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BST eltromat EKR 1500 Translation Of The Original Operating Manual

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BST eltromat Web Guiding System
EKR 1500
with CCD 30000 or
CCD 5000 from hardware version M
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:
05.11.1999
EDV No.:
MD.066.01.01

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Summary of Contents for BST eltromat EKR 1500

  • Page 1 BST eltromat Web Guiding System EKR 1500 with CCD 30000 or CCD 5000 from hardware version M Translation of the Original Operating Manual BST eltromat International GmbH Heidsieker Heide 53 33739 Bielefeld, Germany Telephone: +49 (0)5206 / 999 - 0...
  • Page 2 Definition of the symbols in this manual Attention Comments of this type have to be taken into consideration to protect the operator against mechanical risks Caution Comments of this type have to be absolutely considered to protect the operator against electrical risks press key key combination;...
  • Page 3 5.10 Reset to manufacturers settings Chapter 6 Operation 6.1 Amplifier 6.2 Set point scaling when change over the web edge 6.3 Status indications 6.4 Operation with BST eltromat interface Chapter 7 Remote control Chapter 8 Trouble shooting 8.1 Indications on the EKR 1500 8.2 Indications on the CCD 30000 / CCD 5000M...
  • Page 4 Please follow the instruction of start-up, maintenance and installation as descripted in the operating instruction 1. Description 1.1 General The EKR 1500 system is a microprocessor-controlled amplifier. With the CCD-cameras 30000 and 5000M this amplifier could be used for: - web edge guiding (right or left) - center line guiding Please contact the producer for any different application.
  • Page 5 1.4 Signification of the keys on the front panel 13 15 17 18 19 14 16 key and/or combination of keys function AUTO (1) = automatic guiding = manual positioning = servo-center of the servo component MAN (2) +  / + (4) = manual shifting AUTO (1) + ...
  • Page 6 key and/or combination of keys function Line/Printed edge (20) = No function when guiding system is operating with CCD 30000 / 5000M! Watchdog (21) = No function when guiding system is operating with CCD 30000 / 5000M! 1.5 Signification of the LED´s on the front panel ...
  • Page 7 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.
  • Page 8 ± 9,75V or 0...+ 9,75V, individual adjustable ± 11,75V NAMUR adaption 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 9 CCD 5000 from hardware version M factor 1 in general Exposure time: min. 0,6ms max. 30ms (with interface up to 60ms) Interface: serial internal BST eltromat module bus interface R485 Protection class: IP54 0 – 45 deg. C Ambience conditions:...
  • Page 10 2.3 Viewing ranges/ viewing distances CCD camera Scanning of entire web width Scanning of web width with one camera with one camera per edge Minimum necessary camera measuring range M: ABmax - ABmin M=( ABmax + 2 x J ) x 1,1 + 2 x J x 1,1 ABmax = maximum web width ABmin = minimum web width...
  • Page 11 3. Transport/storage Depending upon the order, delivery will be carried out:  completely built-in and connected with the actuator  as component parts in standard cardboard boxes with cellular lining material If the unit is not incorporated immediately, it should be stored in a dry room. Web Guiding System EDV No.: MD.066.01.01 Chapter: 3.0...
  • Page 12 4. Mounting / Installation 4.1 Location requirements The amplifier has to be installed at dry, vibration-free area. Ambience conditions: temperature: 0 - max. 45 deg. C atmospheric humidity: 5 - 90%, non condensed Web Guiding System EDV No.: MD.066.01.01 Chapter: 4.0 EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99...
  • Page 13 4.2 Installation Mounting plan see point 4.3 1 - Open terminal compartment Pull the two rear mounting rails upward and screw into the mounting wall 2 - Push the housing up- ward so that the moun- ting rails stay flush again in respect of the upper edge of the housing.
  • Page 14 4.3 Mounting plan M4 or Ø 5 housing EKR 1500 4.4 Installation CCD 30000 / CCD 5000M 4.4.1 Connectable components Up to a maximum of three cameras CCD 30000 / CCD 5000M can be connected to one amplifier. A combination with a CCD 2004 camera and/or an Analog Interface module is possible. Attention! The use of a CCD 30000 camera and a CCD 5000 camera within the same system is forbidden.
  • Page 15 4.5 Installation of EMC-wiring disk of the cable shield remove 90mm of fitting external insulation black rubber sealing- parts conical sealing (metal/rubber) unsrew 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, galvanised washer...
  • Page 16 5. Start-up 5.1 Start-up requirements 1) Set DIL-switches according to application. Lageplan EKR 1000 H 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 17 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 18 Schedule 3 Signification of LED´s in the terminal box for service indication The type of indication can be selected by means of S2.7 and S2.8. S2.7 OFF S2.7 ON S2.7 OFF S2.7 ON S2.8 OFF S2.8 OFF S2.8 ON S2.8 ON CCD1 locking from guiding device...
  • Page 19 2) Lay jumper according application The amplifier (standard version with electric motor powered actuator) is preset by manufacturer as follows: - jumper equipotential bonding carried out - jumper signal input 0 ... 10V - jumper signal input 0 ... 10V - jumper tacho 'OFF' - jumper...
  • Page 20 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. Lageplan EKR 1000 H 230V F1 = 0,5AT EPROM Prozessor TRAFO S1.1 S1.2 S1.3 S T U V W X...
  • Page 21 5.2 Start-up 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! Start-up must be carried out by qualified personnel! The system only admits operation with components actually present. 5.3 Basic SET UP Only necessary after installation or change of components connected!
  • Page 22 Alignment of the camera can be carried out in two different ways:  Aligning the camera by means of the standard indicators on the display of the camera  Aligning the camera by means of an oscilloscope connected through the BST eltromat measuring adapter 5.5.1.1 Alignment by means of the standard displays of the camera...
  • Page 23 LED 10 LED 1 S E T U P exposure time in ms   ≤ 0,6 (possibly overexposed)    ≤ 1   ≤ 2    ≤ 3   ≤ 4    ≤...
  • Page 24 3) Adjustment of diaphragm a) The camera has to adjusted on the HF fluorescent lamp and/or on the lightened band, that if possible a minimum of LEDs will be lighten b) If the LEDs indicates no reaction, this procedure has to be repeat again with a larger diaphragm opening.
  • Page 25 4) Adjust camera parallel to the HF fluorescent lamp (fixing of the viewing range) a) Push in the cover until the exposure time increases (position at which the number of LEDs lighted will increase). Mark this position. fluorescent lamp b) Push in the cover until the exposure time increases (position at which the number of LEDs lighted will increase).
  • Page 26 e) Centering of the scanning position to the longitudinal axis of the luminous band / fluorescent lamp Screw in (-) or screw out (+) the adjusting screw X Test of the scanning position compared to the luminous band / fluorescent lamp position of the dark/bright transition alignment...
  • Page 27 5.5.1.2 Aligning the camera by means of an oscilloscope 1) Connect the BST eltromat measuring adapter to the camera. Attention: Only connect and remove connecting cables to the CCD camera that are not live. 2) Connect the standard camera cable to the measuring adapter.
  • Page 28 a) If the camera is properly aligned to the fluorescent lamp/luminous field, i.e. parallel, the following brightness profile appears on the oscilloscope. b) If the camera is not aligned parallel to the fluorescent lamp / luminous field, there is a limited visual field with the following brightness profile.
  • Page 29 9) Adjusting the exposure time The exposure time should be adjusted to 2 – 3 ms. Open or close the diaphragm of the camera lens accordingly. The oscilloscope shows the following image: exposure time 5.5.1.3 Alignment of the camera to the scanning plane (web) (Z-direction) 1) Press ‘PLUS’...
  • Page 30 Example: CCD camera connected as camera 1 (if camera 2 should be aligned, please press key ‘SENSOR RIGHT’ first) 5) Press key ‘AUTO’ prepositioning by displacement (the positioning device AUTO of the camera on the guide bar moves into a limit position) 6) Adjust the camera (screw in or screw out the adjusting screw Z)
  • Page 31 5.5.1.4 Adjustment of focus (the system stays in basic initialization) Press key 'SET UP' on the camera until the parameter 'Indication focus value' will be shown (LED 2 is blinking in addition to LED 10). Push in a well defined contrast into the measuring range of the camera and adjust the focus to a minimum LED 10 LED 1...
  • Page 32 5.5.1.5 Carry out white balance Attention! - Clean lenses and lamps - Old modes will be overruled - If selected by error this compensation, use key for leaving the compensation without change SET UP 1) Remove the material out of the viewing range , that the camera only recognize the HF fluorescent lamp.
  • Page 33 5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2) 5.6.1 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.
  • Page 34 5.6.3 Start-up of servo-center operation Press key ‘S-C’. The servo component must move towards the center and stop there. If the servo component is moving into the final position, exchange the connections 25 and 26. Attention: If using an analog servo-center transducer (CK 37, BI 5 G..) preselect their adjustment of gain.
  • Page 35 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 36 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 37 5.8.3 Lifting of zero level Special application of the DIL switches S1.2 and S2.5. Only significant from software version E00304-01. S1.2 S2.5 lifting of zero level Dither lifting of zero level Dither 5.8.4 Adjustment of DIL switches and jumper S1.2 = “ON“ S1.5 = “OFF“...
  • Page 38 Indication of the actual trigger threshold The trigger threshold of the first contrast transition will be indicated in general (gray scale value 0-255). LED 10 LED 1 S E T U P Trigger threshold A   ≤ 25  ...
  • Page 39 5.10 Reset to manufacturers settings Attention: The reset to manufacturers settings may be carried out after start-up and correct addressing of the cameras (camera 1/2/3). Any preceding adjustments will be overruled! configuration edge 1 edge 2 middle between camera 1 and 2 last bright/dark first dark/bright (two-camera system)
  • Page 40 6. Operation The system only admits operation with the components actually present! 6.1 Amplifier 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 6.1.1 Operating functions Select the desired operating functions as follows: Automatic...
  • Page 41 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 * optimization: during operation see point 5.6.2 * with analog servo-center device see point 5.6.3 Web Guiding System...
  • Page 42 shifting of guiding point In operation mode 'AUTO' with switched off SET UP a shifting of the guiding point for the activated sensing mode is possible via arrow keys (4) and (5). Attention: SET UP must be switched off. After each SET Up the set value will be deleted automatically.
  • Page 43 6.2 Set point scaling when change over the web edge The actual position of web edge or web center-line can be taken over as set point for guiding by means of scaling the set point before switch on the guiding to edge 1, edge 2 or center-line guiding. That means, the web will be guided accurate at this position.
  • Page 44 6.3 Status indications The following typical indications can appear during normal operation. Please pay attention that the bright / dark transition indicates the position of the contrast referred to the measuring range. LED 10 LED 1 S E T U P scanning direction signification ...
  • Page 45 6.4 Operation with BST eltromat interface Parameters of the camera can set and/or changed via a corresponding BST eltromat interface. Programming and procedure see manual of the used interface. Web Guiding System EDV No.: MD.066.01.01 Chapter: 6.0 EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99...
  • Page 46 7. Remote control Truth table for the remote control inputs EKR 1500 (e.g. activation by PLC): Terminal 31 = +24V non regulated supply Terminal 38 = GND (0V) Terminal: 32 33 34 35 36 37 72 70 71 73 Function Automatic Manual Servo Center (S-C)
  • Page 47 8. Trouble shooting 8.1 Indications on the EKR 1500 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-energized, provided that no further error is present. Error Responsible Remedy...
  • Page 48 8.2 Indications on the CCD 30000 / CCD 5000M Error messages will be indicated by fast blinking of the LEDs. Error messages can be deleted by pressing the 'SET UP’ key of the CCD camera. LED 10 LED 1 S E T U P message lighting error during white ...
  • Page 49 9. Maintenance 9.1 Amplifier EKR 1500 The amplifier is maintainance-free. The cleaning of the keyboard should be carry out with a dry, clean and smooth cloth. By high contamination, use for cleaning a usual liquid cleaner, benzine or spirit. The amplifier has to be switched off! 9.2 Camera CCD 30000 / CCD 5000M For optimum guiding results, the lenses of the CCD cameras have to be kept clean.
  • 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. A taking back of the equipment by BST eltromat International GmbH is possible. Please reach the necessary agreements.
  • Page 51 - Shields are pinched in the screwing guiding. out as break contacts). (see installation of EMC-wiring). isolated limit switches Connection of BST eltromat module bus with camera sensor 1 cable Twisted Pair Unitronic-Bus LD 3x2x0,22. Please contact the manufacturer for setting of Plunger cross-bonding boxes.
  • Page 52 Annex 2 General plan EKR 1500 with 1x CCD 30000 / CCD 5000M Interface (see Remote control separate manual) Commander EKR 1500 Set point shifting EFE 1 Servo-center component OMG 4 EFE 1000 CCD 30000 / CCD 5000M sensor 1 Oscillation CK 37 BI5G...
  • Page 53 Annex 3 General plan EKR 1500 with 2x CCD 30000 / CCD 5000M Interface Remote control (see separate manual) Commander EKR 1500 Set point shifting EFE 1 Servo-center component OMG 4 EFE 1000 CCD 30000/ CCD 5000M sensor 1 sensor 2 Oscillation CK 37 BI5G...
  • Page 54 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 55 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.