Page 2: ...pter 11 3 2 1 Inclination adjustment of flap adapter 11 3 2 2 Adjustment of the pressure roller of the flap adapter 11 3 3 Adjustment of the optical label scanner 12 3 4 Adjustment of the mechanical label scanner 13 4 Technical description 14 4 1 Dispenser board 14 4 1 1 Power supply 14 4 1 2 Motordriver 14 4 1 3 Controller 14 4 2 Signals and connection diagrams 15 4 2 1 Inputs 16 4 2 2 Outputs 16...

Page 3: ...4 Flatprinting unit 27 7 4 1 Flatprinter board 27 8 Control signals for external units 28 8 1 How to connect a goods scanner 28 9 Electrical installation 29 9 1 Introduction 29 10 Testmode 31 10 1 Test software 32 10 1 1 Motortest 32 10 1 2 Motor intervall test 33 10 1 3 BUS signal selftest 33 10 1 4 Signal display 34 10 1 5 DIL switch settings 34 10 1 6 Potentiometer settings 34 10 1 7 Firmware V...

Page 4: ...ls 38 14 3 Terms 39 15 Technical data 40 15 1 Dimensions Systemdesign 42 18 Trouble shooting 43 18 1 Trouble shooting Collamat 3600 43 18 2 Trouble shooting checklist 48 Appendix Spare parts Collamat 3600 5999 515 01E 12 06 2007 WM Page 3 47 ...

Page 5: ...rd products ask your competent technical supporter 1 2 Danger Indications The safety symbols and danger advices on the Collamat 3600 and in this manual must strictly be observed Before connecting or disconnecting the labeler to or from the main it must be switched off The labeler C3600 may only be opened by authorized personnel Before opening the labeler C3600 it must be separated from the main po...

Page 6: ...diate hazard for persons DANGER Shock hazard due to high voltage at component DANGER Hazard due to high temperature component ATTENTION ESD warning Electro Static Discharge The PC boards or component may only be touched in an electrostatically protected environment NOTE Important or additional information to Collamat 3600 or to the documentation 5999 515 01E 12 06 2007 WM Page 5 47 ...

Page 7: ...iability latest SMD technology high precision 2 phase steppermotor The traction unit as well as the other peripheral assemblies are mounted on a modular rail The control electronics of the peripheral units are built in the units The units are controlled and driven by signals of the bussystem inside of the modular rail The operating elements for dispensing speed predispensing optical label scanner ...

Page 8: ...The dispenser C3600 is shielded according to the CE directives Only cables which are certifi cated by Collamat Stralfors AG may be used for connecting the dispenser to the peripheral units and the mains power Additional peripheral units must be connected to the auxiliary mains terminal of the dispenser These assemblies must be certificated by Collamat Stralfors AG 2 2 3 Mechanical stability If the...

Page 9: ... Following figure 2 shows these assembly parts with their names on the modular rail Figure 2 Assembly parts Legend 1 Unwinder dancer 5 Modular rail 2 Unwinder 6 Support 3 Traction unit 7 Adapter optional with magnet 4 Paper brake 1 2 3 4 5 6 7 5999 515 01E 12 06 2007 WM Page 8 47 ...

Page 10: ...ver the dispensing edge and finish threading the pa perweb as shown in figure 3 Close the pinchroller Adjust the side guides of the paperweb well leaving 0 5 mm free space to the paperweb s edge 3 1 2 Adjustment of rewinder coupling force Figure 4 The coupling force of the rewinder is factory set Proceed as follows if out of adjustment Detach winding spindle 1 after unscrewing the M5 bolt 3 Screw ...

Page 11: ...ox of the traction unit from the outside Screw in bolt higher braking force Unscrew bolt lower braking force 3 1 4 Longitudinal adjustment on the module rail Figure 6 Unscrew 4 bolts with special tool wrench for socket head cap screws 5 mm one half turn adapter only 2 bolts Move device observing scale on module rail Then tighten bolts equally 2 5999 515 01E 12 06 2007 WM Page 10 47 ...

Page 12: ...ighten nut 1 The pressure force of the flap adapter without magnet or of the magnetic flap adapter is vari able push in button 4 in the direction indicated by the arrow twist for appropriate spring ten sion and adjust until it meets the next stop 3 2 2 Adjustment of the pressure roller of the flap adapter Figure 8 The pressure roller of the adapter can be adjusted depending on the labels and goods...

Page 13: ...web until a label is located below the scanner Continue turning the potentiometer until the LED switches off again The optimum setting is at the center position of the two potentiometer settings witch turned the LED off Remark If the setting of the optical label scanner is faulty the gap between the labels will not be detected After the triggering of a labelling operation the labeler will stop aft...

Page 14: ...ning head the LED on the scanner support must be turned on If this is not the case unscrew the nut on the scanning head and turn it counterclock wise until the LED turns on Turn the scanning head clockwise until the LED turns off Turn the scanner one quarter turn forward and retight the nut Place the gap between the labels under scanning head the LED display must be turned on Note No adjustment is...

Page 15: ...A while running and 2 A when stopped To control the current a chopper circuit with 20 kHz chopper frequency is used Dependent on the dispensing speed the processor generates a fullstep or a halfsteppattern For speeds faster than 10 m min the motor is driven by a fullstep pattern In the case of overheating short circuit or malfunction the motordriver is switched off and the red LED FAULT is illumin...

Page 16: ...nction of the Collamat 3600 Anyway installing the Collamat 3600 you have to consider the rules concerning RMI and ESD to prevent these interferences See also chapter Cabling GND GSC1 12V GND LSC 12V TCY 12V GND RDY FEED IFD IFD 12V X48 a3 a2 a1 L1 N1 X46 9 6 1 F1 2AT 230V 4AT 115V N L X51 F2 3 15AT 1 6AT F3 3 3 7 7 IN X40 L N PE X101 X102 12V 5V TEST DIR X104 1 2 RESET FAULT 7 6 0 5 OUT X1 X14 SPE...

Page 17: ...Vmax 24 V Figure 12 Signal input An input is then active when a current of minimum 4mA is pulled to GND The following inputs are available GSC1 Goods scanner LSC Label scanner READY READY signal for peripheral units 4 2 2 Outputs The outputs are used to control peripheral units There are three different kinds of outputs Isolated output Open Collector output Currentsource output 10nF 2k2 5 V LM339 ...

Page 18: ...quipped with a photocoupler Figure 14 shows the schematic diagram of the Open Collector output IFEED Figure 14 Open Collector outputs 4 2 5 Currentsource output For the IR transmitter of the label scanner TCY a controlled currentsource is used Figure 15 shows the schematic diagram of the currentsource Figure 15 TCY currentsource PC355T 1n 1n Umax 24 VDC Imax 25 mA 5 V PC355T 1n Umax 24 VDC Imax 25...

Page 19: ...in Signal 1 12V 2 12V 1 GND 2 GND 3 READY 4 FEED 3 nc 4 nc 5 LSC 6 GSC1 5 nc 6 nc 7 TCY 8 nc 7 nc 8 TCY 9 nc 10 nc 9 GSC1 10 LSC 11 nc 12 nc 11 FEED 12 READY 13 GND 14 GND 13 12V 14 12V 4 4 Transformer wiring The secondary side of the transformer is connected to the terminals X36 X39 Both violet wires are connected to the terminals signaled with a 7 Both orange wires are connected to the terminals...

Page 20: ...e filter as shown in figure 19 Figure 19 4 6 Grounding of the labeler The grounding of the module rail and of the adapter must be done to terminal X51 For this see also figure 21 110 V 120 V 220 V 230 V 240 V 0 schwarz 2 rot 4 gelb 5 grün 8 grau 9 weiss a3 a2 a1 L1 N1 a3 a2 a1 L1 N1 a3 a2 a1 L1 N1 a3 a2 a1 L1 N1 a3 a2 a1 L1 N1 9 8 2 5 0 4 9 8 2 5 0 4 9 8 2 5 0 4 5 9 4 8 2 0 0 2 4 8 5 9 X48 X46 X48...

Page 21: ...ly units certified by Collamat Stralfors AG may be connected Figure 20 shows the mains output terminal Figure 20 4 8 Connection of the frontpanel The frontpanel must be connected as shown in figure 21 Figure 21 N L 1 F 1 6 9 gelb grün blau braun OUT X41 X51 X41 OUT F 1 L N 6 9 1 X 5 1 braun weiss blau braun gelb grün 5999 515 01E 12 06 2007 WM Page 20 47 ...

Page 22: ...off While working on the motor the labeler must be disconnected from mains The motor is connected inside of the labeler The motorcable is lead through the hole in the middle part of the board The wires are connected to the terminals X30 X33 See also figure 22 Figure 22 Motor connection X31 X33 X32 X30 green black blue violet 5 0 6 7 motorcable 5999 515 01E 12 06 2007 WM Page 21 47 ...

Page 23: ...C1 LSC and FEED signals 1 Speed dependent position delay 2 Length of the predispensing If the predispensing is increased it is executed immediately If it is reduced it is executed after dispensing the next label To generate the holding torque the motor is powered all the time If for any reason no negative edge is detected on the LSC input the labelweb is automatically stopped after approximately 2...

Page 24: ...tion Off On TEST Labelingmode Testmode Labelingmode Testmode DIR Turning direction of the motor Right Left Figure 24 DIL switches 5 2 1 DIL switch TEST This DIL switch selects the testmode For further informations to the testmode please read the chapter Testmode 5 2 2 DIL switch DIR This DIL switch selects the turning direction right or left of the traction motor TEST D I R E i n A u s 5999 515 01...

Page 25: ...ction motor F2 seems to be defective ATTENTION If the dispenser board is defective it must be exchanged Any repairs or modifications not made by Collamat Stralfors AG will expire the guarantee 6 2 Status LEDs The four status LEDs on the dispenser board display show different signals LED Function Fault 5V Illuminated when the 5V for the logic cir cuit are OK Fuse F3 or F1 12V Illuminated when the 1...

Page 26: ...5 7 2 Goods scanners 7 2 1 CS measuring IR scanner Figure 26 7 2 2 NPN Reflective scanner Figure 27 12 V LSC 5 9 1 5 1 12 V GND TCY TRANSPARENCY LABELSCANNER LED LEDs 1 9 4 5 GND GSC1 12V GND 12V 1 5 12 V GSC1 GND GOODSCANNER NPN 5999 515 01E 12 06 2007 WM Page 25 47 ...

Page 27: ...hronous motor of the wrap around adapter WARNING Plugging in of the LEFT or RIGHT connector of the flatcable to the wrong plug can damage the magnet adapter board 12V LSC GND 12V TCY LED ON OFF DELAY L R 220V 220V MAGN MAGN MAGNET Ph N 14 Pol RECHTS LINKS 12 V LSC GND 12V TCY F1 3 15AT FLACHKABEL CP21 CP21 GS070D 12V LSC GND 12V TCY LED ON OFF TIME L R 220V 220V MAGN MAGN MAGNET Ph N 14 Pol RECHTS...

Page 28: ...t red rot schwarz red black schwarz black X4 M 1 2 braun brown weiss white braun brown blau blue gelb grün yellow green IFEED IFEED TCY GND GND 12v 12v LSC L N L N Farbbandmotor Ribbonmotor Collamat Buscable 14 poles Collamat Buskabel 14 polig 5999 515 01E 12 06 2007 WM Page 27 47 ...

Page 29: ...inter is ready If the signal is active this means the NPN output of the device is pulled to GND labelling is not possible 8 1 How to connect a goods scanner The goods scanner is connected to the GSC1 terminals Figure 30 shows the connection of the standard Collamat Stralfors AG IR goods scanner Figure 30 Connection of the CS IR goods scanner Figure 31 shows the connection of a NPN scanner Figure 3...

Page 30: ... An additional 3 pole power cable 3 x 0 75 mm2 feeds the switched mains voltage from the Collamat 3600 to both peripheral units The transmitter 2 pole cable and receiver 3 pole cable of the optical label scanner can di rectly be connected to the dispenser C3600 to the flap adapter or to the flatprinter respec tively In this case the connection to the Collamat 3600 is made by the 14 pole flatcable ...

Page 31: ...1 5 1 9 4 5 GND 12V GND GSC1 12V 3 GND 12V GSC1 Reflex scanner G S IR Goods scanner P5 P4 P2 P3 P1 NPN 3 1 6 4 5 4 5 1 6 N L N L GSC1 GND POWER SUPPLY from flat printer 110 230V FLAP ADAPTER FLAT PRINTER DISPENSER OPTICAL LABEL SCANNER Micro switch POWER SUPPLY 110 230V 50 60Hz 5999 515 01E 12 06 2007 WM Page 30 47 ...

Page 32: ...re is menu driven and self explaining The user language is English To communicate with a PC a serial communication cable is used The figure 33 shows the electrical connections of the serial cable Figure 33 Communication parameters Terminal settings 9600 Baud 8 Bit 1 Stop Bit No Parity TTY Text Figure 34 shows how to connect the Collamat 3600 to a PC Figure 34 Test connections 9Pol D Sub 10Pol Flac...

Page 33: ...llowing help menue will be displayed Helpmenue for C3600 Testprogram H Help M Motortest N Motor intervall test B BUS signal selftest S Signals display D DIL switch settings P Potentiometer settings V Firmware Version Select Testfunctions with the Keys H M N B S D P V The testfunctions can be called with the appropriate keys All testfunctions can be stopped with the spacebar 10 1 1 Motortest The Mo...

Page 34: ...is test a diagnostic connector see figure 35 must be plugged into the busconnector X102 left side Attention To avoid damage of peripheral units or sensors all sensors and bus cables must be removed from the connectors b BUS signal selftest Testing FEED LSC OK Testing FEED READY OK Testing TCY GSC1 OK This test will display faulty signalpairs on the terminal screen If the test is started without th...

Page 35: ...isplay Use spacebar to leave GSC1 READY LSC FAULT OFF OFF OFF OFF 10 1 5 DIL switch settings This test shows the position of the DIL switches It is used to test the function of the DIL switches d DIL switch settings Use spacebar to leave TEST DIR ON OFF n c n c n c n c n c 1 2 3 4 5 6 7 8 9 1 1 1 2 1 3 1 4 1 0 12V 12V F E E D T C Y R E S O U T G N D G N D C L K G S C 1 L S C READY G S C 2 RESIN n ...

Page 36: ...he function of the potentiometers p Potentiometer settings Use spacebar to leave SPEED PRE TCY 0631 0057 0187 10 1 7 Firmware Version This test displays the firmware version number and its release date v Firmware Version COLLAMAT 3600 Version V1 01 Date 28 Nov 1996 5999 515 01E 12 06 2007 WM Page 35 47 ...

Page 37: ...model the polarity of the triggering signal of the hot stamp must be changed This adjustment is to be set with the jumper X105 on the dispenser board to normal or inverse The position of the jumper X105 can be found on figure 11 Umax 24VDC Imax 25 mA HOTSTAMP NPN 12V 24V NPN Input MONITOR IFEED CONTROL SIGNALS GND IFD IFD HOTSTAMP GND PNP MONITOR IFEED PNP Input CONTROL SIGNALS 12V 24V IFD IFD GSC...

Page 38: ...ables All units must be grounded Connect only devices which meet the RMI standards Use power filters in interfered environments and interfered mains supplies 12 2 Setting up The setting up must be done carefully by trained personnel The following items must be observed Visual check of the labeler unit Are all electrical and mechanical units correctly attached Are all connectors accessible Connect ...

Page 39: ...sary and terms 14 1 Short cuts ESD ElectroStatic Discharge RMI Radio Magnetic Interference GND GrouND IR Infra Red LED Light Emitting Diode nc not connected RS232 Standard serial data exchange protocol 14 2 Signals FEED Signal indicating the labelling process GND GrouND GSC Goods SCanner IFEED Isolated FEED signal LSC Label SCanner nc not connected READY READY signal from peripheral units TCY Tran...

Page 40: ...me for a labeler built by Collamat Stralfors AG GSC Goods SCanner Flap adapter with magnet Adapter which moves down to the product during the labelling LSC Label SCanner Position Sticking position of a label on the good Predispensing Predispensing of a label on the peeling plate Motorstep Travelling way of the label for one motorstep Dispensing speed The speed of the goods to which the labels are ...

Page 41: ...20 m min Minimal gap for optical scanner mm 2 Minimal gap for mechanical scanner mm 2 Max diameter of paperroll mm 250 350 Max weight of paperroll kg 10 Noise figure dBA 70 Traction unit System C3600 Driver 2 phase steppermotor 200 steps Motor voltage 40 V Max phase current 4 0 A Type of protection IP40 Ambient temperature 5 40 C Ambient humidity 15 90 non condensing Noise figure max 70 dBA 1 m di...

Page 42: ...left Adapter angle 90 with adjustable snap in locking Recuperating spring force adjustable Additional press time of adapter adjustable Max turning angle 15 Ambient temperature 5 40 C Ambient humidity 15 90 non condensing Label scanner Optical label scanner Mechanical label scanner The informations in this handbook reflect the state of the publication date We reserve the right to make design modifi...

Page 43: ...appenadapter D Für Deckelmontage A Unwinder B Traction unit C Flap adapter D For lid dismantling 266 min 225 max 375 38 245 480 610 Ø 250 Ø 350 140 270 77 A C B D Ø 40 245 175 158 147 160 95 C3620 212 223 105 min 100 C3610 5999 515 01E 12 06 2007 WM Page 42 47 ...

Page 44: ...he diskbrake The torsion spring comes off the knurled knob Wrong kind of torsion spring Exchange the torsion spring against an according torsion spring The unwinder tends to fall off while side labeling Paper roll too heavy Mount a separate clamp to the module rail to stiffen the unwinder rail Dancer roll gets shaky Shaft screw is loose Fix the screw use perhaps Locktite Dancer bearing gets shaky ...

Page 45: ...dapter flap gets shaky Lever fixing screw is loose Remove the flange holding the two knurled rolls and retighten the lever Labels are not dispensed straight forward Peeling bar is worn out Replace the peeling bar Labels form bubbles Labeling speed to fast Reduce labeling speed Labels form wrinkles Labeling speed to slow Increase labeling speed Labeler is misaligned to product transport Realign the...

Page 46: ...omplete trac tion roller The toothed belt roll or the lock ing plate is broken Exchange the toothed belt roll or exchange the locking plate and fix it tight At higher labeling speed the motor stalls Too much friction of the paperweb Check the paperbrake Add Teflon tape to the peel ing bar Reduce all friction of the pa perweb where possible At higher labeling speed the motor stalls Too much frictio...

Page 47: ...on after power on but motor is under power Probably set to Nonstop slave mode Switch Nonstop mode to off The potentiometers are broken Transportation damage Use the original transport box The primary fuse often blows The mains impedance is too low Use an extended power cord The 5V and 12V LEDs are both off Fuse F3 is blown probably re sult of a short of the 12V in the peripheral units Check the pe...

Page 48: ...ength in sense of transport Distance between goods Labeler Speed m min Pieces min Measuring Settings Predispensing Position mm Suppression TCY value Label length Suppression Special Machine environment Conveyor Feeder Taker Other machines around Peripheral units 1 2 3 Screening Mains cables Sensor cables ESD Phenomena Description Description of the malfunctions Accumulation Date ev date and time o...

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