Collamat® 9110i
Contents
1. goods scanning or trigger and the encoder will be connected to the corresponding inputs fitted at the rear panel of the MCS I O with the respective denomination 1 2 G 1 Trigger 1 for the collamat A master 2 Trigger 2 for the collamat B slave and G encoder for the speed measurement of the paperweb Both trigger signals will be delayed according to structure collamat connection Super Controller MCS 24 configuration Super Controller MCS a sophisticated computerized algorithmus and appear again on 4 output connectors out puts 1 amp 2 are dedicated to the collamat A master and outputs 3 amp 4 to the collamat B slave Output 2 and output 4 are connected to the GSC 2 inputs of respectively collamat A and collamat B goods scanning The encoder signal is divided by 10 and appears as exactly the same signal encoder signal 10 on the output connectors 5 amp 6 Output 5 and output 6 are connected to the GSC 1 inputs of respectively collamat A and collamat B encoder input The cabling of the collamat does correspond to the measuring method with incremental encoder All the wirings between super controller and C91 monitor are already done in accordance to the following wiring table wiring table for the super controller MCS I O MCS I O input internal PLC I O ei mnt Oe o e Oe a Ooo fo ee een SO Ces EEER ees asi eens ese a a C91 B on off O channel 6 GSC 1 B As said before the maximu2. Parameter set lt MCS IO Clear parameter set Parameter set gt MCS IO Set Nr Controller 7 Transfer parameter set to MCS IO Parameter set lt MCS IO Set Nr Controller 7 Read parameter set from MCS IO Parameter set gt MCS IO Set Nr 1 Clear parameter set Description The configuration parameters of the MCS IO can be read into and stored in the operator unit From there these saved parameters can be transferred back to the MCS IO Saved parameters can be adjusted without disturbing or interrupting operation This makes it pos sible to prepare the next setting during production Super Controller MCS 5999 590 01A 02 08 99 SB Menu Tree Userlevel Operating mode 35 menu tree Explanation Main menu Program editor Length editor Clear channel Manual mode Program memory Program gt MCS IO Program lt MCS IO Clear program Edit program See Length editor Stich mode Configuration Channel parameter MCS IO Controller MCS T user interface Collamat Parameter Configuration memory Parameter set gt MCS IO Parameter set lt MCS IO Clear parameter set Super user Super user Super user Operator Operator Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Operator Super User Super User Off Of
3. 4 Encoder pulses 1000mm 4550 5 Trigger 1 input input normal 6 Trigger 2 input input normal 7 Station number 1 8 Program version 4 4 Description of configuration Each channel is triggered by one of the two signals Trigger 1 or Trigger 2 The signals Trigger 1 and Trigger 2 originate from the relevant external trigger input black mark sen sor The triggering edge is programmable but it is recommended that the active connecting edge is to be used After triggering the trigger is blocked until the position of the last label This means that if you have programmed 32 labels the trigger will be blocked all this distance Interrupting cancelling the labelling The labelling process can either be interrupted or cancelled in the event of e the speed falling below the minimum speed set for a particular channel e the external enable contact ENABLE input being opened e emergency botton has been pressed In the event of a fault the alarm output will be con nected until the fault is rectified Super Controller MCS 5999 590 01A 02 08 99 SB MCS T user interface 1 Station number 2 Language 3 Length unit Description All the parameters relating to the MCS T user interface are located in the MCS T user interface sub menu 1 Station number Always nr 1 2 Language Choose a language of communication 3 Length unit All lengths and speeds can be either metric or
4. Counter Drive not ready Undervoltage Profiling speed Time observing Division by zero Predispensing too short A leading label edge could not be scanned within the entered label length The cause of this error can be as follows e Missing labels on the label web e Slippage of the traction unit or loss of stepper motor due to hits on the label web or too high frictional force e Value of label length is entered too short e Predispensing greater than label length e Error of label scanning When braking the label a gap was detected during predispensing This happens in the case of transparent or very reflective labels The motor drive card indicates that it is not ready to drive the stepper motor During labelling a mains causing the data to be backed up The monitor con tinues to operate normally The max profiling speed exceeds the max permissible labeller speed An internal protective circuit has detec ted that the calculation time provided is exceeded or a calculation error is in processor The cause may be a very strong electromagnetic disturbance or a program error At the actual measured speed the brake ramp exceeds predispensing e Enter in general the label length two times e Correct predispensing e Adjust suppression of label scanning e Check label scanner and possible clean it e Reduce friction force of entire label web e Adjust of suppression of label scanner e Op
5. controller consisting of EE for dispensing time D MCS IO MCS T 1 electric pack consisting of controlling high speed amp Non stop pro yee cedures operating box control box containing Trafo fuse relays PLC connection clamps main switch and MCS IO 2 set of indication lamps 1 air pressure pack consisting of yes air conditioner pressure regulator injector vacuum valves 1 sensor pack consisting of yes 2 GSC scanner mark reader with brackets fixing adjustment possibilities 1 encoder 1000 Imp 220mm revolution fixing adjustment possibilities with brackets high resolution for super controller ue 1 frame consisting of special design yes Introduction to C9110i 5999 590 01A 02 08 99 SB High speed specific Designation Function two legs tube system with lateral consolida tion g y DA could be transported by stackers 2 horizontal double columns with electrical driven adjustment for mounted dispensing system each column fixed on the respective frame leg frame mounting set 4 fixing angle with gui ding cones to be fixed on the underframe EE ang a A oles 13 Introduction to C9110i s Introduction to C9110i 5999 590 01A 02 08 99 SB 15 Chapter 4 Labeller The overall goal is that our customer can dispense labels as accurate and fast as possible The handling of the labels is done through the labeller The knowledge of its parts and how those c
6. horizontal gui debar can him be slided and fixed along an horizontal profil rail which is fixed at a leg of the mainframe perpendicular to the direction of the paperweb motion Each marksensor system comprises the sensor two guidebars vertical amp horizontal and a profil rail fixed at the corresponding mainframe leg All fixing mechanism are done with screws This posi tioning system allows to place the mark reader or mark sensor over the wall paperweb width and also over the right place in paperweb direction The contact line between adapter roll and paperweb does correspond to the impact line of the labelling process this line has to be placed just over the axe of a back pressure roll The label will be taken in sandwich there and the dispensing is done under stable conditi ons The placement of the adapter in paperweb direction is done with the horizontal adjust ment part of the double column driven by handwheel The placement of the adapter in direction of the paperweb width is electrically driven two steel tube with a traction spindle placed on each mainframe leg for guiding and traction of the corresponding double column The vertical position of the adapter is done with the vertical adjustment of the double column driven by handwheel The encoder delivers the pulses as a frequency directly proportional to the paperweb speed It is composed of a friction wheel which is driven by the paperweb The impact points between friction
7. imperial The units can be changed at any time saved lengths remain unchanged Collamat parameter Controller 7 vmax product Trigger distance Vmax collamat Position collamat Compensation length at vmax product Correction length 1 at speed v1 Correction length 2 at speed v2 Correction length 3 at speed v3 Description All the parameters exept 1 vmax product are assigned respectively for each collamat The values at the left are assigned to collamat A master and the value on the right are assignd to collamat B slave The vmax product is appllied on both collamats 1 Deutsch SZT mm 1 200 m Min 100 0 mm 80 0 m Min 2 0 mm 50 0 mm mm m Min mm m Min mm m Min 100 0 mm 80 0 m Min 2 0 mm 50 0 mm mm m Min mm m Min mm m Min 33 user interface collamat parameter Super Controller MCS 34 Trigger distance between dispensing edge and mark reader Vmax _collamat max dispensing speed Position collamat is the copy of the position parameter on the corrsponding collamat Compensation length is the corresponding delay length at vmax product that has to be compensated Correction length x is a linarity correction at corresponding speed x normally these three correction are not to be used configuration memory Configuration memory Parameter set gt MCS IO
8. trained accordingly User groups Related Informa tion Related sources of information e Operating Instructions C9100 Monitor e Operating Instructions C9100 Traction Unit e Technical Handbook C9100 Chapter 1 Secu rity Chapter 2 About this manual Chapter 3 Intro duction to C9100i Chapter 4 Label ler Chapter 5 Super Control MCS Chapter 6 Ope rating Instruction Chapter 7 Tech nical Data Very important to read before putting C9100i in use to avoid accidents and damages A short explanation for whom this manual is written and a the basic concept behind each chapter General information about the C9100i its concept advantages and application areas The standard components which C9100i consists of are briefly illustrated but for deeper understanding please see chapter 4 and 5 An explanation of its parts such as the unwinder traction unit adapter rewinder and monitor This chapter also revels how you should thread the labeller and do adjustments on the labeller but here you also find the entire menu tree of the monitor The chapter about the Super Controller clarifies its parts and demonstrates its structure The operating instructions are classified in the groups normal operating initiali sation and optimisation The normal operating and the initialisation is done by operator and optimisation by the super user This chapter also guides you through the necessary steps In this chap
9. 0 01A 02 08 99 SB e Increasing production flow with remained accuracy Advantages e Based on known technologies e Easy optimisation according to size shape and material of labels e Non stop operating e Adapted for inline finishing line target market actually the labelling system is very often the slowest aggregate in an inline finishing plant and therefore is slowing down the whole line Labelling speed up to 200 meter minute does correspond actually to a standard overall line speed e Downsize the production costs faster throughout e Faster return of invest e manufacturing amp processing paperindustrie Application areas direct mailing advertising marketing e high production capabilities for down sizing the cost increasing return of invest e adjustment of the labelling throughout The high speed is built on two standard C9110i Collamat in a Non Stop configuration It Structure includes the usual components as traction unit mechanical unwinder rewinder and module rail New components are the air sling with electrical drive for label web placed between unwinder and traction unit and the adapter All these components are fixed to the corresponding module rail The mechanical parts of a dispensing system are fixed on a vertical double columns with horizontal amp vertical adjustments units handwheels All these parts build up the mechani cal dispensing part of one Collamat One monitor is also fixed to the
10. 590 01A 02 08 99 SB approximately 1 meter to make the threading through the traction unit easier Thread the paper under the traction roller between the traction roller and the back pressure roller and then over the back pressure roller Pull out the clamp strap on the rewinder Pull the backing paper over the dancer to the rewinder core and fix the clamp strap again Please make sure that the entire paper web is stretched Unwinder with air sling Compress the two handles on the holding disc and pull it out of the unwinder core Take off the disc and the old label roller Put on the new one thread the unit and put back the holding disc Due to dancing arm type and mounting position the force needs to be adjusted This force can be adjusted with a spring force After you have dismantled the housing around a knob with a lot of holes in it can be seen The force spring is stuck in one of the holes When the knob is pressed in turned and left in a new position the force is changed If the force 19 Take off disc Change label roll Adjust spring force of Unwinder Labeller 20 Adjust the adapter Adjust the press roll Change in the monitor Labeller spring is pressed harder the dancing arm moves more easily to its original position but it takes more force to move the dancing arm down to get more paper The required spring force can be adjusted with the cylinder head screw on the flap adapter The force gets softer
11. 5999 590 01A ollamat 9110 User manual Collamat Stralfors AG CH 4147 Aesch Pfeffingerring 201 Tel 41 61 756 28 28 Fax 41 61 756 29 29 STRALFORS Chapter 1 Security e Reading the User Manual and in particular this chapter on the safety instructions must General Safety be read understood and strictly observed before the C9110i is put into operation Instructions e Location of the User Manual must be permanently available at the C9100i operating site e It must be ensured that the local supply connections voltage frequency etc comply with the installation data Connection of the electrical supply must be carried out by a licensed electrical technician and must also comply with the local regulations in parti cular those relating to protective measures e The monitor C9110i is exclusively intended to control the labeller C9100i e The installation of the labeller C9110i must be done by a trained specialist considering the national specific regulations of prevention of accidents construction of electrical and mechanical systems and noise suppression RMI e The C9100i must only be operated serviced and maintained by persons who are familiar Operator require with the User Manual in force concerning work safety and accident prevention ments e The C9100i must only be operated by trained personnel who have been instructed in its use e It must also be ensured that only authorized personnel are allowed to work with the
12. C9100i e Work with the C9100i which is not covered by the User Manual must be carried out only by Collamat Stralfors AG technical personnel or by staff trained by Collamat Stralfors AG e It is necessary to read this manual Operating Instructions C9100 monitor and traction unit to operate the C9100i e The operator must be familiar with the relevant operating and display units Operating e The operator must understand the effects of an operating function on the system as a whole e The operation of the control and display elements as well as the alarm and monitoring system must be tested before using the module control system e Indicator and monitoring devices must be constantly checked for the occurrence of tran sient operating conditions and limiting values and for warning and alarm messages e The operating procedures for emergencies e g emergency switch off in case of fire must be tested regularly Security Disassembly and repair Service and Maintenance Important warnings Security Before operating the system care must be taken that any loose items are removed from rotating parts of the system nobody is present in the danger area around moving parts of the system all repair work has been completed all protective equipment is in place and in working order Disassembly and repair work must be carried out by trained specialist staff with the aid of the relevant disassembly and repair instructions In the cas
13. an be adjusted will contribute to a smother workflow and better labelling results Standard labelling system with optional air sling The purpose of the unwinder is to continuously provide labels without interference The Unwinder unwinder unit consists of a midi unwinder and an label airsling with a motor for a first trac tion level of the labelweb When the labelweb is moving the dancing arm is to get pulled down and causes the winder to release its brake and cases to feed more paper When no more paper is needed the dancing arm shall be adjusted so that it turns back to its original position by itself This adjustment is done by setting a torsionspring of the unwinder The dancer roller represents a paper buffer to quickly supply or take up the label web Due to Labeller 16 Traction unit Labeller the adjustable spring force the feeding of labelweb could be optimized in function of the demand minimum of hits and tension on the labelweb The spring force is set by turning a Knurled knob in the according position A variable portion of labelweb hangs up on two horizontal axes and builds up an vertical falling down labelweb airsling due to the gravitation On labelweb demand the deepest point of the airsling rise up and the length of the sling becomes shorter This deepest point will be detected at two fixed levels high and low by two sensors This two sensors will respectively switch on and off the traction motor of the airsl
14. and the take off of the waste are explained in the several manuals of the Collamat 9100 Initialisation The operator has to initialise the system for a label that is already optimised This means that the selection and all the adjustment values of the adapter are already documented All necessaries parameters are saved in the appropriate program set number and configura tion number in respectively the monitor and the super controller MCS T Adapters select the right adapter adapter_1 or _2 for respectively short or long labels The adapter has the necessaries ruler with 0 5mm resolution on it that feature allows the opera tor to exactly reproduce the initial adjustments adapter_1 short label D1 distance between axe of pressure roll to dispensing edge adapter_2 long labels D1 distance between axe of pressure roll to dispensing edge D2 position of LSC pack referenced to the holm D3 distance between axe of pressure roll to vacuum plate normally fixed for all labels e Program set on the Monitor select the corresponding program number with the main parameters Predispensing Position Speed e Program set and Configuration set on the Super controller MCS T For each label the operator has to select the corresponding No and Configuration No from the MCS T and to down load it to the MCS IO select program memory select Program to MCS IO Operating Instruction 5999 590 01A 02 08 99 SB 39 sel
15. ckward shift will increase linearly according the difference between dispensing speed and goods speed This maximum delay length does correspond to the fastest defined goods speed and could be easily measured on the paper This delay length is the most important input parameter to a dedicated super con troller The super controller take care of this delay and control the two Collamats by means of an advanced time controlled GSC2 signal A part from the super controller we also need a special adapter which allows an optimal procedure of the label application Once the label has the right speed the front label edge will be pressed between the press roll and the paperweb at this moment the label will be torn away with the goods and the contact area between label end of label and backing paper must be set to a minimum The distance between axis of press roll and dispensing edge has to be adjusted in accordance to the label length Our adapters have all necessaries features so the super user or the normal user can do these adjustments to a very easy way Two adapters cover the whole label ranges adapter type 1 for short label length from 18mm to 40mm and adapter type 2 for long label length from 35mm to 95mm Both adapters have a press roll which is fixed on the usual adapter the long adapter is equipped with an additional vacuum plate for driving longer labels Adapter type 2 with vacuumplate d Ken yy d Bro i Introduction to C9110i 5999 59
16. corresponding vertical double columns with a dedicated bracket set Mechanical dispensing part and the monitor build up one complete dispensing system Each dispensing system is mounted on a hori zontal adjustment unit double steel tube which is electrically driven This does allow the displacement of each dispensing system over the whole width of the Paperweb Each hori zontal adjustment unit is fixed on the legs of the frame On this frame are also fixed an operating box a control box with a pressured air system fixed on it encoder wheel for paperweb speed and goods scanners mark readers The mainframe with all parts could easily be placed and fixed on a rack see also installation Introduction to C9110i 10 The super controller is composed of two boxes the I O box or MCS IO modular control system input output and the terminal box or MCS T All parameters from the super control ler could be visualised edited saved and recalled with this terminal Each label has its dedicated set of parameters which will be loaded in the MCS IO This loaded parameter set in the MCS IO is managing the actual labelling process The terminal box can store up to 99 parameter sets The MCS T communicate with the MCS IO over a serial data link The MCS IO is fixed in the control box and the MCS T could be connected temporarily to the operating box for editing purposes The control box fit at the rear of the C9110i contains the main connection transforma
17. could also be downloaded or read back from the MCS IO Inside the MCS IO only one group for respective the Program and the Configuration is stored ina non volatile memory This actually stored pair of groups makes the system working The MCS IO is able to store up to 99 groups Each pair of group Nr could be assigned to a label type More details below under point menue structure The human machine interface is build up of an operator box for controlling the system mode see below under operating box and the terminal of the super controller MCS T for parameters program and configuration and visualisation Both elements are accessed from the front of the system the operating box is fixed ona tube and the terminal is placed on a little desk fixed on the same tube under the operating box A connector fixed on the wall side of the box does allow the connection between the two MCS units MCS IO amp MCS T 5999 590 01A 02 08 99 SB operating box and Terminal unit of the super controller SEILER Sala S The box has an 1O Terminal with 6 buttons a LCD display two push buttoms three swit ches an error lamp and an emergency stop buttom The operator can with the terminal select between three system operating modes and in case of Nonstop mode set the number of goods between the two collamats The three system operating modes are non stop 0 both collamats active 1 both collamats inactive 2 The u
18. d store from to the non volatile memory Super Controller MCS 5999 590 01A 02 08 99 SB 29 2 program setting placement of one or several labels up to 32 referenced to the formular edge norml user setting the pulse width in duration at output 1 to 4 3 program memory read save the parameter sets up to 99 for programming in the MCS terminal and read save from to the MCS IO 4 configuration setting all the necessaries parameters for speeds dispensing goods and delay com pensations 3 configuration memory read save the parameter sets up to 99 for configuration in the MCS terminal and read save from to the MCS IO Program editor Program editor Length editor Configuration memory Clear channel Length editor Length editor Controller Channel 1 1 Distance from edge Pulse duration at vmax Clear channel Clear Channel Controller Channel 1 1 Clear channel Description Length editor set length of position of the label from the formular edge which corresponds to the black mark Up to 32 successive labels could be sequentially placed with reference to the formular edge Super Controller MCS 30 The start of each position is related to the edge of the sheet This enables the position of individual labels to be changed without affecting other labels Example of position Paper run direction channel 1 The pulse duration for each output of t
19. during Power off for easily threading and installing the paper web The purpose of the adapter is to dispense the label on its product There are two adapters Adapter one for the labels with a length under 30 mm and one between 40 and 95mm The no mans land between 30 and 40 mm depends on the label stiffness form adhesive and for the optimal solution we recommend the super user to test both The purpose of the rewinder is to collect the baking paper and make it easy to remove for Rewinder the user If the C9100i is switched on without having fixed the backing paper or if the backing paper is torn apart during the application the dancer will shot up to maximum speed position but will stop after 8 rotations It can be restarted when the dancer is at stop speed position and a reset of the stop command The power supply and the electronic control are built into a metal casing All peripherals Monitor are connected to a connector box connected to the monitor back panel by one single D sub connector A large heat sink allows to operate the monitor without additional fan The monitor can be mounted in various positions The monitor contains the following assem blies e Noise filter with voltage selector The noise filter keeps EMI outside to prevent any inter ference with the electronic control and also prevents EMI to be transmitted to the mains Supply The voltage selector allows versatile adaption of the power supply to different main vol
20. e delay of run stop of the relevant dispenser When in use in an endless forms operation the PLC must be told how many pro ducts there are between the Collamats at the start This is done at the control box with the key GSC Operating Instructions The operating instructions are classified in three groups General e the normal operating where the adapter and all parameter are already set he opera tor or normal user starts stops the system feeds it with the consumable label rolls and removes the backing paper e the initialisation where the operator has to adjust the adapter and set all parameters in the monitor and super controller according to already known values e the optimisation where the super user has to define the adapter adjustment and also to define all the needed parameters in the monitor and super controller in case of a brand new label The super user is a trained person who understands the optimisation rules described below e Power on sequence Normal operating switch on the main switch on the control box external side wall press the on button on the operating box be sure the emergency switch is set to off set the Collamat disable switch to on right position set the run stop switch off each monitor to run set the vacuum enable switch to on right position if the error lamp is lighting turn the reset key to the right and go back to the left e Select the system mode on the programmin
21. e of damage or faults which cannot be rectified by the user the customer ser vice or its representatives must be informed The continuous operational readiness and reliability of the control and monitoring elec tronic systems depends vitally on strict observance of the maintenance instructions plan and carrying out the maintenance and repair work precisely Before disconnecting parts of the control and monitoring electronics the person respon sible shift leader is to be informed that the corresponding parts of the system are out of action Before carrying out work on parts of the control system which carry voltage power must be disconnected from the appropriate areas Only original manufacturer s spare parts are to be used to replace defective modules The use of non original spare parts will exclude all liability on the part of the manufactu rer Use only the cleaning materials explicitly indicated or recommended by the manufactu rer After removal defective electronic components and units must be stored correctly Le protected in particular against damp For transport parts are to be provided with shock proof packing Take notice of the technical data of the C9100i Especially the environment conditions must be observed Install the C9100i at a dry location protected from splashing water Operate the C9100i only by trained personnel In case of non authorized modifications the guarantee will become void Before connec
22. e the label position on the goods with respect of the formular edge the black mark on the formular does coincide with the formular edge beginning of a new formular A serie of 32 labels could theoretically be programmed and placed with one black mark GSC Trigger The set clear channel allows to reset already programmed channels The controller has 4 channels which correspond to the 4 outputs output 1 to output 4 described above under connection Channel 2 and channel 4 drive GSC 2 of Collamat A respective Collamat B Channel 1 and channel 3 are the respective copies of channel 2 and channel 4 and have to be therefore progammed absolutly identically They are connected to the internal PLC for counting the goods crossing the respective mark rea der Super Controller MCS 26 memory Human machine interfaces Super Controller MCS Remark output 1 amp 3 are always active also when the corresponding dispenser collamat does not work In comparison output 2 and 4 drives directly the coresponding collamat over the GSC 2 signal and can for this reason only be active when the assigned dispenser works More details below under point menue structure All parameter groups program and configuration could be saved and read back from a non volatile memory in the MCS T From there the corresponding sets could be edited and saved back under a dedicated Nr for the programming group and for the configuration group Each group Nr
23. ect See also e Operating instructions C9100 Traction unit e Operating instructions C9100 Monitor e Technical handbook C9100 Labeller 5999 590 01A 02 08 99 SB 23 Chapter 5 Super Controller MCS The C9100i super control is used for the computerized control of labelling The Super Con troller MCS consists of one terminal unit with the designation MCS T and one control unit with the designation MCS O The terminal unit and the control unit are linked toge ther by means of a cable The power supply is provided by the MCS IO which supplies the input terminal with 24 VDC via this cable The input terminal is only used for the purpose of programming and storage of parameters Once programmed the MCS IO controllers can also operate without the terminal unit All the parameters of the controller are classified in two groups with the respective designation Program and Configuration The program parameter group can be set by an operator normal user The configuration paramater group belongs to an engineering activity and has to be set by a trained user the super user Programs and configurations can be loaded from the MCS IO controllers The super Control system can communicate in several languages The desired language can be set in the configuration menu Dimensional units can also be set Length in mm or 1 16 and speed in m min or feet min The collamat detects the goods at a determined place over the pa
24. ect the corresponding Program No transfer the program to the MCS IO see also Chapter 5 Super Controller MCS e Go to normal operating Once the initialisation is done the operator goes to the normal operating mode and start the labelling system adapter selection Optimisation With each new label the super user has to define the adapter selection amp adjustments and the several parameters for the monitor and the super controller e Adapters selection adapter selection Selection is made in consideration of the label length if the length is over 40mm select always adapter_2 long labels if the length is lower than 30mm select always adapter_1 short labels else both adapter could be used but the experince will guide the selection in consideration of label shape stiffness and adhesive e Adapter adjustments adaper adjust the contact between pressure roll and paper does correspond to a line the contact line ments setting rule 1 the distance between contact line and dispensing edge is the bridge length or D1 and has a value equal label length 2mm All length could be referenced to a standard label of 50mm length with following adjustment D1 53 on the D1 ruler Examples if the label has a length of 60mm we place the adapter so we can read 43 on the ruler if the label has a length of 40mm we place the adapter so we can read 63 on the ruler e Monitor parameter program rule 1 parameters pred
25. f On Off On Off On Off On Off On Off On Off On Off On Off On Off On Off On Off On Off Transfer program to MCS IO Read program from MCS IO Display alter the parameters of indi vidual channels in the MCS IO con troller Display alter the parameters of indi vidual MCS IO controller Display alter the parameters of the MCS T user interface Super Controller MCS eR Super Controller MCS 5999 590 01A 02 08 99 SB 37 Chapter 6 Operating Instruction When carring out operating instructions you have to be aware of that C9100i continues a Introduction monitor a MCS Terminal and an operating box In principle each MCS T user interface each MCS IO controller and the individual channels in the MCS IO controller must be con figured The configuration parameters are divided into the following Nonstop control with a PLC Nonstop Since the nonstop function is controlled by a PLC the Collamats have to be configured in normal mode That means they should NOT be configured in Master Slave mode but confi gured as single dispensers in the monitor menu tree programming change program label ling mode normal labelling The PLC has both of the Collamat goods signals as input connected to output 1 and output 3 of MCS IO and control the release of both the Collamats This means that the PLC controls the entire nonstop function counts the pro ducts in between the Collamats and the PLC controls th
26. g panel panel on the operating box one of three system modes can be selected by the programming panel Operating Instruction 38 non stop on both Collamat oft both Collamat press key 4 press enter key set the right number by the increment decrement arrows key according following rule 0 non stop 1 on 2 off The normal mode is the non stop mode the other two modes will not further be of interest e Set the GSC2 3 counter value In non stop mode it is important to declare always the amount of goods between the two Collamats working respectively as a master and a slave press key 3 and select the right value with the corresponding arrow key remark before selecting a new menu tree with the adequate key number press always first key F1 and then press the wished key e Release the labelling procedure set the Collamat disable switch to off left position one of the Collamat is labelling changing the active Collamat is done by pressing the Collamat Switch button Each time this button is pressed for a brief moment the active labeller will be changed Each Collamat will automatically stop when consumable stock are low LLO signal or waste are full Rewinder full signal The other Collamat will automatically start at the right moment without missing a label on a goods or labelling twice a goods The non stop proce dure the placement of the new label web
27. he corresponding has to be set in time this time does correspond to the pulse duration time at maximum goods speed Clear channel select the output channel select clear channel and press enter taste The corre ponding parameters value will be cleared Super Controller MCS 5999 590 01A 02 08 99 SB 31 Program memory memory Program memory Program gt MCS IO Edit program Program lt MCS lOy Clear program Clear program Clear program Program Nr 70 Clear program edit program Edit program Program Nr 10 Length editor Description of program memory The programming parameters of the MCS IO can be read into and stored in the operator unit From there these saved parameters can be transferred back to the MCS IO Saved positions can be adjusted without disturbing or interrupting operation This makes it possible to prepare the next set ting during production The length editor does correspond to the procedure already described above under Program editor length editor Super Controller MCS 32 Configuration Configuration Channel parameterr Configuration memory MCS IO controller MCS T user interface channels Channel parameter Controller Channel 7 7 1 Trigger source trigger 1 2 Vmin 0 m Min 3 Reaction if v lt vmin clear sequence 4 Enable input off controller MCS IO controller Controller 1 3 Trigger source trigger 1
28. ignal READY at the starting time of the labelling Not ready 1 The lock in the traction unit is open TUNIT Paperend 3 The label roll is empty The position value is to low for the actual labelling speed The label is stuck in the false position on the goods Position too short The measured goods speed is higher Max speed than the entered max labelling speed Labelling becomes faulty Pabet sock The labelling stock of the unwinder is full l The rewinder disk of the rewinder is Rewinder full full Adjustment of the label scanner not possible The scanner is defective or it is scanned on label instead of gap or the baking paper is not transmitted enough No LSC Adjust Nonstop mode Error messages Monitor Collamat Solution Reduce the cadence Reducing time activated by the READY signal 1 Close lock of traction unit or paper brake 2 Insert a new label roll Increasing the position value or reducing the labelling speed Reducing the goods speed or if possible increase the max labelling speed Replace empty label roll Remove the label roll from the reewinder disk Shift gap under the label scan ner and adjust it again Possibly exchange defective scanner Do not do anything not applient with C9100i nonstop with PLC Technical Data 42 Error Error message Error cause Solution 10 11 12 13 14 15 16 Technical Data Label too long LSC
29. ing The airsling acts as a two points regulator the airsling is able to feed continously on a soft manner no hits and variation of tension on the web the demanded labelweb from the following dispensingsy stem The purpose of the traction unit is to keep the paper web steady and tight before dispen sing and after dispensing having the paper in a pull state which causes the entire paper web to move and is the actual feed of the labels Traction unit 1 Traction roll 2 Back pressure roll 3 Knurled knob 4 Deflection shaft 5 Backing paper web 5999 590 01A 02 08 99 SB 17 Turn the knurled knob by 90 in order to ease the back pressure roll at the traction roll For right hand version turn clockwise otherwise counterclockwise Position the back pressure roll in the middle of the backing paper In order to do this the set screw needs to be release If the back pressure roll not is under tension an error message will appear paper traction end The paper brake has to be fix and hold the label web steady Before label ling the entire label web must be stretched to avoid label errors The traction unit as well as the other peripherals are mounted on a module rail All parts are surfaced treated to protect from corrosion The special coating of the traction roller affords permanent torque transmission to the paper web without slip The force of the paper web brake is adjustable The traction roller can be easily turned by hand
30. ispensing set the value for a sliding contact between front label edge and pressure roll all other parameters are constant with followingvalue position Omm speed measuring mode encoder 2 20mm max speed 60m Min Operating Instruction 40 e MCS T program amp configuration rule 1 compensation length set to Omm Start labelling process at 60m Min goods speed Start labelling process at maximum goods speed measure the delay distance between the label position for the two goods speeds put this value as the new compensation length All other values remain constant Store this parameters to a label corresponding program number the normal user or operator could always select them Label adjustment Label position on the adapter while Stop phase in dispensing mode figure 1 6 8 S 3 P E BT BE A 7 Definition 1 vacuum plate 2 dispensing edge 3 pressroll 4 paperweb formularweb 5 labelweb backpaper 6 label 7 contact line 8 touch line Mechanical adjustment rules b c label length d D1 a b label length 2mm a c 2mm Operating Instruction 5999 590 01A 02 08 99 SB 41 Chapter 7 Technical Data Error handling When a fault has occurred on the Collamats monitor press enter correct the fault accor ding to the list below and then press enter again Error cause Error message External appliance flat printer hot satmp etc has not yet released the s
31. label Further the normal user or operator has just to call back the assigned parameters and to adjust the adapter that is the procedure of the dispensing initialisation During the labelling operation after optimisation and initialisation the user or operator has just to feed the dispenser with label rolls consumable and to take off the backingpaper waste Assembly of a high speed standard system C9110i non stop al Introduction to C9110i Concept The system is built up on two Collamat C9110 both mounted on one frame The whole system could easily be integrated in a production line and mounted just over the paperweb goods on one underframe For the optimal placement of the label on the goods each Collamat could be moved in 3 directions one vertical and two horizontal respectively as inline and transversal to the paperweb direction The dispensing system works in two ranges a normal and a high speed range In the normal range the dispensing speed is synchronised with the goods speed at the moment of the impact between label and goods and during the whole application process both speeds goods and label have exactly the same value which corresponds to the nor mal Collamat dispensing method In the high speed range the dispensing speed is always lower than the goods speed and the Collamat act as a delayed system in time The result does correspond to a shift back ward of the label position the length of this ba
32. m backward shift of the label position is reached by the highest goods speed This length can be measured and put in the MCS T terminal as a parame ter whith the designation compensation length the value of this highest goods speed does correspond to an other parameter vmax product The highest possible goods speed is determined by experiences and depends mainly from the size of the label The best compensation accuracy is reached by setting the parameter value of vmax product just a little higher for instance 5 than the effective possible highest goods speed The swit ching between fixed and synchronized dispensing modes on the collamat is set at the value vmax collamat which is an other configuration parameter of the controller The super controller sets an I O output out 1 for Collamat A and out 2 for Collamat B in function of the actual measured goods speed compared to the defined value for vmax 5999 590 01A 02 08 99 SB 25 collamat This two outputs drive the ready signals of the collamat see wiring table above All these mentioned parameters belong to the group Collamat Parameter inside the configuration parameters of the controller below a table of all Collamat Parameter with the corresponding function description Table of Collamat Parameter on the super controller parameter designationt ymax product set the maximum possible speed for the goods Trigger distance le
33. ngth between mark sensor and dispensing edge ymax Collamat switching value between low speed range and high speed range Position Collamat copy of the position value set as parameter on the collamat Correction length 1 length value 1 as linearity correction at speed v1 for the speed value 1 point of support Correction length 2 length value 2 as linearity correction at speed v2 for the speed value 2 point of support Correction length 3 length value 3 as linearity correction at speed v3 for the speed value 3 point of support Compensation length length value to be compensated at vmax product this parameter is valid for both dispensing unit Collamat A amp B all other parameters exist twice and belong to a set each dedicated to their respective dispensing unit Collamat A and Collamat B this parameters are generally not configurated Aside the configuration set Collamat Parameter we have also the set Channel parame ter the set MCS IO controller and the set MCS T userinterface All these 4 sets belong to the Configuration Group and are explained more in details below under point menue structure The program group with the designation Progam editor is composed of two sets with the Programming respective designations length editor and clear channel The main purpose of the length editor is to defin
34. perweb or conveyor and start the labelling process start of labelweb motion after a delay time which is function of the position value and a predetermined labelling speed The collamat is working in the synchronized labelling mode at low speed range the speed measurement of the goods is done with the signal of an encoder The synchronized mode means that the label ling soeed matches the speed of the goods at the moment of dispensing At high speed range the collamat will switch to the fixed dispensing mode or asynchronous labelling mode that means the labelling speed is done at a fixed value independendly of the actual goods speed This changes of labelling mode are driven with the state of the collamat input Signal ready All values of the position fixed labelling speed etc are set as parameters on the collamat see also the op erating manuals C91monitor amp traction unit In the high speed range the labelling process acts as a roughly first order delayed process the result is a linear backward moving position of the label on the goods which increases linearly with the goods speed The super controller MCS 1I O compensates this delay by generating an approriate new GSC signal which is connected to the collamat The MCS I O is therefore from an electri cal point of view placed between the goods detection systems goods scanner or mark reader in case of formulars and the collamat The signal of each mark reader GSC
35. se of the operating box including the terminal is self explaining Aside the terminal following buttons are assigned to functions as described below three switches for release pneumatic on off release collamats on off reset for new starting procedure after failure and stop state two push buttons for switch on the control logic after power on switch between collamats while in nonstop mode The connector for the external removable link with the MCS T is internally connected fixed wiring with the MCS IO 27 operating box Super Controller MCS 28 Terminal The terminal MCS T is build up of a LCD display and a set of push buttons The following general rules explain how the user can navigate edit store and recall all the necessary parameters Menu structure main 1 Main menu Program editor configuration memory Program memory Configuration program 2 Program editor Length editor Clear channel Program memory Program gt MCS IO Edit program Program lt MCS IO Clear program configuration 3 Configuration Channel parameter Collamat Parameter MCS IO controller MCS T userinterface Configuration memory Program editor configuration memory Program memory Configuration Description 1 main navigation between programming and configuration modes for the purpose of para meter setting and file handling of parameter sets call an
36. se to the label web when system is running The label web can be as sharp as a knife Symbol descrip tion ATTENTION Indicates danger of damaging the Collamat 8600 9100 or other system componenis 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 Security ATTENTION ESD warning ElectroStatic Discharge The PC boards or components may only be touched in an electrostatically protected environment NOTE Important or additional information to C9100i or to the documentation Protection action In case of emergency press emergency botton to stop the system Before using system be sure that you know where the emergency botton is Security 5999 590 01A 02 08 99 SB Chapter 2 Use of this manual Congratulations to the purchase of the Collamat High Speed System C9110i The intended target group for the manual is the personal involved in the daily operations i e the normal users and also the personal who is in charge for fine tuning the whole system dispensing optimization in case of using a new label i e the super users New label means new values for one of the relevant label parameters which are size shape material and release Once one of this relevant parameters will change the dispensing optimisation has to be executed The super user has to be
37. tages e Transformer which supplies the power for the labeller unwinder rewinder and monitor e Interface p c board which connects the motor drive to the power supply and to the con troller The electronic part of the power supply is also installed on the interface p c board which shapes all input and output signals to and from the controller e Controller p c board comprises a Hitachi H8 5332 micrcontroller EPROM with a soft ware LC display and short stroke keyboard and the nonvolatile memory The LC dis Labeller 18 play has four lines with 20 characters each and a background illumination The controller p c board communise from panel and controller in one component All settings are done via keyboard Panel monitor panel COLLAMAT Legend 1 4 line LCD 8 RUN LED 2 Labeling mode key 9 ESC key 3 Programming key 10 Keyboard 0 9 4 Configuration key 11 dot Key 5 Service indication key 12 ENTER key 6 RUN STOP key 13 UP key 7 STOP LED 14 DOWN key Actions The actions here mentioned are adjustments needed to optimise the system Daily chores such as threading the labeller will also be mentioned here Thread of label The paper web will be pulled from the unwinder over the dancer in between the two rollers before the air sling into the paper loop and from there to the traction unit Conduct the paper web under the paper break and pull it to the dispensing edge Pull out the paper web Labeller 5999
38. ter the error handling of the labeller is simplified and gives direction were other technical data is to be found Use of this manual eR Use of this manual 5999 590 01A 02 08 99 SB Chapter 3 Introduction to C9110i C9110i is not only a very fast dispensing system it is also a non stop system C9110i General can dispense labels on goods with a speed of up to 200m min with an accuracy of 1 5mm Goods have to be endless and flat Paperweb and the sizes of the labels have to be inside a specified range length from 20 to 95 mm width from 30 to 95 mm The dispen sing of a new label has first to be optimized by means of a well defined procedure the dis pensing optimisation for a label This optimisation mainly consist in the choice and adjustment of an Adapter but also in setting some parameters on a Super controller and on the dispensing controller C91 Monitor The optimisation procedure takes in considera tion the relevant label parameters size shape material release and also of relevant labelling parameters maximum goods speed maximum dispensing speed label place ment on the goods placement for goods sensor and dispensing head Please find in chapter operating instruction in this manual the detailed description of the dispensing optimisation Once this optimisation procedure is done all necessary parameters and set point values have to be assigned to this new label and saved assign a parameter set to a type of
39. timise the positioning of label scanner e Optimise the label sensiti vity Switch off the motor Wait 10 seconds before switching on again If the error has not disap peared the monitor is damaged and has to be repaired by a spe Clalist Reduce the goods speed or possibly increase the max labeller speed Switch off and on the monitor If the error persists please note all monitor settings and contact your technical supporter Reduce the goods speed or increase predispensing 5999 590 01A 02 08 99 SB 43 The operation can only stop due to three different reasons Nonstop Error e both Collamats have LLO low label e or RWF rewinder full e or both of the Collamats are NOK not OK After a nonstop fault the system must be new started and the number of products bet ween the Collamats must be reprogrammed at the control box with the GSC key For technical data about Further informa ion e the labeller please see Technical handbook Collamat 9100 Ho Technical Data
40. ting non standard products ask your competent technical supporter Peripherals to the C9100i must only be connected to the mains socket of the monitor These devices must be approved by Collamat Stralfors AG The specifications of the mains socket are specified in the Technical Appendix The safety symbols and the danger advice on the C9100 and in this manual must strictly be observed 5999 590 01A 02 08 99 SB e The C9100i must only be set up in switched off condition Before connecting or discon necting the labeller C9100i to or from the monitor switch off the monitor Monitor and dis tribution box are only allowed to be opened by authorized personnel e Danger of pinching hair jewellery ties clothes etc into the traction unit e Danger of injury by cutting fingers in the paper web zone e Danger of injury in the dancer roller zone of the C9100i rewinder and unwinder e Danger of injury in the case of non expert use of the C9100i in the paper stock control zone Residual dangers are sources of danger inherent in the design of the machine which Residual danger cannot be eliminated by means of design measures or protective equipment The C9100i is constructed in accordance with currently accepted technology and the recognised rules concerning work safety Nevertheless the following residual dangers may affect the user in the course of work e Touching the exposed pins of the mains plug can cause electric shocks e Don t be clo
41. tor control relays fuse PLC MCS IO opto couplers and connection clamps On a side wall of the box is fitted the electrical power switch and the pneumatic or compressed air set This set is composed of one manual main valve one maintenance unit air conditioner with pressure input regulator and two switch regulator set for both dispenser The operating box allows the control of the labelling system by means of buttons lamps and compact lO panel for power on power off safety off and setting the system operating mode non stop on off further and in non stop mode the operator can switch on bet ween Collamats and set the GSC 2 counter value The MCS T could be connected to the MCS IO over an 9 poles connector fit at the side wall of the operating box and could be placed on a little desk just under the operating box Blockdiagram of the relevant components LSC label scanner GSC goods scanner M C91 monitor U unwinder T traction unit R rewinder The encoder and mark readers are fixed to the frame and can be individually and very easily be displaced in each direction The mark sensor or goods scanner can be slided and Introduction to C9110i 5999 590 01A 02 08 99 SB fixed on a vertical guide bar for optimizing the distance between sensor and mark mark placed on the paperweb formular or goods This sensor with the vertical guidebar can be slided and fixed on an horizontal guidebar in direction of the paperweb The
42. wheel and paperweb does correspond to a short friction segment equal to the thickness of this wheel This friction segment is parallel to the adapter roll and needs also a back pressure under the paperweb For this reason this friction segment will be placed over the back pressure roll of the master collamat axe over axe The encoder can be positioned over the whole paperweb area of concern in the same manner as the mark reader This encoder positioning system comprises a vertical guidebar for the sensor with sliding and fixing possibilities the mark reader a cross profil rail between the mainf rame legs for sliding and fixing the vertical guide bar the cross profil rail can be slided in direction of paperweb width and fixed on two other profil rails fixed each on the inside wall of the corresponding mainframe legs The whole structure offers a great flexibility while installing or optimising the labelling pro cess 11 Introduction to C9110i 12 Standard compon Standard components list ents Designation Function High speed specific 2 dispensing system consisting each of mechanical part consisting of Unwinder midi no air sling smother feeding of labelweb yes traction unit no guiding amp pressing the labels accor adapter_1 amp adapter_2 short amp long labels ding high speed rules yes rewinder no module rail no vertical double columns with h amp v adjust no monitor 1 super
43. when the screw is turned clockwise The slope of the flap adapter can be changed To release the knob two turns is needed Extend the screen by hand position the adapter in required position and fix the knob again Adapter with vacuum plate geg Depending on your labels and your goods you want to adjust the press roller Menu Tree Userlevel Run Stop mode Labelling Mode Label jog Operator Stop Select program Operator Stop Information display Operator Run Reset counter Operator Stop Preset counter Operator Stop Select counter Operator Run 5999 590 01A 02 08 99 SB Menu Tree Reset nonstop Programming Change program Label scanner sensitivity Label length Label suppression Presdispensing Position Speed Maximum speed goods suppression Labelling mode Profiling Program name Program preset Configuration User menu Language User level Error handling Nonstopmode Adaptermagnet Motor direction Polarity ifeed Service functions Software version Error sequence Self test Remote control Userlevel Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Super User Run Stop mode 21 Labeller 22 Menu Tree Userlevel Run Stop mode Working time ooo esemme een Motor running 2 aeee een RUN STOP Operator Sel
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