Download
Share
Print this page
  1. Manuals
  2. Brands
  3. BST Manuals
  4. Control Systems
  5. eltromat EKR 1500
  6. Translation of the original operating manual

BST eltromat EKR 1500 Translation Of The Original Operating Manual

Hide thumbs Also See for eltromat EKR 1500:

Advertisement

Quick Links

Download this manual
BST eltromat Web Guiding System
EKR 1500
with analogue sensors and CCD 2004
Translation of the
Original Operating Manual
BST eltromat International GmbH
Heidsieker Heide 53
33739 Bielefeld, Germany
Telephone: +49 (0)5206 / 999 - 0
Fax:
E-Mail:
+49 (0)5206 / 999 - 999
info@bst-international.com
Edition:
12.04.2011
EDV No.:
V3D.010.01.03

Advertisement

loading
Need help?

Need help?

Do you have a question about the eltromat EKR 1500 and is the answer not in the manual?

Questions and answers

Related Manuals for BST eltromat EKR 1500

Summary of Contents for BST eltromat EKR 1500

  • Page 1 BST eltromat Web Guiding System EKR 1500 with analogue sensors and CCD 2004 Translation of the Original Operating Manual BST eltromat International GmbH Heidsieker Heide 53 33739 Bielefeld, Germany Telephone: +49 (0)5206 / 999 - 0 Fax: +49 (0)5206 / 999 - 999 E-Mail: info@bst-international.com...
  • Page 2 Definition of the symbols in this manual Attention Instructions with this symbol safeguard the operator from injury Caution Instructions with this symbol must be strictly adhered to failure to do so could result in electrocution press key key combination; between the keys means that these keys have to be actuated simultaneously LED ‘OFF’...
  • Page 3 Contents Chapter 0 Contents Chapter 1 Description 1.1 General 1.2 Connectable components 1.3 Operating elements 1.4 Significance of the keys on the front panel 1.5 Significance of the LEDs on the front panel 1.6 Safety instructions 1.7 Emissions Chapter 2 Technical data 2.1 EKR 1500 2.2 Optical edge sensor IR 2001...
  • Page 4 Please follow the instructions of Start-up, maintenance and installation as described in the operating instructions 1. Description 1.1 General The EKR 1500 system is a microprocessor-controlled web guiding system. This guiding system may be used for: - web edge guiding (right or left) - center-line guiding - guiding on continuos or interrupted printed lines - guiding on continuos or interrupted printed edges...
  • Page 5 1.3 Operating elements * The amplifier includes all necessary operating elements. Option: - Remote control by external signals, sensors or keys Attention! External keys will interlock the reverse function keys at the amplifier. - If system locking is desired (e. g., in case of machine stop), this can be achieved by means of external contacts or signals from the PLC.
  • Page 6 1.4 Signification of the keys on the front panel key and/or combination of keys function AUTO (1) = automatic guiding = manual positioning = servo-center of the servo component  / + (4) + MAN = manual shifting + AUTO = shifting of guiding point to the left * + SET UP + AUTO = increase of gain ...
  • Page 7 1.5 Signification of the LED´s on the front panel * The LED’s on the keys indicate the switched-on function. * The blinking of LED’s AUTO (1) , MAN (2) , S-C (3) , SET UP (6) or LED- arrays 10 - 14 and/or 15 - 19 indicate a fault message.
  • Page 8 1.6 Safety instructions * Installation of the BST eltromat equipment into the production machine according to the relevant rules ( EN 294, EN 349) and the specific branch-oriented regulations for prevention of accidents, such as: - Safety distance between BST eltromat equipment and customer´s specification, e. g. machine walls, construction etc.
  • Page 9 ± 9,75V or 0... + 9,75V, individual adjustable ± 11,75V NAMUR adaptation with output ± 11,75V tacho input for motor powered actuator * Interface: serial interface RS485 for BST eltromat module bus * Protection class: IP 54 * Ambience conditions: temperature: 0 - max. 45 deg.C...
  • Page 10 Edge sensor IR 2001 Power supply: by amplifier Measuring band: 12mm, typical Maximum sensing range: 15mm, typical Output: analogue Protection class: IP54 Ambience conditions: temperature: 0 - 45 deg.C atmospheric humidity: 5 - 90%, non-condensed Dimensions (standard application): W = 40mm H = 95mm L = 107mm Edge sensor IR 2002...
  • Page 11 Ultrasonic sensor US 2003, US 2008 Power supply: by amplifier Measuring band: 15mm, typical Maximum sensing range: 15mm, typical Output: analogue Protection class: IP54 Ambience conditions: temperature: 0 - 45 deg.C atmospheric humidity: 5 - 90%, non-condensed Dimensions (standard application): W = 25mm H = 76mm L = 113mm...
  • Page 12 Min. line width: 0,8mm Sensor resolution: 2000 pixel Exposure time: min. max. 20ms Interface: serial interface RS485 for BST eltromat module bus Protection class: IP54 Ambience conditions: temperature: 0 - 45 deg.C atmospheric humidity: 5 - 90%, non-condensed Weight: 845g Pneumoelectric transducer ZT 6.008...
  • Page 13 3. Transport/Storage Depending upon the order, delivery will be carried out: - completely built-in and connected with the actuator or - as component parts in standard cardboard boxes with cellular lining material. If the unit is not incorporated immediately, please storage it in a dry room until mounting. Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 3.0...
  • Page 14 4. Mounting / Installation 4.1 Location requirements The amplifier has to be installed in a dry, vibration-free area. Ambient temperature: 0 - max. 45 deg.C 4.2 Mounting plan M4 or Ø 5 housing EKR 1500 Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 4.0 with analogue sensors and CCD 2004...
  • Page 15 4.3 Installation Mounting plan see point 4.2 1 - Open terminal compartment Pull the two rear AU TO mounting rails upward SET UP ENTER and screw into the MA N SENSOR RIGHT SENSOR LEFT mounting wall S - C BRI GHT DARK 2 - Push the housing up- ward so that the moun-...
  • Page 16 4.4 Installation of EMC-wiring remove 90mm of disk of the cable shield external insulation fitting black rubber sealing- parts conical sealing (metal/rubber) unscrew nut and sealing parts and pin them up to the end of the cable figure 1 figure 2 insulated cable leads remove 60mm of shield, so galvanised washer...
  • Page 17 4.5 Installation of pneumatic sensing system 1. Pneumatic edge sensors have to be mounted in such a way that with horizontal web path the connection S1, carrying the higher pressure, is placed below (air escape S1 turned towards above). 2. Slip the hose ends onto the corresponding connection pieces S1 and S2.1at the pneumo- electronic transducer ZT 6.008.
  • Page 18 5. Start-up 5.1 Requirements for Start-up 1. Set DIL-switches according to application. Lageplan EKR 1500 EPROM Prozessor TRAFO S1.1 S1.2 S1.3 S T U V W X S1.4 S1.5 JX12 JX13 JX14 S1.6 S1.7 H1 H J K L M N S1.8 S2.1 H3 S2.2...
  • Page 19 Schedule 1 Special functions of the DIL switches S1 and S2 from software version E0030401 S1.2 S2.5 function electric motor powered actuator  lifting of zero level OFF  Dither OFF electric motor powered actuator  lifting of zero level ON ...
  • Page 20 2. Lay jumper according to the application The amplifier (standard version with electric motor powered actuator) is preset by manufacturer as follows: jumper O-P equipotential bonding carried out jumper J-K signal input 0...10V jumper M-N signal input 0...10V tacho ‘OFF’ jumper D-E jumper A motor ±...
  • Page 21 3. Set line voltage Make sure that the voltage on the name plate of the amplifier corresponds to the actual supply voltage! Correct in case of deviation. 230V Lageplan EKR 1000 H EPROM F1 = 0,5AT Prozessor TRAFO S1.1 S1.2 S1.3 S T U V W X...
  • Page 22 Sensor GL 240 1) Switch on sensor 2) After 15 minutes warm up time carry out the compensation:  Remove the upper housing cover. Both the fluorescent lamp and the electronics are accessible.  A measuring instrument with an internal resistance greater than 10 kOhm/V should be connected between the connections 3 and 6.
  • Page 23 5.4.2 Basic initialisation The basic initialisation has to be carry out once at first start-up. The amplifier recognised hereby the connected components. The LED array of the CCD 2004 indicates the exposure time (signification see point 5.4.3) 1. Actuate simultaneously keys ‘PLUS’ and ‘SET UP’ SET UP 2.
  • Page 24 5.4.3 Indication of the CCD 2004 exposure time LED array exposure time  2ms  4ms  6ms  8ms  10ms  12ms  14ms  14ms = LED 'ON' = LED 'OFF' 5.5 Determine desired sense of rotation for manual operation 1.
  • Page 25 5.6.1.1 Procedure for web edge guiding 1. Adjust guiding to ‘MAN’ or ‘S-C’ 2. Select sensors 3. Press key ‘SET UP’ SET UP 4. Remove material from the sensor and clean the lenses! Press key ‘ENTER’ ENTER 5. Cover the sensor with the material to be guided! Press key ‘ENTER’...
  • Page 26 5.6.1.2 Procedure for guiding to web center-line 1.Adjust guiding to ‘MAN’ or ‘S-C’ 2. Preselect both sensors 3. Press key ‘SET UP’ SET UP 4. Remove all material from the sensors and clean the lenses! Press key ‘ENTER’ ENTER 5. Cover the sensors with the material to be guided! Press key ‘ENTER’...
  • Page 27 5.6.2 Check and/or determine guiding direction 1) Press key ‘edge left’ (8) 2) Press key ‘AUTO’ If the actuator guides the material out of the viewing range, DIL switch S 1.1 has to be switched over. Setting is required only for the first start-up. If the type of the web material requires reversion of the guiding direction, this happens auto- matically during the material-SET UP.
  • Page 28 5.6.4 Start-up of servo-center operation Press key ‘S-C’ The servo component must move towards the center a and stop there. If the servo component is moving into t the final position, DIL switch S1.3 has to be switched over. Attention: If using an analogue servo-center transducer (CK 37, BI 5 G..) preselect the adjustment of gain.
  • Page 29 5.7 Electric powered actuators Attention! During the start-up the actuator will carry out positioning movements ! The machine must be protected against danger of injury according to the relevant rules and regulations! 5.7.1 Use of limit switches Limit switches for limitation of the regulating distance (stroke) can be used only with electric motor powered actuators.
  • Page 30 5.8 Hydraulic powered actuators 5.8.1 Zero point adjustment Also by adjustment of DIL switches, carry out a zero point adjustment when using an electrical-hydraulic guiding unit with plunger coil regulator Procedure: 1) switch on electrical-hydraulic guiding unit and EKR 1500 2) Press key ‘MAN’...
  • Page 31 5.8.4 Adjustment of DIL switches and jumper S1.2 = ”ON” S1.5 = ”OFF” Set jumper ”B” Set jumper ”D-E” 5.9 Preparation for BS 100 and ZT 6.008 1) Switch on lateral channel compressor unit BS 100 and check sense of rotation (see arrow marking on compressor housing) if necessary, correct sense of rotation.
  • Page 32 5.10.2 White balance In the presence of critical material contrasts, the scanning qualities of the CCD 2004 sensor Can possibly be optimized by a white balance. For standard applications the adjustment made at the factory will be okay. Attention: * the white balance must carried out at working temperature of the sensor (abt.
  • Page 33 Example 2 white paper fixed at scanning position Important: Please note that the paper is positioned exactly as the web will run in the machine. The paper must be without wrinkles or washboard marks. While carrying out the white balance, make sure that the paper is not moving. 4) Press key 'SET UP line' or 'SET UP edge' at the CCD 2004 camera.
  • Page 34 5.4.3 Sensor SET UP 1) Position the CCD 2004 camera laterally over the web so that the desired line or printed edge is situated in the light spot Edge scanning CCD 2004 Line scanning CCD 2004 LED display LED display LED dispaly LED display edge bright/dark...
  • Page 35 5.10.5 Adjustment of gain for sensor 3 Condition: - web is drawn-in - actuator is not moved into a limit position 1) Press key 'AUTO' AUTO 2) Press key 'SET UP' SET UP Increase gain with key 'PLUS', until the guiding device starts oscillating (rough adjustment by holding the key pressed, fine adjustment by touching the key) Decrease adjustment of gain with key 'MINUS', until the...
  • Page 36 6. Operation The system only admits operation with the components actually present! Function key and control symbols on the front panel Operating functions green coloured area Preset functions red coloured area Setting and control functions blue coloured area 6.1 Operating functions Select the desired operating functions as follows: Automatic - Press key ’...
  • Page 37 Servo-Center S-C - Press key ‘S-C’ 6.1.2 Preset functions Web edge guiding, left web edge* Web edge guiding, right web edge* * in running direction of the material Web center-line guiding 6.1.3 Setting and control functions Adjustment of gain * basic adjustment: automatically after material SET UP * optimisation: during operation see point 5.6.3 Web guiding system EKR 1500 EDV-No.: V3D.010.01.03...
  • Page 38 shifting of guiding point 1) Press key ‘AUTO’ Shifting of guiding point with key ‘PLUS’ or ‘MINUS’. The indication of shifting occurred via EKR display. The possible shifting of guiding point is max. 80% and/or. +/- 40% from the max. viewing range of the sensors. Note: If the ‘remote precision adjustment EFE 1’...
  • Page 39 6.2 Test of material contrast and scanning with optical sensors Press simultanously key ‘SET UP’ and ‘PLUS’ The LED arrays indicates the absolute SET UP senor signals. Clean lenses of the sensors and determine the contrast according to the graph below. indication indication left sensor...
  • Page 40 6.3.2.1 Digital mode of operation Advantages  guiding to,interrupted edges is possible  locking occurs automatically  very thin lines can be detected (minimum 0,5mm)  an additional edge sensor can be used for the watchdog function  width of lines will be checked, other printings will be ignored ...
  • Page 41 6.3.2.2 Analog mode of operation Advantages  disturbing influences such as reflexions are suppressed to a large extent  with edge guiding, the capture range is unlimited. The material will be guided back even when leaving the viewing range of the CCD 2004 sensor ...
  • Page 42 4) Position sensor and/or material in such manner that the line is situated in the middle of the light spot 5) The LED on the face indicates the analog mode. The remaining LEDs indicate the position of the line. 6) SET UP is completed. b) Material SET UP ‘edge’...
  • Page 43 EXAMPLES FOR MATERIAL SET UP AND RESULTING TYPE OF GUIDING: During the material setup, the system is adjusted automatically to the first line or edge detected within the light spot The scanning direction is from left to right, as shown by the arrow. CCD 2004 Scanning direction Line outside the...
  • Page 44 6.4 Watchdog function 6.4.1 General This function will be used to control the position of the web edge when guiding to a reflection or line sensor. The edge sensor detects the actual web position when the printed line or edge is interrupted or has got lost.
  • Page 45 6.4.3 Preparations - Carry out separate start-up for guiding with reflection/line sensor and guiding with edge sensor. Optimize gain for both sensors (only necessary for first start-up). Attention: A change of gain is only effective on the reflection/line sensor when the watchdog function is switched on.
  • Page 46 7. Remote control Truth table for the remote control inputs EKR1000 (e.g. activation by PLC): Terminal 31 = +24V non regulated supply Terminal 38 = GND (0V) Terminal 34 35 36 37 function Automatic Manual Servo-Center (S-C) Edge left (watchdog ‘OFF’) Edge right (watchdog ‘OFF’) Servo-center guiding (watchdog‘OFF’) X Guiding to a printed line / edge...
  • Page 47 8. Trouble shooting When an error is detected, the relay ”System OK” falls off. When pressing ENTER , the error message is switched off, and the relay ”System OK” Note is re-energised, provided that no further error is present. Error Responsible Remedy actuator / guiding device...
  • Page 48 Error Responsible Remedy LEDs at the commander With connected FVG 1000 are blinking as follows: During shifting of guiding point actuate shifting into opposite via arrow keys a limit stop was direction reached. Displacement of the web will be stopped. LEDs at the commander With connected FVG 1000 are blinking as follows:...
  • Page 49 Amplifier has to be switched off! 9.2 Camera CCD 2004 BST eltromat can deliver spare lamps if lamp(s) within the camera CCD 2004 break down. For replacement of lamp(s) have to be used separate instructions: * CCD 2004 up to hardware version G: V3D.011.01.01 * CCD 2004 from hardware version H: V3D.012.01.01...
  • Page 50 Regarding the guiding equipment, please bear in mind that mainly electric/electronic components are involved. The disposal of which is subject to the relevant legal rules and regulations. Returning the equipment to BST eltromat International GmbH is possible by prior arrangement. Web guiding system EKR 1500 EDV-No.: V3D.010.01.03...
  • Page 51 The corresponding terminals stay free! - Shields are pinched in the screwing. (see installation of EMC-wiring). R = 10 kOhm Connection of BST eltromat module bus with cable FVG 1000 Module  Pneumo- Twisted Pair Unitronic-Bus LD 3x2x0,22.
  • Page 52 - Not required components will fall away! The corresponding terminals stay free! - Shields are pinched in the screwing. (see installation of EMC-wiring). Connection of BST eltromat module bus with cable Twisted Pair Unitronic-Bus LD 3x2x0,22. Please contact the manufacturer for setting of cross-bonding boxes.
  • Page 53 Start-up of the Actuator EMS 17 / EMS18 Connected to EKR 1500 / EKR 1000 / CCD Line Guider Requirements for Start-up Start-up is carried out according to chapter 5 of the appropriate operating manual. For the connection of the actuator EMS 17 / EMS 18 the following additional adjustments have to be executed.
  • Page 54 Attention! The adjustment of the guiding device is carried out very slowly! 2. Press key ‘ENTER‘. The final position is stored. ENTER 3. Move the guiding device to the desired final position via the other arrow key. The final position limits the guiding movement in this direction.