HM Collamat AG Bodenmattstrasse 34 CH-4153 Reinach Switzerland

HM Collamat AG Bodenmattstrasse 34 CH-4153 Reinach Switzerland
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
Collamat 3600
5999.515-01E
Technical handbook
Index
Page
1 Safety advices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Important Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Danger Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Symbol descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 The labeler C3600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1 Prevention of accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.2 Noise suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.3 Mechanical stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Assembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Traction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.1 Threading the labelweb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 Adjustment of rewinder coupling force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.3 Readjustment of paper brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.4 Longitudinal adjustment on the module rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Flap adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
4.2.3 Isolated output IFEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.4 Open-Collector-output IFEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.5 Currentsource-output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Connection diagrams BUS X101, X102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Transformer wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Connection of the mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Grounding of the labeler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Connection of the mains output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Index
Page
4.8 Connection of the frontpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.9 Motor and motorcable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Normalmode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 DIL-switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 DIL-switch TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 DIL-switch DIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Peripheral units and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 Optical label scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Goods scanners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.1 G&S measuring IR-scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.2 NPN-Reflective scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Magnet adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 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 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11 Control of a hotstamp with the IFEED signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12 Cabling and setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.2 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13 Version numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14 Glossary and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Index
Page
14.1 Short cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.2 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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1 Safety advices
1.1 Important Warnings
Before installing and operating the Collamat 3600 read following safety
instructions:
The labeler C3600 is exclusively determinated for labelling goods.
The installation of a Collamat 3600 has to be done by a trained specialist.
For this you have to consider the national specific regulations of
prevention of accidents
mechanical stability
construction of electrical and mechanical systems
noise suppression
Take notice to the technical data of the Collamat 3600. Especially the environment conditions must be observed.
The operation of the Collamat 3600 must be done by trained personnel.
In case of non-authorized modification guarantee will fall.
Before connecting non-standard 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 power.
It exists danger of pinching hairs, jewelry, ties, clothes etc. into the traction unit
It exists danger of injury by cutting fingers in the area of the paper web.
It exists danger of injury in the area of the dancer of the unwinder of the Collamat 3600.
It exists danger of injury in the area of the paper stockcontroller of the Collamat 3600.
For operation on the Collamat 3600 the operating personnel must keep to a safely
place to prevent injury from the products being labeled.
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1.3 Symbol descriptions
ATTENTION
Indicates danger of damaging the Collamat 3600 or other system components, with a potential consequential danger of injuries.
DANGER
Indicates an immediate 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.
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2 Introduction
2.1 General informations
This technical handbook describes the construction and the function of the Collamat 3600. In
addition to the operating instructions, it contains the necessary tips and adjustments to get optimum use of the Collamat 3600. The descriptions of each electrical or mechanical device also
helps for quick error analysis and error elimination.
We recommend you to replace the complete electronic boards. Return it to Collamat Stralfors
AG or to its representative for repair. You can then feel sure, that the high quality standard of
the Collamat 3600 can also be guaranteed after repair.
2.2 The labeler C3600
Special characteristics of the Collamat 3600:
resistant to wear, no clutch/brake-system
robust, stable
easy installation and operation due to the modular construction
quick change-over to other labelling tasks
high performance
high reliability
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, as well as
the mains switch are placed right on the body of the traction unit itself. All parts are corrosionproof, the feedroller of the traction unit is provided with a special coating for permanent nonslip
torque transmission onto the paperweb. The rewinding force of the rewinder as well as the
braking power of the paper brake are adjustable at the traction unit from the outside.
The installation of the Collamat 3600 must be done by trained personnel. For this you have to
consider the national specific regulations of:
prevention of accidents
noise suppression
mechanical stability
construction of electrical and mechanical systems
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2.2.1 Prevention of accidents
While installing and connecting the Collamat 3600 take care that the signal cables and power
cables can't become obstacles. The cables must be placed and installed according to the national safety requirements. Take care that the signal cables are not placed beneath power
cables.
The power switch and the controll elements must easily be accessible.
2.2.2 Noise suppression
The dispenser C3600 is shielded according to the CE directives. Only cables which are certificated 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 Collamat 3600 is used on a movable stand, this stand must be capable to be tilt 10° in
each direction. See also following figure 1:
10°
10°
Figure 1: Stability of the stand
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2.3 Assembly parts
The assembly parts are mounted and placed on a modular rail. Following figure 2 shows these
assembly parts with their names on the modular rail:
1
2
3
4
5
6
7
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
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3 Mechanical adjustments
3.1 Traction unit
3.1.1 Threading the labelweb
1
Figure 3
Thread the labelweb as shown in figure 3 up to the dispensing edge and draw it out by approx.
1 m. Detach the labels from the paperweb at the drawn-out web. Then open the pinchroller by
turning the knob (1), place the paperweb over the dispensing edge and finish threading the paperweb 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
3
2
1
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 M8-bolt (2) accordingly:
in=
harder coupling
out=
softer coupling
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3.1.3 Readjustment of paper brake
2
Figure 5
The braking force is factory-set to an optimum value. Should it, however, be unadjusted, readjust it with the M3-bolt (2) in the web-end controlbox 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.
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3.2 Flap adapter
3.2.1 Inclination adjustment of flap adapter
2
1
3
4
Figure 7
The inclination of the flap adapter can be changed against the module rail: unscrew nut (1) with
two turns (refer to figure 7), with special hexagonal spanner (included as accessory). Push
adapter in the direction indicated by the arrow (2), turn to desired setting at ring (3). Retighten
nut (1).
The pressure force of the flap adapter without magnet or of the magnetic flap adapter is variable: push in button (4) in the direction indicated by the arrow, twist for appropriate spring tension and adjust until it meets the next stop.
3.2.2 Adjustment of the pressure roller of the flap adapter
5
6
Figure 8
The pressure roller of the adapter can be adjusted depending on the labels and goods:
Horizontal adjustment with the knurled nut (5)
Vertical adjustment with the hexagonal nut (6)
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3.3 Adjustment of the optical label scanner
Gitter
LED
1
min. 2 mm
Figure 9
Proceeding of the adjustment of the optical label scanner:
Switch on the Collamat 3600. Set the label scanner potentiometer to zero. Pull the labelweb so
that the gap is located below the marking 1 of the scanner. Turn the potentiometer until the red
LED on the scanner goes off. Continue pulling the labelweb 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 after approx. 0.75 m of the labelweb.
For transparent labels, please use the mechanical label scanner.
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3.4 Adjustment of the mechanical label scanner
The mechanical label scanner (not used on magnetic flap adapter) is an alternative to the optical label scanner and is mainly used for transparent labels.
LED
1
2
1. Scanner support
2. Scanning head
3. Nut
3
2 - 6 mm
Figure 10
Adjustment:
Place the label under the scanning 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 counterclockwise 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 necessary on the traction unit!
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4 Technical description
4.1 Dispenser board
All the electronic devices including power transformer, except of the main switch with indicator
lamp, are located on a printed board. The dimensions of the board are approximately 215 x
234 mm. Figure 11 shows the board with all the connectors and terminals.
The description is divided into power supply, motordriver, controller and firmware.
4.1.1 Power supply
The power supply unit generates the two regulated voltages +12 V/1A and + 5 V/1 A for the
logic, as well as an unregulated DC voltage of approx. 40 V/3.5 A for the steppermotor. The
stabilization is done by linear voltage regulators.
4.1.2 Motordriver
The driver board consists of 2 H-bridge circuits to drive the two motor phases. The phase current is 4 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 illuminated. In this case the labeler must be switched off and on again.
4.1.3 Controller
The single chip micro-controller H8/532 with external 32 K-Byte EPROM controls the functions
of the labelling process.
All outputs are buffered by photo-couplers.
All the inputs are pulled up to +12V with 2.2 K and are equipped with a low-pass filter.
The A/D-converter scans periodically the value of the settings of the 3 potentiometers
(R101....R103).
The control current of the label scanner is generated by a controlled current source.
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SPEED
PREDISP
TCY
X48
5 0 6 7
X104
a3
a2
a1
L1
N1
X46
1
9
FAULT
F1
6
L N
2
OUT
RESET
2AT 230V
4AT 115V
TEST
1
DIR
X51
3.15AT
F2
IC2
1.6AT
F3
X101
X39
X105
X36
5V
12V
X102
X1
X14
3 3 7 7
IN
X40
N PE
+12V
IFD
IFD
RDY
FEED
GND
TCY
+12V
+12V
LSC
GND
+12V
GND
GSC1
L
Figure 11: Dispenser board
4.2 Signals and connection diagrams
All in- and outputs are equipped with filter elements to prevent electromagnetic interference.
These components also prevent interference caused by electrostatic discharge. The interference can lead to malfunction 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.
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4.2.1 Inputs
The inputs are used to connect peripheral units and sensors. The inputs are activated while
they are pulled to GND (0 Volt). The peripheral units from Collamat Stralfors AG have NPNoutputs to 0 Volt.
Figure 12 shows the schematic diagram of the inputs:
+12 V
+12 V
2k2
10k
IN
100k
1n
+
LM339
10k
GND
+5 V
2k2
H8/532 Input
4k7
10nF
On: >4mA (or < 2 V)
Off: 0mA (or > 8 V)
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
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4.2.3 Isolated output IFEED
This output is completely isolated to the electronic circuit of the labeler. Figure 13 shows the
schematic diagram of this isolated output:
+5 V
+
-
Umax.: 24 VDC
Imax: 25 mA
PC355T
1n
1n
Figure 13: Isolated output IFEED
4.2.4 Open-Collector-output IFEED
For better resistance against interferences, the Open-Collector-output IFEED is also equipped
with a photocoupler. Figure 14 shows the schematic diagram of the Open-Collector-output
IFEED:
+5 V
+
PC355T
Umax.: 24 VDC
Imax: 25 mA
1n
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:
+12 V
PWM
H8/532
10k
100k
OP-AMP
LM358
TCY
BCP54-16
100n
10n
4 IR-LEDs
100
Figure 15: TCY-currentsource
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4.3 Connection diagrams BUS X101, X102
The buscable of the peripheral units is connected to the connectors X101 or X102. The cable
must be placed inside of the module rail to prevent interferences. Figure 16 shows the position
of the buscable connectors on the dispenser board:
X102
1
X101
1
Figure 16
Connector X102
Pin Signal
Connector X101
Pin Signal
1
+12V
2
+12V
3
READY
4
FEED
5
LSC
6
7
TCY
8
9
Pin Signal
Pin Signal
1
GND
2
GND
3
nc.
4
nc.
GSC1
5
nc.
6
nc.
nc.
7
nc.
8
TCY
nc.
10 nc.
9
GSC1
10 LSC
11 nc.
12 nc.
13 GND
14 GND
1
13
2
14
14
13
2
1
11 FEED
12 READY
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 signaled with a 3. See also Figure 17:
violett
X36
X39
orange
3
3
7
7
Figure 17
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The primary side of the transformer is connected to the terminals X46 and X48. Dependent to
the mains voltage the transformer is connected as shown in figure 18:
110 V
220 V
120 V
X48
230 V
X48
X48
240 V
X48
X48
9
a3
0
a3
9
a3
0
a3
0
a3
5
a2
2
a2
5
2
4
8
a2
a2
L1
2
5
4
8
a2
L1
5
2
4
8
L1
0
N1
9
N1
9
N1
a1
8
4
2
0
a1
8
4
9
5
L1
N1
L1
N1
X46
0 = schwarz
a1
X46
X46
2 = rot
4 = gelb
5 = grün
a1
X46
8 = grau
a1
X46
9 = weiss
Figure 18: Transformer wiring
4.5 Connection of the mains input
The powercord must be connected to the terminal X40. To prevent interferences it must be
looped through a ferrite-filter as shown in figure 19:
2 Windungen
X101
X25
IN
X40
L N PE
braun
gelb/grün
blau
Ferrit-Filter
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.
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4.7 Connection of the mains output
Peripheral units like the flatprinter or the adapter with magnet are connected to the mains output. To this terminal only units, certified by Collamat Stralfors AG, may be connected. Figure
20 shows the mains output terminal:
9
6
gelb/grün
blau
L N
OUT
X41
braun
F1
1
X51
Figure 20
4.8 Connection of the frontpanel
The frontpanel must be connected as shown in figure 21:
braun/weiss
blau
9
6
L N
OUT
X41
braun
F1
1
X51
gelb/grün
Figure 21
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4.9 Motor and motorcable
Attention:
The motor never must be dismantled !
Steppermotor heats up during operation !
When connecting or disconnecting the motor, the labeler must be switched
off !
While working on the motor, the labeler must be disconnected from mains !
X31
X33
5
0 X32
6 X30
7
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:
green
black
blue
violet
motorcable
Figure 22: Motor connection
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5 Firmware
5.1 Normalmode
After turning on the labeler, the DIL-switches are scanned to figure out the working mode.
The dispensing of a label is triggered by the negative edge of GSC1 (Goods scanner input).
READY must not be active (12 Volt). The stop of the labelling is triggered by the detection of
the gap (LSC) and performing the remaining steps for the predispensing.
The timing diagram of the signals is shown in figure 23:
Signal
GSC1
Clock
LSC
FEED
1
2
t
Figure 23: Timing diagram of the GSC1, 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 meters.
At speeds faster than 10 m/min, the steppermotor is driven in the fullstep-mode. For slower
speeds, in the halfstep-mode.
The minimum speed is 3 m/min. The maximum speed is 20 m/min.
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5.2 DIL-switches
The dispenser board contains two DIL-switches. These switches are used to select different
operating modes. The following table and figure 24 show the functions and the positions of the
DIL-switches:
Switch
Function
Off
On
TEST
Labelingmode/ Testmode
Labelingmode
Testmode
DIR
Turning direction of the motor
Right
Left
TEST
DIR
Aus
Ein
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.
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6 Trouble shooting
6.1 Fuses
The Collamat 3600 contains three fuses:
Fuse
Voltage
Value
Part. No.
F1 110V:
230V:
Mains voltage
4AT
2AT
5*20mm
5*20mm
74030800
74030341
F2
Motordriver 40V
3.15AT 5*20mm
74031216
F3
Logic 12 V, 5V
1.6AT 5*20mm
74031135
To exchange the fuses, the cover of the Collamat 3600 must be removed.
If the fuse of the main voltage is blown, the indicator lamp of the power switch is not illuminated
when the Collamat 3600 is switched on.
If an external peripheral unit like flatprinter or flap adapter is working without any movement of
the traction 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 circuit are OK
Fuse F3 or F1
12V
Illuminated, when the 12V for the sensors Fuse F3 or F1
are OK
Short circuit in the sensor supply
RESET
Flashes while turning power on
Flash while running
Watchdog RESET
Software failure
FAULT
Motordriver supervision
Overheating, short circuit, undervoltage,
fuse F2
For trouble shooting, please use the checklist on the last page of the handbook.
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7 Peripheral units and sensors
7.1 Optical label scanner
5
+12 V
9
1
LSC
(LABELSCANNER)
GND
5
1
+12 V
TCY (TRANSPARENCY)
Figure 25
7.2 Goods scanners
7.2.1 CS measuring IR-scanner
5
1
5
+12V
GSC1
4
GND
9
LED
+12V
1
GND
LEDs
Figure 26
7.2.2 NPN-Reflective scanner
NPN
+12 V
GSC1
GOODSCANNER
GND
Figure 27
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7.3 Magnet adapter
GS070C
TIME
ON
14 Pol
OFF
F1
3,15AT
LED
R
FLACHKABEL
RECHTS
TCY
+12V
GND
LSC
+12V
MAGN
MAGN
220V
220V
L
LINKS
+12 V
LSC
GND
MAGNET
+12V
TCY
Ph N
GS070D
DELAY
ON
MAGN
MAGN
CP21
CP21
220V
220V
F1
3,15AT
14 Pol
OFF
L
TCY
+12V
GND
LSC
+12V
LED
R
FLACHKABEL
RECHTS
LINKS
+12 V
LSC
GND
MAGNET
+12V
TCY
Ph N
Figure 28
The mains voltage must be connected inside of the flap printer or inside of the dispenser.
The factory setting of the trimmer TIME is on MINIMUM. The trimmer is used to set a delaytime
for the releasing of the magnet.
The terminals CP21 are used to connect the synchronous 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.
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7.4 Flatprinting unit
7.4.1 Flatprinter board
S1
P1
rot / red
X3
1
2
3
rot, schwarz
red, black
schwarz / black
1
2
braun / brown
weiss / white
M
X4
Farbbandmotor
Ribbonmotor
braun / brown
L N
L N
blau / blue
gelb,grün
yellow,green
12v
/LSC
12v
GND
GND
IFEED
/TCY
Collamat Buskabel 14 polig
Collamat Buscable 14 poles
X6
/IFEED
X5
Figure 29
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8 Control signals for external units
The signals FEED and READY are used to control external units.
FEED (Output)
The FEED signal indicates that the labeler is dispensing. This means that the steppermotor is
turning. With this signal an external flatprinting unit can be controlled. See herefore figure 23.
READY (Input)
The signal READY is used to signal that a connected peripheral device like hotstamp or flatprinter 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
GND
GSC1
+12V
GND
LSC
+12V
TCY
+12V
GND
The goods scanner is connected to the GSC1 terminals. Figure 30 shows the connection of the
standard Collamat Stralfors AG IR goods scanner:
brn
grn
brn
wht
yel
grn
IR
GND
+12V
GND
GSC1
+12V
Figure 30: Connection of the CS IR goods scanner
GND
GSC1
+12V
GND
LSC
+12V
TCY
+12V
GND
Figure 31 shows the connection of a NPN-scanner:
NPN
GND
GSC1
+12 V
Figure 31: Connection of a NPN-scanner
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9 Electrical installation
9.1 Introduction
The cabling must be done like shown in figure 32. The controlsignals FEED and READY, the
supply +12 Volt and ground, are fed through the 14 pole flatcable to the flatprinter and the
magnet adapter. 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 directly be connected to the dispenser C3600, to the flap adapter or to the flatprinter respectively. In this case, the connection to the Collamat 3600 is made by the 14 pole flatcable.
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Micro-switch
GND
GSC1
GSC1
+12V
GND
GSC1
+12V
G&S IR Goods scanner
2
6
P2
3
4/5
9
OPTICAL LABEL SCANNER
3
5
1
9
6
5
1
FLAP
ADAPTER
P1/P2
NPN
Reflex scanner
GND
1
GND
+12V
5
FLAT
PRINTER
1
4/5
3
P4
1
P1
6
3
P5
9
4
X101
1
3
2
POWER SUPPLY
from flat printer
110/230V
P6
5
3
L
4/5
6
1
3
P7
3
X102
DISPENSER
POWER SUPPLY
110/230V
50/60Hz
N
LN
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P8
P4
P5
P2
P3
P1
6
1
4/5
Figure 32: Connection diagram
Page 30 / 47
2
10 Testmode
The firmware of the Collamat 3600 has a standard test and diagnostic routine. If the DIL-switch
TEST is switched on while turning the power on, the firmware starts the test and diagnostics
routine. See also figure 24.
In the testmode, the motor is started and stopped periodically with the speed, set on the
SPEED potentiometer. If there are any labels threaded through the Collamat 3600, the labels
will be dispensed periodically.
In the testmode, the Collamat 3600 can be controlled by an ASCII-terminal or a PC with a terminal emulation software. The communication with the Collamat will be done through the connector X104 using the RS232 protocol. The test software 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:
9Pol D-Sub
10Pol Flachkabel
2
3
5
3
5
9
10 pol
1
1
Figure 33
Communication parameters
Terminal settings
9600 Baud, 8 Bit, 1 Stop Bit, No Parity
TTY, Text
X60
X61
Figure 34 shows how to connect the Collamat 3600 to a PC:
SPEED
POS
PREDISP
TCY
X48
5
X103
0
6
7
a 3
a 2
a1
L 1
1
X104
X106
1
N1
9
PC
6
NS
R1
R2
L N
OUT
FAULT
DEL
COM1
X46
1
RESET 2
F1
2AT 230V
4AT 115V
TEST
1
DIR
X51
2.5AT
F2
1.6AT
F3
3
7
ERR
ERR
GND
GND
IN
X 4 L0
N
P E
+12V
+12V
GSC3
GSC2
NSTPO
NSTPI
IFD
GND
+12V
IFD
FEED
X1
LSC
RDY
GND
TCY
GND
+12V
+12V
+12V
GSC1
GND
X101
7
X25
3
X39
X105
X36
5V
12V
X102
Diagnosestecker
Figure 34: Test connections
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10.1 Test software
When the Collamat 3600 is connected to the terminal, it must be switched on. At this moment
the DIL-switch TEST must be set to on. The traction unit begins to turn with the speed set on
the SPEED potentiometer. The terminal shows the following message:
COLLAMAT 3600
V1.01
Motor intervall test.
Use spacebar to leave
Pressing the spacebar stops the motor intervall test. Now the following 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 Motortest is used for measuring the phase currents of the motor. The motor turns with
the speed set on the SPEED potentiometer.
>m
Motortest. Use spacebar to leave
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10.1.2 Motor intervall test
The Motor intervall test tests the labelling functions of the Collamat 3600. If a label web is
threaded through the dispenser, labels will be dispensed periodically with the speed set on the
SPEED potentiometer.
>n
Motor intervall test.
Use spacebar to leave
10.1.3 BUS-signal selftest
The BUS-signal selftest tests all in- and outputs of the Collamat signalbus. For this 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 the
diagnostic connector the following message is displayed:
>b
BUS-signal selftest
Testing FEED+LSC......not OK !
Testing FEED+READY....not OK !
Testing TCY+GSC1......not OK !
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Figure 35 shows the schematic diagram of the diagnostic connector:
+12V 1
nc
+12V 2
nc
READY 3
1
FEED 4
LSC
5
GSC1 6
TCY
1
7
14
GSC2 8
RESOUT 9
14
CLK 1 0
RESIN
11
nc
12
nc
GND 13
nc
GND 14
nc
Figure 35: Diagnostic connector
10.1.4 Signal display
This test displays the levels of the input signals. It is used to test the function of the sensors
and input circuits.
>s
Signals display. 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
5999.515-01E 12.06.2007 WM
Page 34 / 47
10.1.6 Potentiometer settings
This test shows the position of the potentiometers. It is used to test the 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
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11 Control of a hotstamp with the IFEED signal
Two different type of hotstamps (NPN or PNP) can be connected. Figure 36 shows how to
connect different hotstamps. Figure 37 shows the timing diagram.
MONITOR
HOTSTAMP
MONITOR
NPN-Input
CONTROL SIGNALS
IFEED
+
-
IFD
+12V / +24V
NPN
IFD
GND
HOTSTAMP
PNP-Input
CONTROL SIGNALS
IFEED
+
-
IFD
+12V / +24V
PNP
IFD
GND
Umax: 24VDC
Imax: 25 mA
Figure 36: Connection of IFEED
GSC1
LSC
FEED
IFEED
IFEED normal
IFEED invers
STAMP
T
Figure 37: Timing diagram
Dependent to the manufacturer and the model, the polarity of the triggering signal of the hotstamp 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.
5999.515-01E 12.06.2007 WM
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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 labelling. Most times misplaced layout of the cabling, RMI and ESD interferences disturb the labelling. 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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13 Version numbers
Dispenser board
Part number
Version
5215.7400A
Basic version from first series
5215.7400B
Second revised version
Firmware
Version
Date
Characteristics/Modifications
1.00
06. 28. 1996
Basic version from first series
1.01
11. 28. 1996
Correct handling of the READY signal
14 Glossary and terms
14.1 Short cuts
ESD
RMI
GND
IR
LED
nc
RS232
ElectroStatic Discharge
Radio Magnetic Interference
GrouND
Infra Red
Light Emitting Diode
not connected
Standard serial data exchange protocol
14.2 Signals
FEED
GND
GSC
IFEED
LSC
nc
READY
TCY
Signal indicating the labelling process
GrouND
Goods SCanner
Isolated FEED signal
Label SCanner
not connected
READY signal from peripheral units
TransparenCY, control current for the label scanner IR-diodes
5999.515-01E 12.06.2007 WM
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14.3 Terms
Stopping accuracy: Accuracy of the paper transportation
Unwinder: Device that carries the full paperweb rolls and unwinds it
Adapter: Part of the labeler by which the label is peeled off from the paperweb and applied
onto the products
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 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 sticked
Startfrequency: Highest possible frequency for a steppermotor to start moving without loss of
steps
Traction Unit: Part of the dispenser with drive unit and electronic control
5999.515-01E 12.06.2007 WM
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15 Technical data
Dispenser general data (standard values)
System
Units
C3610
Version
C3620
right/left
Dispensing speed
m/min
3.0-20
Min. label width
mm
Max. width of the paperweb
mm
Min. label length
mm
10
Min. label length at max. dispensing speed
mm
20
Stop accuracy
mm
± 1 mm @ 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
10
95
160
< 70
Traction unit
System
Driver
C3600
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 distance
System
C3610
C3620
Weight
12 kg
14 kg
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Midi-unwinder
Diameter of the roll core
42 mm
Max. outside diameter of roll
350 mm
Max. weight of roll
10 kg
Spring dancer with automatic brake
Flap adapter
System
C3610
Max. width of paperweb
95 mm
Weight
1.9 kg
Version
C3620
160 mm
2.2 kg
right/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
Ambient humidity
+5-40°C
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 modifications.
5999.515-01E 12.06.2007 WM
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15.1 Dimensions - systemdesign
A
480
610
B
50
Ø3
0
25
C
38
77
245
Ø
min. 225
140
266
160
C3620
95
C3610
212
147
158
223
175
245
105
D
270
min. 100
max. 375
Ø 40
A) Abwickler
B) Vorzugwerk
C) Klappenadapter
D) Für Deckelmontage
5999.515-01E 12.06.2007 WM
A) Unwinder
B) Traction unit
C) Flap adapter
D) For lid dismantling
Page 42 / 47
16 Troubleshooting
16.1 Troubleshooting Collamat 3600
The troubleshooting will proceed along the paperpath. See following figure:
2
4
X61
3
X60
1
SPEED
TCY
POS
5
6
0
X48
7
X103
a3
1
a2
X104
X106
a1
1
L1
N1
1
X46
6
OUT
9
FAULT
DEL
NS
R1
R2
L N
2
RESET
F1
2AT 230V
4AT 115V
TEST
1
DIR
X51
3.15AT
F2
1.6AT
F3
5V
12V
3
7
IN
X40
L
N PE
+12V
ERR
ERR
GND
GND
NSTPI
GSC3
NSTPO
IFD
IFD
GND
+12V
+12V
GSC2
RDY
FEED
TCY
GND
+12V
X1
LSC
GND
+12V
+12V
GSC1
GND
X101
7
X25
3
X39
X105
X36
X102
Unit
1. Unwinder
2. Adapter
3. Traction unit
4. Control print
1. Unwinder troubleshooting
SYMPTOM
DIAGNOSIS
ACTION
Labels peel off at the dancer Dancer roll diameter is too small Change the standard roll
roll
against a roll with enlarged
diameter
Dancer arm is bent and
breaks
Dancer arm materiel is too weak Use new dancer arms
or too thin (older Collamat)
(C3600/C6600/C8600)
Flange of the fixed disk
breaks
Material defect, wrong type of
aluminum
Replace flange against new
series flange
Unwinder blocks
Disk touches the diskbrake
Shift the disk on the unwindershaft away from the
diskbrake
Shaft is blocked
Lubricate the bearings on the
shaft
Diskbrake does not open
Readjust the diskbrake
The torsion spring comes off Wrong kind of torsion spring
the knurled knob
Exchange the torsion spring
against an according torsion
spring
The unwinder tends to fall off Paper roll too heavy
while side labeling
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
Module rail is worn out by the Replace module rail and
dancer axle
dancer axle
Paperweb falls off in side la- Missing side labeling kit
beling applications
5999.515-01E 12.06.2007 WM
Mount the side labeling kit to
the Collamat
Page 43 / 47
2. Adapter troubleshooting
SYMPTOM
Labels run through
DIAGNOSIS
ACTION
Roll-up cable is broken
Replace roll-up cable
Label sensor cable is broken
Replace label sensor cable
IR transmitter cable is broken
Replace transmitter cable
IR transmitter LED broken
Replace transmitter print
Label sticks below the label
sensor
Remove the sensor and
clean it properly
IR light guide is blind
Replace IR light guide
TCY-potentiometer is
misadjusted
Readjust TCY, check
DATA-HOLD-switch
Label scanner position not over Place the scanner over the
the label
label transport path
Pressing roll is worn out
Roll is pressed too hard to the
goods
Lift the labeler, reduce the
adapter spring force
Pressing roll axle hangs/is
bent down
Fixing hex nut is loose
Retighten the hex nut (apply
Locktite)
Pressing roll axle is bent or
broken
replace the axle
Adapter 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 Realign the labeler
transport
Adapter tilts down while
labeling
Backing paper not threaded be- Tread the paperweb correctly
tween the adapter roll pair
between the adapter roll pair
Paperweb breaks behind the Lateral paperguides hurt the
peeling bar
paperweb
Enlarge the space between
the paperguides
Paperbrake set too hard
Reduce the braking force
Peeling bar is too sharp
Use peeling bar with a bigger
radius
Add Teflon tape around the
peeling bar
5999.515-01E 12.06.2007 WM
Peeling bar touches the goods
Lift the labeler/adapter away
from the goods
Paperweb is perforated
Use unperforated paperwebs
or use a peeling bar with bigger radius
Page 44 / 47
3. Traction unit troubleshooting
SYMPTOM
DIAGNOSIS
ACTION
Pressure roller is shaky
Pressure roller shaft is broken
Replace pressure roller shaft
Traction roller turns in the
wrong direction
Problems in the rewinder clutch Release the breaking force of
the rewinder
Feltdisks are worn out
Replace the felt disks
Parallel pin inside the rewinder
shaft is blocked
Release the parallel pin clean
and lubricate it
Potentiometer settings have DATA-HOLD-switch active
no effect
Switch it off
Motor is very hot
No fault
This is normal for a stepper
motor
Motor makes high frequent
noise
No fault
This is normal for a stepper
motor
Traction roller is shaky while Pin at the front flange of the tra- Exchange pin or if necessary
power on
tion roller is broken or worn out exchange the complete traction roller
The toothed belt roll or the lock- Exchange the toothed belt
ing plate is broken
roll or exchange the locking
plate and fix it tight
At higher labeling speed the Too much friction of the
motor stalls
paperweb
Check the paperbrake
Add Teflon tape to the peeling bar
Reduce all friction of the paperweb where possible
At higher labeling speed the Too much friction of the
motor stalls
paperweb
Clutching force of the rewinder
is too high
Paperweb breaks behind the Lateral paperguides hurt the
paperbrake
paperweb
Paperbrake set too hard
Check the unwinder dancer
Release the breaking force of
the rewinder or
replace the felt disks
Enlarge the space between
the paperguides
Reduce the braking force
4. Control print troubleshooting
SYMPTOM
Motor is dead, power switch
is not illuminated
DIAGNOSIS
No mains connected to trafo
ACTION
Check for correct main
connection
Check main fuse
Check internal main switch
wiring
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4. Control print troubleshooting
SYMPTOM
DIAGNOSIS
Motor is dead, power switch Motordriver probably not
is illuminated, FAULT-LED is working
on
ACTION
Check motordriver fuse F2
Check for undervoltage
Check for motordriver
overheat
Check on motorwires for
short connection
Check trafo wiring
Motor turning direction is
wrong
Wrong DIL-switch DIR setting
Change DIL-switch DIR
Wrong Motor wiring
Reconnect motor wires according to the Technical
Handbook
Motor makes noise and
shakes. It does not turn
correctly
Faulty motor driver chip
Replace the board
Missing connection of one motor wire
Connect motor wires according to the Technical
Handbook
No action after power on but Probably set to Nonstop slave
motor is under power
mode
Switch Nonstop mode to off
The potentiometers are
broken
Use the original transport box
Transportation damage
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 result of a short of the 12V in the
peripheral units
The 12V LED is off
Probably result of a short of the Check the peripheral units
12V in the peripheral units
The 5V LED is off
Probably result of a short of the Replace the board
5V in the processor part
The RESET LED is on
Undervoltage of the 5V circuit
The RESET LED periodically Microprocessor error
flashes
EPROM faulty
5999.515-01E 12.06.2007 WM
Check the peripheral units,
replace the fuse (1.6AT)
Replace the board
Replace the board
Replace the EPROM
Page 46 / 47
16.2 Trouble shooting checklist
Ser. No. Dispenser board:
Ser. No. Labeler:
Mains voltage:
Frequency Hz:
Temperature °C:
Humidity %:
Interference level (Burst):
Interference level ESD
(Static):
Width:
Length:
Gap:
Thickness:
Transparency:
Material:
Paperweb
Width:
Thickness:
Transparency:
Goods
Kind:
Material:
Shape:
Length:
Width:
Height:
Speed m/min
Length in sense
of transport:
Distance between
goods:
Labeler
Speed m/min:
Pieces / min:
Measuring:
Settings
Predispensing:
Position mm:
Suppression:
TCY value:
Label length:
Suppression:
Machineenvironment
Conveyor:
Feeder:
Taker:
Peripheral units
1
2
Screening
Mains cables:
Sensor cables:
ESD-Phenomena
Description:
Description of the
malfunctions:
Accumulation:
Machine-Type:
Environment
Labels
Special:
Other machines around:
3
Date / ev. date and time of the last disturbances:
Comments:
Disturbance registered by Name:
Date:
Please make a copy of this list before using it.
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Page 47 / 47
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