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BST Eltromat ekr 500 digital Installation And Operating Manual

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Web Guiding System
Installation and
Operating Manual
ekr 500 digital
MD.408.EN.12/1.6.x
Translation of the Original Manual

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  • Page 1 Web Guiding System Installation and Operating Manual ekr 500 digital MD.408.EN.12/1.6.x Translation of the Original Manual...
  • Page 2 BST eltromat International GmbH Heidsieker Heide 53 D-33739 Bielefeld Tel.: +49 (0) 5206 999 0 Fax: +49 (0) 5206 999 999 E-Mail: info@bst-international.com Internet: www.bst-eltromat.com This documentation is protected by copyright. The translation as well as reproduction and distribution in any form is forbidden without the approval...

  • Page 3: Table Of Contents

    Table of contents Table of contents 1 About This Document.................. 8 What You Need to Know.................... 8 Target Group.........................  8 Storage and Distribution .................... 8 Meanings of the Safety Instructions and Symbols ............ 8 1.4.1 Safety Instructions ...................... 8 1.4.2 Symbols.........................
  • Page 4 Table of contents 4.1.9 Weight and Dimensions .................... 34 Control Panel ...................... 35 4.2.1 Ambient Conditions .................... 35 4.2.2 Protection Category .................... 35 4.2.3 Power Supply ...................... 35 4.2.4 Display.........................  35 4.2.5 Weight and Dimensions .................... 35 Power Pack........................ 36 Sensors........................
  • Page 5 Table of contents Plug Connection ...................... 74 7.9.1 X60 - Actuator Connection EMS 17/18/21/22 ............ 74 7.9.2 X70 - Power Supply .....................  75 7.9.3 X100 ... 103 - Connection of CAN Bus Participants .............  76 8 Commissioning.................... 77 Safety Instructions ......................  77 Requirements......................
  • Page 6 Table of contents 9.4.2 Actuator Blocked (Motor Overcurrent) .............. 117 9.4.3 Impermissible Supply Voltage...................  118 9.4.4 Motor Control Timeout.....................  118 9.4.5 Controller Interlock Active .................. 119 9.4.6 Keyboard Interlock Active .................. 119 9.4.7 Setup Lock.........................  120 9.4.8 Actuator Bus Connection Fault .................  120 9.4.9 Control Panel Bus Connection Fault................
  • Page 7 Table of contents 10.3 Remote Control With External Control Keyboard.............  184 11 Maintenance and Cleaning................ 185 11.1 Safety Instructions .................... 185 11.2 Maintenance Table .................... 186 11.3 Maintenance and Cleaning work ................ 186 11.3.1 Cleaning the Controller Housing ................ 186 11.3.2 Cleaning the Control Panel Housing................

  • Page 8: About This Document

    About This Document About This Document What You Need to Know These instructions help you to work with the system in a safe, simple and successful manner. The following instructions must be observed in order to avoid hazards and incorrect operation: Every user must have read these instructions in full before ■...

  • Page 9: Symbols

    Observe the accompanying documents (e.g. order confirmation) ► for this system and the operating instructions of the entire system. The latest version of these instructions can be obtained in all available languages at: www.bst-eltromat.com ekr 500 digital – Installation and Operating Manual 9/204...

  • Page 10: About Safety

    The product must only be operated using the components that ■ belong to the system. An exception are such third party com- ponents that have been supplied by BST eltromat International or have been explicitly approved for being operated with the system.

  • Page 11: Non-Intended Use

    Incorrect or negligent handling by the customer ■ Any intervention, modification or conversions on the product ■ without the express approval of BST eltromat International GmbH The use of unsuitable operating materials or spare parts ■ Operation of the product near to sources of interference, e.g.

  • Page 12: Non-Intended Modification Of Electronic Data

    BST eltromat International GmbH. Virus scan- ners or other scan or registration programs must not (be able to) access products via networks. Writing, deleting and editing of system data / files on BST ■ eltromat products is not permitted. Exempt from this is service work carried out at the instruction of BST eltromat International GmbH.

  • Page 13: Safety Instructions

    About Safety Safety Instructions Every user must read and follow the safety instructions in these instructions before working with or on the system. The following contains general safety instructions that always have to be observed. Special safety information that must be observed for certain work will be specified at the start of the respective chapter of these instructions.
  • Page 14 About Safety WARNING Danger of death from actuator movements! When the position control is switched on, the actuator can carry out positioning movements independently when operating in manual mode. Parts of your body could be crushed, cut or hit. Make sure that no persons remain in the vicinity of the pivot / ►...

  • Page 15: Qualification Of The Personnel

    About Safety Qualification of the Personnel The qualifications required by the personnel are defined as follows: Instructed personnel have been instructed comprehensively by the operating company and informed about the following points: Tasks assigned ■ Possible hazards when carrying out the tasks ■...

  • Page 16: Duties Of The Operating Company And Personnel

    About Safety Duties of the Operating Company and Personnel 2.5.1 Duties of the Operating Company The operating company of the entire system is responsible for safety in the workplace as well as for the information and training of the personnel. In particular, for the entire life-cycle of the system and the entire system, the operating company must ensure that: All relevant legal safety, accident prevention and environmental ■...

  • Page 17: Duties Of The Personnel

    About Safety 2.5.2 Duties of the Personnel Each and every employee is responsible for their own safety. In particular, each and every employee must abide by the following instructions: Read these instructions completely before working on or with ► the system and follow all safety instructions. Observe all warning instructions on the system and entire system.

  • Page 18: Personal Protective Equipment

    About Safety Personal Protective Equipment When carrying out certain activities, you have to wear personal protective equipment in order to avoid accidents and injuries. Personal protective equipment includes, depending on the activity: Protective clothing ■ Safety helmet ■ Safety shoes ■...

  • Page 19: Guarantee And Liability

    The warranty terms are specified in the sales documentation. 2.8.1 Disclaimer BST eltromat International GmbH is not liable for damage or defects arising from any incorrect or non-intended use of the product, see Non-intended Use, page 11. Liability for defects does also not apply if the fault originates from...

  • Page 20: Design And Function

    Design and Function Design and Function Design The ekr 500 digital comprises the controller and the removable control panel. 3.1.1 Controller The housing of the controller includes the entire control electrics and connections for all necessary web guiding components (sensors, actuator, servo center transducer, remote controls, etc.). Two housing types are available.
  • Page 21 Design and Function 3.1.2 Control Panel The control panel is fitted on the front of the device in the factory. Fig. 2: Controller with control panel fitted If necessary (e.g. if the controller is installed in a position difficult to access on the machine) the control panel can be detached and installed in a central operator panel or a customer-supplied control station.

  • Page 22: Function

    Design and Function Function With web edge guiding or web center-line guiding in automatic mode, one or two edge sensors connected to the controller detect the current position (ACTUAL position) of the material web and transmit the respective information to the integrated position controller.

  • Page 23: Control And Display Elements

    Design and Function Control and Display Elements On the control panel you will find all control and display elements that you need for the operation of the web guiding system. Fig. 4: Control panel 3.4.1 Graphic Display The graphic display of the control panel displays the different operating statuses and all relevant control parameters during operation.

  • Page 24: Message Output "System Ok

    Design and Function Message Output “System OK“ The controller is equipped with a message output with potential- free changeover contact. In a fault-free state, the message “System OK” is active at the output. If a fault is detected, the relay switches and the message output signalizes that a fault is present in the system.

  • Page 25: Connectable Components

    Design and Function Connectable Components The figure shows the standard components of the web guiding system that you can connect to the controller. Controller External Controller with ekr 500 digital control panel control panel detached efe digital ⎓ 24 V Actuator without position feedback Edge sensors...

  • Page 26: Designation Of The Sensors

    In this operating manual, the sensors are designated with Sensor 1, Sensor 2 and Sensor 3. In accordance with the BST eltromat definition, the following assignment applies between the sensors and the selector keys for the guiding mode:...

  • Page 27: Line And Contrast Sensor (Sensor 3)

    Design and Function 3.7.2 Line and Contrast Sensor (Sensor 3) In conjunction with the CLS Pro 600 line and contrast sensor, the controller permits guiding on continuous or interrupted printed lines or contrast edges. In this case, the line and contrast sensor is connected to the controller as Sensor 3.

  • Page 28: Ccd Cameras (Sensor 1/2)

    Design and Function 3.7.3 CCD Cameras (Sensor 1/2) The assignment of the web edges to the selector keys for the guiding mode can be obtained from the following figures. One-camera system CAN address = 21 Left edge Fig. 8: Web edge guiding with one CCD camera CAN address = 21 Left Right...

  • Page 29: Accessories

    Design and Function Accessories For accessories and the order address, see Accessories and Spare Parts, page 194. Nameplates The nameplates are located on the top of the controller and on the rear of the control panel. The nameplate displayed is only an example. Please obtain the current data from the nameplate attached to the product.

  • Page 30: Technical Specifications

    Technical Specifications Technical Specifications Controller 4.1.1 Ambient Conditions DANGER Danger of death when operated in potentially explosive areas! The system must not be installed or operated in potentially ► explosive areas. Ambient condition Permissible values Working temperature 0 to +45 °C Storage temperature -10 to +70 °C Humidity during operation...

  • Page 31: Power Supply

    Technical Specifications 4.1.4 Analogue Inputs Analogue sensors (terminal strip X1) 0 … 10 V⎓ or 0 … 20 mA Input signal sensor 1/2 (can be switched using DIL switch S7) Power supply 24 V⎓ / max. Σ 0.3 A Internally on the spring-cage Connection terminal block Position feedback EMS 17 … 22 (terminal strip X7) Input signal 0 …...

  • Page 32: Digital Inputs / Outputs

    Technical Specifications 4.1.5 Digital Inputs / Outputs Digital inputs (terminal strips X14, X15, X16) Remote control, remote precision adjustment EFE 1000 < 4 V⎓ (low), > 8 V⎓ (high) (terminal 9 – 30) < 4 V⎓ (low), > 8 V⎓ (high) Switching is carried out via the Controller interlock hardware, i.e.

  • Page 33: Message Output "System Ok

    Technical Specifications 4.1.7 Message Output "System OK" Terminal strip X11 Voltage Max. 24 V∿/⎓ Current Max. 1 A Internally on the spring-cage Connection terminal block 4.1.8 Bus Interface Connectable components IR 2011, IR 2012 ■ (optical edge sensor) Terminal strip X8 US 2010 ■ (plug X102, X103) (ultrasonic edge sensor) CCD CAM 100*, CCD Pro*...

  • Page 34: Weight And Dimensions

    Technical Specifications 4.1.9 Weight and Dimensions Controller without control panel Weight Approx. 1.18 kg Dimensions (details in mm) Fig. 12: Dimensions of the controller with control panel fitted Fig. 13: Dimensions of the controller without control panel 34/204 ekr 500 digital – Installation and Operating Manual...

  • Page 35: Control Panel

    Technical Specifications Control Panel 4.2.1 Ambient Conditions Ambient conditions Permissible values Working temperature 0 to +45 °C Storage temperature -10 to +70 °C Humidity during operation 5% to 90 %, non-condensing Closed, dry building, Place of installation height above sea level < 2,000 m 4.2.2 Protection Category Control panel without controller...

  • Page 36: Power Pack

    Dimensions (details in mm) Fig. 14: Control panel dimensions Power Pack Only the following power packs may be used for the power supply of the controller including the BST eltromat components connected: Power pack from Puls GmbH Type ML100.100 BST eltromat order number...

  • Page 37: Sensors

    Technical Specifications Sensors 4.4.1 Edge Sensors Optical edge sensor IR 2011 Fork width 40 mm 70 mm 24 mm 20 mm Digital mode (±12 mm) (±10 mm) Measuring range 16 mm 16 mm Analogue mode (±8 mm) (±8 mm) Supply voltage 12 to 30 V⎓ (including ripple) Current consumption 20 mA (24 V⎓) Light emitter wave length 630 nm...
  • Page 38 Technical Specifications Optical edge sensor IR 2012 Fork width 40 mm 125 mm Measuring range 12 mm (±6 mm) Supply voltage 12 to 30 V⎓ (including ripple) Current consumption 20 mA (24 V⎓) Light emitter wave length 950 nm Output signal (analogue mode) 0 to 10 V⎓ (±2.5%) Output signal (digital mode) CAN bus Polarity reversal protection...

  • Page 39: Line And Contrast Sensor

    Technical Specifications Ultrasonic edge sensor US 2010 Fork width 40 mm 70 mm Measuring range 12 mm 12 mm Supply voltage 12 to 30 V⎓ (including ripple) Current consumption 40 mA (24 V⎓) Ultrasonic frequency 164 kHz Output signal (analogue mode) 0 to 10 V⎓ (± 2.5%) Output signal (digital mode) CAN bus Polarity reversal protection (supply)

  • Page 40: Ccd Camera

    Technical Specifications 4.4.3 CCD Camera CCDPro 30000/5000 Technical data, see separate instruction manual CCD camera CCDPro 30000/5000, EDP no. MD.167. CCD CAM 100 Technical data, see separate instruction manual CCD camera CCD CAM 100, EDP no. MD.465. 40/204 ekr 500 digital – Installation and Operating Manual...

  • Page 41: Electric Motor Powered Actuators

    Technical Specifications Electric Motor Powered Actuators Type Stroke Gearbox Spindle Nominal Nominal ratio dimensions actuating force actuating speed [mm] [mm] [mm/s] EMS 5 1 : 1 8 x 1 EMS 10 1 : 1 12 x 2 2.4 : 1 5 : 1 EMS 16 2.4 : 1 16 x 5...
  • Page 42 Technical Specifications Type Stroke Gearbox Spindle Nominal Nominal ratio dimensions actuating force actuating speed [mm] [mm] [mm/s] 1.3 : 1 2.4 : 1 4.2 : 1 EMS 18/CX 1.3 : 1 2.4 : 1 16 x 5 4.2 : 1 1.3 : 1 2.4 : 1 4.2 : 1 1.3 : 1...

  • Page 43: Emissions

    Technical Specifications Emissions Continuous sound level (A evaluated, equivalent) < 70 dB(A) RoHS Conformity This product complies with the EC Directive  2011/65 (so-called RoHS* Directive). The limits values for hazardous substances in electrical and electronic equipment specified there are not exceeded by this product.

  • Page 44: Transport, Delivery And Storage

    Transport, Delivery and Storage Transport, Delivery and Storage Transport WARNING Danger of death and material damage caused by incorrect transportation! Death and crushing from goods being transported falling. The lifting gear must not be fixed on the handles. ► Never stand under the suspended goods being transported. ►...

  • Page 45: Scope Of Delivery

    Transport, Delivery and Storage Scope of Delivery Obtain the scope of delivery from the delivery documents or confirmation of order. Unpacking the Delivery 1. Check the packaging for external damage and, if necessary, make a complaint to the supplier. 2. Carefully open the packaging. 3.

  • Page 46: Installation

    Cordon-off the work area in order to prevent access by un- ► authorized persons (e.g. by setting up barriers). Make sure that all parts of the machine where the BST eltromat ► components have to be installed have a sufficient load bearing capacity.

  • Page 47: Selecting The Installation Location

    ► into the machine. Cover the affected area of the machine with film or paper. Parts falling down may damage the machine. Do not climb onto or walk on BST eltromat components or ► unsuitable parts of the machine. Ensure that there is sufficient free headroom. If the free head- ►...

  • Page 48: Installing The Controller

    Installation Installing the Controller This chapter describes the procedure for installing the controller with control panel fitted. 6.3.1 Installation Positions You can install the controller in four different positions (see figure). Horizontal installation Vertical installation When delivered, the controller is prepared for installation in posi- tion ①.

  • Page 49: Securing Hole Template

    Installation 6.3.2 Securing Hole Template Fig. 16: Securing hole template for the controller 6.3.3 Space Needed to Open the Housing Cover The figure shows the free space around the housing of the controller that is needed to open the housing cover completely. Fig. 17: Space needed to open the housing cover ekr 500 digital –...

  • Page 50: Installing The Controller

    Installation 6.3.4 Installing the Controller NOTICE Damage to the system from drilling dust and loose parts! Drilling dust, splitter and loose parts may damage the machine. Before carrying out drilling or installation work, cover the ► affected area of the machine with film or paper. After installation work, check that the bolts are screwed tight.

  • Page 51: Turning The Control Panel

    Installation 6.3.5 Turning the Control Panel When using the controller with the control panel fitted, you can change the position of the control panel as described below. Fig. 19: Detaching the control panel 1. Unscrew the securing screws ① of the control panel ②. 2.

  • Page 52: Installing The Control Panel

    Installation Installing the Control Panel This chapter describes the procedure for installing the control panel when using the controller with the control panel detached (see Control Panel, page 21). Strong electro-magnetic fields in the immediate vicinity of the control panel may result in malfunctions. Do not install the control panel in the vicinity of components or lines that use mains power.

  • Page 53: Wall Mounting

    Installation 6.4.3 Wall Mounting Securing Hole Template Fig. 21: Securing hole template control panel Installing the Control Panel NOTICE Damage to the system from drilling dust and loose parts! Drilling dust, splitter and loose parts may damage the machine. Before carrying out drilling or installation work, cover the ►...
  • Page 54 Installation 2. Unscrew the four securing screws ③ of the control panel ④ and store in a safe place. These screws are required for the wall mounting of the control panel. 3. Pull the control panel ④ off forwards from the controller ⑤. In doing so, pull the connecting cable and the plug ①...
  • Page 55 Installation 6.4.4 Console Installation Installation Cut-Out Fig. 22: Installation cut-out Installing the Control Panel NOTICE Damage to the system from drilling dust and loose parts! Drilling dust, splitter and loose parts may damage the machine. Before carrying out drilling or installation work, cover the ►...
  • Page 56 Installation 2. Unscrew the four securing screws ③ of the control panel ④ and store in a safe place. These screws are required for the wall mounting of the control panel. 3. Pull the control panel ④ off forwards from the controller ⑤. In doing so, pull the connecting cable and the plug ①...
  • Page 57 Installation Fig. 23: Top view, Console installation 7. Screw the four threaded pins ⑦ into the securing plates ⑧ until the control panel ④ is held firmly in place. 8. Use the optional cable extension to connect up the control panel to the controller (see Cable Extension, page 52). 9.
  • Page 58 Installation 6.4.5 Magnet Attachment The optionally available magnet installation set (order no. 148 887) enables the control panel to be fitted to a level ferro-magnetic surface (e.g. on the machine frame). Safety Instructions Neodymium magnets have special features with which the users must be familiar so that they do not harm themselves or cause damage to their surroundings.
  • Page 59 Installation Installing the Control Panel 1. Fix the four magnets ④ from the magnet installation set to the control panel ③ using the M3 x 25 countersunk screws ⑤, hexagon nuts ① and serrated washers ②. 2. Carefully fix the control panel ③ to a ferro-magnetic surface. 3.

  • Page 60: Electrical Connection

    Electrical Connection Electrical Connection Safety Instructions DANGER Danger of death from electric shock! Life threatening injuries caused by incomplete switching off or residual current. Switch the machine off completely, switch free of voltage and ► wait 10 minutes before carrying out the electrical connection. Check that the unit is voltage-free.

  • Page 61: Cable Routing

    Electrical Connection Cable Routing WARNING Severe injuries and property damage caused by routing the cables incorrectly! Cables routed incorrectly may lead to tripping, falling and subsequent accidents. Route the cable free of tension and well anchored. ► Ensure that no tripping or catching points are created. ►...

  • Page 62: Connecting The Cables

    Electrical Connection Connecting the Cables Cables up to 0.75 mm Use core end sleeves with collar for the connections (DIN 46228/ Part 4). The crimping must be carried out gas tight (no cross-crimping). ■ There must be no gaps between the conductor and the core ■...

  • Page 63: Emc Suitable Wiring

    Electrical Connection EMC Suitable Wiring Figure Wiring step Unscrew the union nut on the cable gland. ► Pull out the clamping insert from inter- ► mediate support. Attention! When pulling out the clamping insert, do not bend it (do not press too hard). Strip cable back by 8 mm so that the screen ►...

  • Page 64: Ensuring Equipotential Bonding

    Electrical Connection Ensuring Equipotential Bonding Electrostatic charges (ESD) must not discharge via the system. Devices for discharging must be installed before and after (in the web running direction) the installed system. In the contact areas of connections, remove the paint as this act as an insulator and prevents equipotential bonding.

  • Page 65: Connections On The Controller

    Electrical Connection Connections on the Controller The connector sockets and cable glands are located on the bottom of the controller housing. These allow different web guiding components to be connected. The figure shows the arrangement of the connections for both housing types. Fig. 26: Connector sockets on the controller You can find the function of the connector sockets in the table on the following page.
  • Page 66 Electrical Connection Designation Socket Function Note Leads internally to Connection power supply 24 V⎓ terminal strip X6 Leads internally to Connection actuator terminal strip X7 Leads internally to X100 Connection control panel terminal strip X9 Connection Drive Module 160 (external output stage for actuator EMS 23)* Leads internally to X101 Connection line and contrast sensor CLS Pro 600...

  • Page 67: Terminal Strips

    Electrical Connection Terminal Strips The following figure shows the position of the terminal strips (X…) on the processor board of the controller. Fig. 27: Terminal strips on the processor board ① Nameplate ② Hardware version ekr 500 digital – Installation and Operating Manual 67/204...

  • Page 68: Terminal Assignment

    Electrical Connection Terminal Assignment 7.8.1 Overview Terminal strip Socket Function Note (Processor board) (Housing) Connection sensor 1 (analogue) Guiding mode Connection sensor 2 (analogue) Guiding mode Power supply 24 V⎓ Connection actuator Position feedback actuator (EMS 17 … 22) Connection servo center transducer OMG 4 X102 Connection sensor 1 (CAN bus) Guiding mode...

  • Page 69: Terminal Strip X1 - Sensor 1/2 (Analogue Connection)

    Electrical Connection Terminal strip Socket Function Note (Processor board) (Housing) CAN bus extension Digital inputs 1 … 6 Remote control, electronic remote precision adjust- ment EFE 1000 Digital inputs 7 … 12 Digital outputs 1 … 4 Programming in the Programing interface (USB) factory 7.8.2 Terminal Strip X1 - Sensor 1/2 (Analogue Connection) Function Comments Terminal...

  • Page 70: Terminal Strip X7 - Actuator, Omg 4

    Electrical Connection 7.8.4 Terminal Strip X7 - Actuator, OMG 4 Connection actuator EMS 5/10/16/17/21/22, servo center transducer OMG 4 (Wiring on terminal strip X7) Function Wire colour Note Terminal OMG 4 10/16 17/21/22 EMS 22 Power supply actuator / OMG 4 (see also Terminal +24 V⎓...

  • Page 71: Terminal Strip X8 - Sensor 1/2 (Can Bus)

    Electrical Connection 7.8.5 Terminal Strip X8 - Sensor 1/2 (CAN Bus) X102 Function Wire colour Comments Terminal +24 V⎓ brown Power supply sensor 1 CAN1-H white CAN 1 high blue Ground CAN 1 CAN1-L black CAN 1 low X103 Function Wire colour Comments Terminal +24 V⎓...

  • Page 72: Terminal Strip X10 - Controller Interlock, Omg 4, Omg 8, Ck 37, Efe 1

    Electrical Connection 7.8.7 Terminal Strip X10 - Controller Interlock, OMG 4, OMG 8, CK 37, EFE 1 Function Wire colour Note Terminal OMG 4 OMG 8, CK 37 EFE 1 +24 V⎓ Output +24 V⎓ for controller interlock Applies for all operating modes Controller (Automatic, Manual mode, Center interlock positioning).

  • Page 73: Terminal Strip X14 - Digital Inputs 1

    Electrical Connection 7.8.10 Terminal Strip X14 - Digital Inputs 1...6, EFE 1000 Function Wire colour Note Terminal EFE 1000 Connect with +24 V⎓ Output +24 V⎓, max. 200 mA terminal 71 (X11). Input 1 Input 2 Input 3 See the truth table for digital inputs (Truth Tables, page 177) Input 4 Input 5...

  • Page 74: Plug Connection

    Electrical Connection Plug Connection 7.9.1 X60 - Actuator Connection EMS 17/18/21/22 The actuator is connected to the controller using an 8-pin micro- style connector M12 according to DIN IEC 61076. For connecting the actuators EMS 17, EMS 21 and EMS 22, you require an optional adapter cable (order number 154 374), see also Accessories, page 194 View X Socket...

  • Page 75: X70 - Power Supply

    Electrical Connection 7.9.2 X70 - Power Supply The power supply is connected to the controller using a 3-pin plug according to CEN 175301-803, DIN 43650 (3 x 0.75 mm , cable dia- meter 4.5 mm to 6 mm). Panel connector Coupling Fig. 29: Contact assignment in the plug connector Contact Signal Wire colour...

  • Page 76: X100

    Electrical Connection 7.9.3 X100 ... 103 - Connection of CAN Bus Participants The CAN bus participants (control panel, digital edge sensors, external control keyboard, ...) are connected to the controller using a 4-pin micro-style plug M8. View X Socket (female) View X Plug (male)

  • Page 77: Commissioning

    Commissioning Safety Instructions WARNING Danger of death and material damage caused by incorrect commissioning! Have the commissioning carried out by BST eltromat service ► personnel or authorized personnel only. DANGER Danger of death caused by the machine starting up! Parts of your body could be crushed, cut, drawn in or hit.

  • Page 78: Requirements

    Commissioning NOTICE Damage caused by operating the actuator in generator mode! Operating the actuator in generator mode can lead to the destruction of the controller or the actuator. Provide suitable measures for removing or converting the ► resulting energy (e.g. external ballast circuit or electrically isolating the actuator from the controller).

  • Page 79: Setting The Dil Switches

    Commissioning Setting the DIL Switches Before commissioning the web guiding system, you must set the DIL switches on the processor board of the controller according to the application. NOTICE Damage to the components from working on live parts. Before opening the controller, switch off the power supply. ►...

  • Page 80: Using The Dil Switch

    Commissioning 8.3.2 Using the DIL Switch NOTICE Damage to the DIL switch from incorrect use! Deformation of the movable sliders or contacts may lead to mal- functions. Observe the DIL switch instructions for use. ► Precautionary measures For setting the DIL switch, use plastic tweezers with smooth ►...

  • Page 81: Setting Dil Switch S4

    Commissioning 8.3.3 Setting DIL Switch S4 Using DIL switch S4, carry out the following settings: Reverse the guiding direction ■ Activate electronic remote precision adjustment EFE 1 ■ Select the actuator to be used ■ Select the servo center transducer to be used ■...

  • Page 82: Setting Dil Switch S5

    Remote control inputs activated S5.5 Remote control inputs deactivated Connector socket X101 is configured as internal BST eltromat CAN bus, i.e. it behaves in the same manner as connector sockets S5.6 X100, X102 and X103 Connector socket X101 is configured as...

  • Page 83: Setting Dil Switch S6

    Commissioning 8.3.5 Setting DIL Switch S6 Using DIL switch S6, carry out the following settings: Activate the Master-Slave guiding (from firmware version 1.5.x) ■ Deactivate the evaluation of the DIL switches ■ DIL switch Function Note S6.1 – S6.5 Reserved Master-Slave guiding S6.6 = ON is activated...

  • Page 84: Setting The Jumper

    Commissioning Setting the Jumper Using jumper JX1 on the processor board of the controller, activate the galvanic separation (electrical isolation) for the connector socket X101 of the controller. Fig. 32: Jumper JX1 on the processor board Jumper Function Application plugged Electrical isolation not active. 24 V⎓...

  • Page 85: Checking The Device Addresses

    Commissioning Checking the Device Addresses The device addresses for the controller and the control panel are pre-set in the factory. The settings usually do not have to be modified. In event of malfunction or non-defined behaviour of the controller or control panel, the settings for the device addresses must be checked.

  • Page 86: Control Panel Device Address

    Commissioning 8.5.2 Control Panel Device Address The device address of the control panel has been pre-set to 1 in the factory (delivery state). The device address must only be edited in agreement with the manufacturer! You can set the device address of the control panel using the rotary switch S1 on the control panel board.

  • Page 87: Setting The Terminating Resistors

    Commissioning Setting the Terminating Resistors The internal terminating resistors for the controller and the control panel are switched on in the factory (delivery state). 8.6.1 Terminating Resistor of the Controller Using sliding switch S3 on the processor board, switch the internal terminating resistor for the connector socket X101 on or off depending on the application.
  • Page 88 Commissioning Setting the terminating resistor NOTICE Damage to the components from working on live parts. Before opening the controller, switch off the power supply. ► 1. Electrically isolate the controller. 2. Open the controller’s housing cover. 3. Check the setting of the sliding switch S3 on the processor board.

  • Page 89: Terminating Resistor Of The Control Panel

    Commissioning 8.6.2 Terminating Resistor of the Control Panel The internal terminating resistor of the control panel is switched on in the factory (delivery state). The internal terminating resistor must only be switched off in agreement with the manufacturer! In event of malfunction or non-defined behaviour of the controller or control panel, the setting for the terminating resistor must be checked.
  • Page 90 Commissioning Checking the terminating resistor NOTICE Damage to the components from working on live parts. Before opening the housing, disconnect the plug on the ► connecting cable for the control panel from the controller. 1. Disconnect the plug on the connecting cable for the control panel from the controller.

  • Page 91: Commissioning The Actuator Without Position Feedback

    Commissioning Commissioning the Actuator Without Position Feedback Actuators without positions feedback: EMS 5, EMS 10, EMS 16, ECO EMS 22 8.7.1 Set the Guiding Direction for Center Positioning If you use a servo center transducer (OMG 4, OMG 8, CK 37), you have to check the guiding direction for the operating mode Center Positioning.

  • Page 92: Setting The Gain Of The Servo Center Transducer

    Commissioning 8.7.2 Setting the Gain of the Servo Center Transducer If you use a servo center transducer (OMG 4, OMG 8, CK 37), then you have to set its gain. Fig. 37: Display the controller gain of the servo center transducer Setting the gain WARNING Danger of death from actuator movements!

  • Page 93: Commissioning The Actuator With Position Feedback

    Commissioning Commissioning the Actuator With Position Feedback Actuators with position feedback: EMS 17, EMS 18, EMS 21, EMS 22, EMS 23 8.8.1 Set the Guiding Direction for Center Positioning If you use an actuator with position feedback, you have to check the guiding direction for the operating mode Center positioning.

  • Page 94: Setting Stroke Limitation And Servo-Center Position

    Commissioning 8.8.2 Setting Stroke Limitation and Servo-Center Position For actuators with position feedback, you must set the position of the software limit switches for the stroke limitation and the servo- center position. The setting is carried out with the assistance of a special setting menu.
  • Page 95 Commissioning When new position values are taught in, the factory default settings will be overwritten. The relevant symbol (sensor 1, sensor 2 or servo-center position) will be inversely displayed after teaching in a new value. WARNING Danger of death from actuator movements! During function tests, parts of your body may be crushed, cut or hit.
  • Page 96 Commissioning Setting the servo-center position The servo-center position must be located within the positioning range of the actuator which is limited by both software limit switches. 1. Using the arrow keys, move the actuator to the desired position for the central position of the guiding device. The position indicator of the actuator displays the value supplied by the position feedback.

  • Page 97: Activating Position Control

    Commissioning 8.8.3 Activating Position Control The position control for actuators with position feedback (EMS  17  …  23) brings about a self-locking of the actuator. With position control switched on, the actuator stops in the traversed to position when in manual mode, independently of any external forces acting on the drive.

  • Page 98: Setting The Motor Rotation Direction

    Commissioning Setting the Motor Rotation Direction When commissioning, you have to check the assignment of the arrow keys to the positioning direction (motor rotation direction) of the actuator. The definition of the sensors (Sensor 1, Sensor 2, Sensor 3) is described in chapter Designation of the Sensors, page 26.

  • Page 99: Setting The Guiding Direction

    Commissioning 8.10 Setting the Guiding Direction 8.10.1 Guiding Direction for Web Edge Guiding and Web Center-Line Guiding (Sensor 1/2) When commissioning, you have to check the assignment of the selector keys for the guiding mode to the positioning direction of the actuator.

  • Page 100: Performing The Material Setup

    Commissioning 8.11 Performing the Material Setup In order to achieve optimal guiding results, you have to carry out a material setup during the initial commissioning of the web guiding system (see Performing the Material Setup, page 124). During the material setup the controller is automatically adjusted to the properties of the material to be scanned.
  • Page 101 Commissioning 4. Keep increasing the gain using the right arrow key until control oscillations occur (the guiding device starts to tremble). 5. Keep reducing the gain using the left arrow key until the oscillation ceases (stable guiding operation). If you desire a slower reaction of the control, you can reduce the gain even further.

  • Page 102: Commissioning The Electronic Remote Precision Adjustment (Optional)

    Commissioning 8.13 Commissioning the Electronic Remote Precision Adjustment (Optional) If an optional electronic remote precision adjustment EFE  1 or EFE  1000 is connected to the controller, you must check the operating direction of the control elements (potentiometer or arrow keys) during commissioning. 8.13.1 EFE 1 Fig. 42: Electronic remote precision adjustment EFE 1 Checking the operating direction of the potentiometer...

  • Page 103: Efe 1000

    Commissioning 8.13.2 EFE 1000 Fig. 43: Electronic remote precision adjustment EFE 1000 Checking the operating direction of the arrow keys 1. Press the Manual mode key. The LED of the key will illuminate. The controller switches to manual mode. 2. Press the left arrow key of the remote precision adjustment and observe the guiding device.

  • Page 104: Service Indications

    Commissioning 8.14 Service Indications 8.14.1 Service LEDs Overview The following figure shows the position of the service LEDs H1 to H53 on the processor board of the controller. Fig. 44: Service LEDs on the processor board Service LED Display function H1 – H12 Status of the remote control inputs H13 –...

  • Page 105: Status Display Of Remote Control Inputs

    Commissioning 8.14.2 Status Display of Remote Control Inputs LED Meaning Remote control input 1 active (1 signal (+24 V⎓) on terminal 10) Remote control input 2 active (1 signal (+24 V⎓) on terminal 11) Remote control input 3 active (1 signal (+24 V⎓) on terminal 12) Remote control input 4 active (1 signal (+24 V⎓) on terminal 13) Remote control input 5 active...

  • Page 106: Display Of Bus Status

    Commissioning 8.14.4 Display of Bus Status Name Condition Bus designation Meaning The unit is in the initialization phase. STOPPED No data transfer takes place. The device is in PREOPERATIONAL mode. FLASHING PREOPERATIONAL The initialization is completed. The device can be started. OPERATIONAL The unit is in OPERATIONAL mode.

  • Page 107: Operation

    Operation Operation Safety Instructions WARNING Severe injuries and material damage due to faulty operation! Ensure that operating is carried out by qualified and adequately ► instructed personnel only. Control Panel Fig. 45: Control panel On the control panel you will find all control and display elements that you need for the operation of the web guiding system.
  • Page 108 Operation Function Designation Description Automatic Automatic web guiding Operating mode Manual Manual positioning of the guiding device selection mode Center Center positioning of the guiding device positioning Sensor 1 Guiding to the left web edge Sensor 2 Guiding to the right web edge Web center-line guiding Guiding mode selection...

  • Page 109: Operation Display

    Operation Operation Display 9.3.1 Overview The operation display in the display of the control panel shows the different operating states and all relevant control parameters as graphical symbols and numeric values. You will find the meanings for the individual symbols in the following illustration. Application with edge sensors Fig. 46: Operation display for application with edge sensors Pos.
  • Page 110 Operation Application with CCD cameras Fig. 47: Operation display for application with CCD cameras Pos. Symbol Display function ① Operation display CCD camera (left edge) Operation display line / contrast sensor ② (Sensor 3) ③ Operation display CCD camera (right edge) ④...

  • Page 111: Operation Display Edge Sensors (Sensor 1/2)

    Operation 9.3.2 Operation Display Edge Sensors (Sensor 1/2) The operation displays for sensor 1 and sensor 2 appear only if the respective edge sensors are connected to the controller. Fig. 48: Operation displays edge sensors The appearance of the operation display depends on the connec- tion type (CAN bus or analogue connection) of the edge sensor.

  • Page 112: Operation Display Line And Contrast Sensor (Sensor 3)

    Operation Displaying the web position (example) Guiding setpoint = 0 Guiding setpoint = - 6 mm The web edge is located in the The web edge is displaced by center of the sensor scanning -6 mm from the center of the area. sensor scanning area.
  • Page 113 Operation Symbol meanings The value specifies the relative position of the line or ① contrast transition in relation to the sensor scanning area. ② The dashed line marks the center of the sensor scanning area. Line guiding: The white bar marks the current position of the line. ③...

  • Page 114: Operation Display Ccd Cameras

    Operation 9.3.4 Operation Display CCD Cameras The operation display for the CCD cameras appear only when the respective CCD cameras with the correct CAN address are connected to the controller. One-camera system Fig. 50: One-camera system operation display CAN address camera 1 = 21 Dual-camera system Fig. 51: Two-camera system operation display CAN address camera 1 = 21...
  • Page 115 Operation Operation display CCD camera Symbol meanings CAN address of the assigned CCD camera One-camera system: 21 ① Dual-camera system: camera 1 = 21, camera 2 = 31 (see CCD Cameras (Sensor 1/2), page 28) ② The triangle marks the guiding setpoint. The dashed line marks the center of the camera measuring ③...

  • Page 116: Actuator Operation Display

    Operation 9.3.5 Actuator Operation Display The operation display for the actuator appears only if an actuator with position feedback or a servo centre transducer (OMG 4, OMG 8, CK 37) is connected to the controller. Fig. 52: Actuator Operation Display Actuator Operation Display Symbol meanings ①...

  • Page 117: Special Displays

    Operation Special Displays If a fault or an extraordinary operating state occurs during opera- tion of the web guiding system, this is shown by a symbol in the display. The meaning of the different symbols is described in the following chapters. For troubleshooting, see Troubleshooting, page 188.
  • Page 118 Operation 9.4.3 Impermissible Supply Voltage If the supply voltage of the controller is outside the permissible range then the warning symbol Supply voltage appears next to the operation display of the actuator. Fig. 55: Screen display with impermissible supply voltage If the supply voltage lies inside the permissible voltage range again then the symbol automatically fades out.

  • Page 119: Controller Interlock Active

    Operation 9.4.5 Controller Interlock Active When the controller interlock is active, the warning symbol Controller interlock active appears in the display next to the operation display of the actuator. Fig. 57: Screen display with active controller interlock A controller interlock (e.g. when the machine is stopped) can be triggered via the digital inputs, by an external switch or a PLC signal.

  • Page 120: Setup Lock

    Operation 9.4.7 Setup Lock With active setup lock, the information text SETUP LOCK flashes in the centre of the bottom display border if the SETUP button is pressed. Fig. 59: Screen display with active setup lock With active setup lock, the SETUP button of the control panel is blocked.

  • Page 121: Edge Sensor Bus Connection Fault

    Operation 9.4.10 Edge Sensor Bus Connection Fault If a fault occurs in the bus connection between the controller and a digital edge sensor, the respective sensor symbol flashes in the display. Fig. 62: Screen display with an active fault in the bus connection for a digital edge sensor Press the ENTER button to confirm the error message.

  • Page 122: Loss Of The Line / Contrast Transition

    Operation 9.4.12 Loss of the Line / Contrast Transition With line / contrast guiding using the CLS  Pro  600 line and con- trast sensor (sensor 3), an explanation mark appears in the display in front of the symbol for sensor 3 in the event of an interruption of the print or loss of the printed line / contrast transition to be scanned.

  • Page 123: External Motor Output Stage Fault (Drive Module 160)

    Operation 9.4.14 External Motor Output Stage Fault (Drive Module 160) This display appears only if an electric motor powered actuator of type EMS 23 is connected to the controller. If the hardware power monitoring of the external motor output stage (Drive Module 160) reports a fault, the warning symbol External motor output stage fault appears in the display of the controller next to the operation display of the actuator.

  • Page 124: Performing The Material Setup

    Operation Performing the Material Setup 9.5.1 Overview WARNING Risk of cutting on sharp edges of the material web! Severe cutting injuries from the edges of the running material web. Never touch the edges of running material webs. ► Carry out the material setup only when the production machine ►...
  • Page 125 Operation Generating bright / dark values The illustrations show the procedure for generating the bright / dark values. Bright value Completely clear the sensor's scanning area (no material in the ► scanning area). Dark value Completely cover the sensor’s scanning area with the material ►...
  • Page 126 Operation Fig. 68: Screen display with analogue connection of the sensor ① Dark value (graphical display) ② Current value (graphical display) ③ Bright value (graphical display) ④ Spanner symbol = manual material setup ⑤ Dark value (maximum value) ⑥ Current value ⑦...

  • Page 127: Activating The Material Setup

    Operation 9.5.2 Activating the Material Setup You activate the material setup (manual or automatic) in the setup menu. Fig. 69: Setup menu ① Automatic material setup ② Manual material setup Activating the material setup 1. Press the Manual mode key. The LED of the key will illuminate. The controller switches to manual mode.

  • Page 128: Procedure For Web Edge Guiding

    Operation 9.5.4 Procedure for Web Edge Guiding Automatic Material Setup This chapter describes the normal procedure for saving the bright / dark values for the web edge guiding. 1. Remove any material that may be present from the connected edge sensors and clean the sensor scanning areas. 2.
  • Page 129 Operation Manual Material Setup This chapter describes the procedure for saving the bright / dark values for the web edge guiding with critical contrasts. 1. Remove any material that may be present from the connected edge sensors and clean the sensor scanning areas. 2.

  • Page 130: Procedure For Web Center-Line Guiding

    Operation 9.5.5 Procedure for Web Center-Line Guiding Automatic Material Setup This chapter describes the normal procedure for saving the bright / dark values for the web center-line guiding. 1. Remove any material that may be present from the connected edge sensors and clean the sensor scanning areas. 2.
  • Page 131 Operation Manual Material Setup This chapter describes the procedure for saving the bright / dark values for the web center-line guiding with critical contrasts. 1. Remove any material that may be present from the connected sensors and clean the sensor scanning areas. 2.
  • Page 132 Operation 8. Completely clear the scanning area of sensor 2 (no material in the scanning area). The bright value measured is displayed. 9. Press the ENTER key. The bright value for sensor 2 is saved. The screen display shows the operating step necessary for generating the dark value for sensor 2.

  • Page 133: Selecting The Guiding Mode

    Operation Selecting the Guiding Mode You can select between the following guiding modes. Guiding to the left web edge (Sensor 1) ›› An edge sensor or a CCD camera is connected to the controller as sensor 1. Press the Sensor 1 key. ►...

  • Page 134: Selecting The Operating Mode

    Operation Selecting the Operating Mode 9.7.1 Manual Mode In this operating mode, you can change the position of the guiding device. WARNING Danger of death from actuator movements! Parts of your body could be crushed, cut or hit. Make sure that no persons remain in the vicinity of the pivot / ►...

  • Page 135: Automatic

    Operation 9.7.2 Automatic In this operating mode, automatic web guiding is carried out depending on the guiding mode selected (guiding to the left or right web edge, web center-line guiding, line or contrast guiding). WARNING Danger of death from actuator movements! Parts of your body could be crushed, cut or hit.

  • Page 136: Setting The Guiding Setpoint

    Operation Setting the Guiding Setpoint The guiding setpoint is the desired position of the web edge, printed line or contrast transition in the sensor scanning area. It can be adjusted in the Automatic operating mode using the arrow keys. The guiding setpoint is saved separately for each guiding mode.

  • Page 137: Adjusting The Guiding Setpoint

    Operation Display for CCD cameras Symbol meanings ① The triangle marks the guiding setpoint during operation. ② The dashed line marks the center of the sensor scanning area ③ The black bar marks the guiding setpoint ④ Numeric display of the guiding setpoint 9.8.1 Adjusting the Guiding Setpoint 1.

  • Page 138: Accepting Current Position Of A Web Edge As Guiding Setpoint

    Operation 9.8.2 Accepting Current Position of a Web Edge as Guiding Setpoint This accept function* allows you to use the current position of the web edge in the sensor measuring range as the new guiding set- point for the web guiding system. * from firmware version 1.5.x Function In manual mode, you can move the material web into the desired...
  • Page 139 Operation Acceptance mode 3: Automatic acceptance with remote control signal ›› The acceptance mode is activated (Parameter w-setup by input = ON). ›› Function table 5 (Table 5) or 6 (Table 6) for the allocation of the digital inputs and outputs is active (see Selection of Function Table, page 178).

  • Page 140: Saving And Loading The Guiding Setpoint

    Operation 9.8.3 Saving and Loading the Guiding Setpoint The memory of the controller allows you to save four different parameter sets for the guiding setpoint, and to re-load them when required. In this way, you reduce the setup time for repeat orders. In each of the four parameter sets, the controller saves the guiding setpoint for the following guiding modes: Web edge guiding with sensor 1...
  • Page 141 Operation Symbol Meaning Note Parameter set 1 is loaded Factory setting Parameter set 2 is loaded Parameter set 3 is loaded Parameter set 4 is loaded Loading the guiding setpoint ›› Function table 1 (Table 1) or 4 (Table 4) for the allocation of the digital inputs and outputs is active (see Selection of Function Table, page 178).

  • Page 142: Entering An Offset Value For The Guiding Setpoint

    Operation 9.8.4 Entering an Offset Value for the Guiding Setpoint The offset value for the guiding setpoint* is used for web center- line-guiding with CCD camera when the CCD camera is mounted in the machine off-center, but the material web should be guided through the machine in the middle.
  • Page 143 Operation Application example Offset Controller display screen Fig. 72: Determining the offset value for the guiding setpoint ① Position of the machine center ② Position of the center of the camera measuring range ③ Set guiding setpoint (≙ offset value) The value ③ displayed corresponds with the offset between the center of the camera measuring range and the machine center.

  • Page 144: Optimizing The Controller Gain

    Operation Optimizing the Controller Gain You use this function to set the gain for the different guiding modes. The controller gain is normally set once during commissioning (see Adjusting the Controller Gain, page 100). If control oscillations occur during operation (the guiding device trembles), the controller gain has to be optimized.
  • Page 145 Operation After a pre-set time (Timeout) has elapsed after pressing the key for the last time, the display of the gain is auto- matically faded out. If control oscillations do not occur we recommend setting the maximum gain. ekr 500 digital – Installation and Operating Manual 145/204...

  • Page 146: Special Guiding Functions

    Operation 9.10 Special Guiding Functions 9.10.1 Watchdog Function The Watchdog function is used to prevent the web from wandering after the total loss of the printed line or contrast transition during line or contrast guiding. If the printed line or the contrast transition disappear from the scanning area of the line and contrast sensor (e.g.
  • Page 147 Operation Before switching on Before switching on the Watchdog function for the first time, the following preparation measures must be carried out: Carry out separate commissioning for the guiding with the ► CLS Pro 600 line and contrast sensor and the guiding with the edge sensor (capture sensor).
  • Page 148 Operation 3. Press the Automatic key on the controller. The LED of the key illuminates. The controller switches to automatic mode. 4. Press both arrow keys on the controller at the same time. The guiding setpoint for sensor 3 is reset to the value 0. If the optional electronic remote precision adjustment EFE 1 is connected to the controller then the guiding setpoint must be set to the value 0 using the potentiometer of the EFE 1 (see EFE...

  • Page 149: Speed-Dependent Guiding

    Operation 9.10.2 Speed-Dependent Guiding In automatic operating mode, the speed-dependent guiding* ensures for an optimum guiding behaviour even at low machine speeds. If the speed-dependent guiding is activated, a tachometer symbol appears in the operating display of the actuator. The control of the actuator is limited automatically below an adjustable speed range.

  • Page 150: Operation

    Operation 9.10.3 Master-Slave Guiding Function The Master-Slave guiding* is used when two material webs have to be guided together precisely to the edge (laminating control). In doing so, the positions of both material webs are detected by two edge sensors or two CCD cameras. * from firmware version 1.5.x Slave web Guiding...

  • Page 151: Master-Slave Guiding

    Operation Guiding Modes The Master-Slave guiding permits the following guiding modes. Master-Slave guiding with edge sensors with CCD cameras Guiding Guiding Guiding Web center-line guiding to the left web edge to the left web edge to the right web edge Slave Slave Slave...
  • Page 152 Operation Operation Display If the Master-Slave guiding is active, the letter M (Master) appears next to the operation display for sensor 1. It indicates that sensor 1 detects the position of the Master web. The letter S appears next to the operation display for sensor 2. It indicates that sensor 2 detects the position of the Slave web.

  • Page 153: Tear-Off Detection

    Operation 9.10.4 Tear-Off Detection The Tear-Off Detection* is used for the web edge guiding with CCD camera if, during operation of the web guiding system, material defects (tear-off) are to be expected on the web edges to be scanned. The function detects both tears into the material web (inward tear) as well as projecting material (outward tear).
  • Page 154 Operation Material web Tear Tear Sensor signal Minimum change of the sensor value Tear-off detection Start tear tear detected detected Blocking hold time Actuator correction signal Blocking delay time Blocking Fig. 80: Function principle of the tear-off detection With the following parameters of the public parameter list (parameter list 0), you can activate the tear-off detection and adapt the function to your individual application.

  • Page 155: Calling Up The Setup Menu

    Operation 9.11 Calling up the Setup Menu In the setup menu, activate the different setting functions and service displays of the controller. The setup menu comprises several pages. Fig. 81: Setup menu Calling up the setup menu 1. Press the Manual mode key. The LED of the key illuminates.
  • Page 156 Operation Setting functions and service displays Symbol Component Function Description See Automatic Material Performing automatic Setup, page 128 and Auto- material setup matic Material Setup, page Edge sensor See Manual Material Performing the manual Setup, page 129 and material setup Manual Material Setup, page 131 See Setting Stroke...

  • Page 157: Displaying System Information

    Operation 9.12 Displaying System Information This service display shows the hardware, firmware and bootloader versions installed in the controller and control panel. Fig. 82: Display of the system information (example) ① Controller ③ Firmware version ② Control panel ④ Hardware version ⑤...

  • Page 158: Displaying System Components

    Operation 9.13 Displaying System Components This service display indicates the system components that are connected to the controller. Fig. 83: Display of the system components connected (example) You will find the meaning for the individual symbols in the following table. Pos. System Type (example) component ①...

  • Page 159: Displaying Switch Positions

    Operation 9.14 Displaying Switch Positions This service display indicates the settings of the switches on the processor board of the controller. As such, you can check the switch positions without having to open the controller. Fig. 84: Display of the switch positions (example) The settings of the following switches are displayed: Switch Setting function...

  • Page 160: Performing Basic Settings Of The Ccd Camera

    Operation 9.15 Performing Basic Settings of the CCD Camera 9.15.1 Safety Information WARNING Risk of cutting on sharp edges of the material web! Severe cutting injuries from the edges of the running material web. Never touch the edges of running material webs. ►...
  • Page 161 Operation Calibration template You need a calibration template for the calibration of the CCD camera. Standard calibration template Fig. 85: Standard calibration template * Other lengths on request The bar width and the hole width of the standard calibration template (order number 229 894) are each 10 mm. Width of hole Width of bar 10 mm...
  • Page 162 Operation Inserting the Calibration Template Before you start with the calibration, you have to insert the calibration template into the field of vision of the CCD camera and secure it in place (see figure). Fig. 88: Correct alignment of the calibration template ①...
  • Page 163 Operation CCD Camera Calibration The calibration of the CCD camera is carried out using a special setting menu. ›› The CCD camera is aligned precisely mechanically. The procedure for alignment is described in the operating manual of the CCD camera. ››...
  • Page 164 Operation During the calibration, the symbol of an hour glass appears in the display for approx. 30 seconds. Once the procedure has finished, the results of the calibration are displayed. Fig. 90: Display of the calibration results ① Number of contrast transitions detected ②...
  • Page 165 Operation 9.15.3 Material Thickness Compensation When Does the Material Thickness Compensation Have to Be Carried Out? In order to attain the optimum guiding / measuring results, we recommend that a material thickness compensation is carried out for thicker materials. This function can be used to compensate measurement errors that result from the material thickness.
  • Page 166 Operation 3. Determine the distance A of the camera housing to the upper edge of the calibration template. Application with CCD camera "CCDPro" Application with CCD camera "CCD CAM 100" Marking of the sensor level Definition of distance A: Definition of distance A: Distance from the lower edge of the camera housing Distance from the sensor level of the CCD camera to the upper edge of the calibration template...
  • Page 167 Operation 7. Set the material thickness determined using the arrow keys. 8. Press the ENTER key. The new value for the material thickness is saved. The following appears in the displayed: Fig. 94: Entry of the distance between the calibration template and material ①...

  • Page 168: Setting The Material Thickness (After Changing The Material)

    Operation 9.15.4 Setting the Material Thickness (After Changing the Material) This setting is necessary if you want to process materials with different thicknesses in the production. In order to attain optimum guiding / measurement results, after changing the material the new material thickness must be entered on the controller.

  • Page 169: Electronic Remote Precision Adjustment (Option)

    Operation 9.16 Electronic Remote Precision Adjustment (Option) As a result of the machine properties or the requirements of the production, it may be necessary to correct the position of the web away from the guiding device. The optional electronic remote precision adjustment devices EFE ...

  • Page 170: Extended Device Settings

    Operation 9.17 Extended Device Settings You have access to the extended device settings via the public parameter lists of the controller. You use the different parameters to adapt the behaviour of the controller to your individual application. 9.17.1 Editing the Parameter Value ››...
  • Page 171 Operation Fig. 98: Edit the parameter value ① Parameter designation ② Parameter index ③ Parameter value ④ Edit field 5. Select the desired parameter using the arrow keys. 6. Press the Sensor 3 key. An edit field for the parameter value appears in the display. 7.

  • Page 172: Public Parameters Lists

    Operation 9.17.2 Public Parameters Lists Parameter List 0 You can activate the special extra functions of the controller using the parameters of parameter list. Function Parameter Description Parameter Note Factory value setting Acceptance Automatic acceptance (OFF) deactivated (OFF) w-setup when activating the man->auto automatic operating Acceptance...
  • Page 173 Operation Function Parameter Description Parameter Note Factory value setting Automatic acceptance Line monitoring (OFF) (OFF) cls ref width of the line width when (with sensor by var activating the auto- CLS Pro 600) matic operating mode (ON) Adjustment of In automatic operating the guiding set- Adjustment of the mode:...
  • Page 174 Operation Parameter list 3 (WebWidthCalib) The parameters in this parameter list are used to determine the following basic settings for the operation of the controller with CCD camera: Definition of the bar and hole width of the calibration template ■ used Width of hole) Width of bar)

  • Page 175: Restoring Factory Default Settings

    Operation 9.18 Restoring Factory Default Settings When restoring the factory default settings, the values of all guiding parameters (e.g. controller gain, guiding set- point, bright / dark values of the sensors, etc.) are over- written by the factory default settings. Fig. 100: Rotary switch S1 on the process board Restoring factory default settings NOTICE...

  • Page 176: Remote Control (Digital Inputs / Outputs)

    Remote Control (Digital Inputs / Outputs) Remote Control (Digital Inputs / Outputs) 10.1 Safety Information WARNING Mortal danger from remote controlled movements of the actuator! When controlling the controller remotely from an external source (remote control inputs, external control keyboard), the actuator carries out adjusting movements automatically.

  • Page 177: Digital Outputs

    Remote Control (Digital Inputs / Outputs) 10.2.3 Truth Tables Digital inputs Function Terminal strip Terminal H10 H11 H12 Automatic — Manual operation — Centre position — Web edge guiding — Sensor 1 Web edge guiding — Sensor 2 Web center-line guiding —...

  • Page 178: Digital Inputs / Outputs Configuration

    Remote Control (Digital Inputs / Outputs) You can deactivate the remote control function using the DIL switch S5.5 in order to simplify commissioning (see Setting DIL Switch S5, page 82). 10.2.4 Digital Inputs / Outputs Configuration You configure the allocation of the digital inputs and outputs of the controller using the function tables.
  • Page 179 Remote Control (Digital Inputs / Outputs) Function tables 0 to 7 Function table 0 (Table 0), factory setting Inputs / No. Terminal Function outputs Automatic, Manual mode, Centre positioning Web edge guiding Sensor 1, Web edge guiding Sensor 2, Web centre-line guiding Sensor 1 and Sensor 2 Inputs Arrow key right, arrow key left Line / contrast guiding Sensor 3...
  • Page 180 Remote Control (Digital Inputs / Outputs) Function table 2 (Table 2) Inputs / No. Terminal Function outputs Automatic, Manual mode, Centre positioning Web edge guiding Sensor 1, Web edge guiding Sensor 2, Web centre-line guiding Sensor 1 and Sensor 2 Inputs Arrow key right, arrow key left Line / contrast guiding Sensor 3...
  • Page 181 Remote Control (Digital Inputs / Outputs) Function table 4 (Table 4) Inputs / No. Terminal Function outputs Automatic, Manual mode, Centre positioning Web edge guiding Sensor 1, Web edge guiding Sensor 2, Web centre-line guiding Sensor 1 and Sensor 2 Accept the current web position analogue Sensor 2 as guiding setpoint for analogue Sensor 1 or vice-versa Inputs...
  • Page 182 Remote Control (Digital Inputs / Outputs) Function table 5 (Table 5) Inputs / No. Terminal Function outputs Automatic, Manual mode, Centre positioning Web edge guiding Sensor 1, Web edge guiding Sensor 2, Web centre-line guiding Sensor 1 and Sensor 2 Inputs Arrow key right, arrow key left Line / contrast guiding Sensor 3...
  • Page 183 Remote Control (Digital Inputs / Outputs) Function table 7 (Table 7), from firmware version 1.5.8 Inputs / No. Terminal Function outputs Automatic, Manual mode, Centre positioning Web edge guiding Sensor 1, Web edge guiding Sensor 2, Web centre-line guiding Sensor 1 and Sensor 2 Inputs Arrow key right, arrow key left Line / contrast guiding Sensor 3...

  • Page 184: Remote Control With External Control Keyboard

    Remote Control (Digital Inputs / Outputs) 10.3 Remote Control With External Control Keyboard The external control keyboard efe  digital is equipped with the necessary operating and display elements in order to remote control the functions of the controller. See separate operating instructions External control keyboard efe digital, EDP no.

  • Page 185: Maintenance And Cleaning

    Risk of injury and material damage caused by incorrect main- tenance / cleaning! Have the maintenance and cleaning carried out only by ► qualified personnel that have been instructed by BST eltromat service personnel or authorized personnel. Carry out the maintenance and cleaning as described in the ►...

  • Page 186: Maintenance Table

    Maintenance and Cleaning 11.2 Maintenance Table The following table gives you an overview of the necessary main- tenance tasks and intervals. The maintenance intervals specified are reference values. With particularly intensive stress / soiling, the intervals must be reduced. Carry out the respective maintenance and cleaning as described in the following chapters.

  • Page 187: Cleaning The Edge Sensor Housing

    Maintenance and Cleaning 11.3.3 Cleaning the Edge Sensor Housing The edge sensors are maintenance-free. Cleaning the housing Clean using a dry, clean and soft cloth. ► Use a commercially available liquid cleaner in event of ► intensive soiling. Cleaning the measurement window (optical sensors) Clean carefully using a dry, clean and soft cloth (e.g.

  • Page 188: Troubleshooting

    Danger of death and material damage caused by incorrect troubleshooting! Have the troubleshooting carried out only by qualified personnel ► that have been instructed by BST eltromat service personnel or authorized personnel. Eliminate the fault only with the following measures stated or ►...
  • Page 189 Troubleshooting In operating mode Center positioning the actuator / the guiding device moves to an end position and remains stationary there. Reverse the guiding direction of the actuator. ► The actuator guiding direction is incorrectly set. See Setting the Guiding Direction, page 99. The servo center transducer used (OMG 4, OMG 8, Check the installation position of the servo ►...
  • Page 190 The external motor output stage Drive Module 160 Drive Module 160 and replace it if necessary. is defective. Contact BST customer services. ► The actuator / the guiding device has moved to an end position and the motor switch off does not function. The LEDs of keys on the control panel and the screen display flash.
  • Page 191 Troubleshooting An exclamation mark is shown in the sensor symbol of a digital edge sensor in the display. Check the cable connection between the ► controller and edge sensor. Malfunctions have occurred several times in the communication between the controller and a To delete the malfunction display switch off the ►...
  • Page 192 Troubleshooting The controller does not react to any operation. The warning symbol Faulty bus connection on the control panel is shown in the display. Check the cable connection between the ► controller and control panel. Fault in the bus connection between the controller Check the correct cable connection on terminal ►...
  • Page 193 Troubleshooting During line and contrast scanning using the CLS Pro 600 line and contrast sensor an exclamation mark is displayed in front of the symbol for Sensor 3. Check print for missing print. ► The printed line / contrast transition to be scanned Repeat the setup on sensor CLS Pro 600 (see the ►...

  • Page 194: Accessories And Spare Parts

    Accessories and Spare Parts Accessories and Spare Parts 13.1 Order Address BST eltromat International GmbH Heidsieker Heide 53 D-33739 Bielefeld Germany Tel.: +49 (0) 5206 999 767 Fax: +49 (0) 5206 999 0 E-Mail: service@bst-international.com http: www.bst-eltromat.com 13.2 Accessories Pos.

  • Page 195: Customer Services

    Customer Services Do you have any questions about this product? Or for any of the other products or services of BST eltromat International? Then please contact the following address. In order to be able to reply to your request as soon as possible,...

  • Page 196: Shutting Down And Disposal

    Also note the legal regulations as well as local recycling guidelines for this purpose. Returning the system to BST eltromat International GmbH is always possible. About this and for all other queries, please contact BST eltromat Customer Services, page 195. 196/204...

  • Page 197: Connection Diagram

    Connection Diagram Connection Diagram 16.1 Application with Edge Sensors Extension cable or spiral cable 0.5 m / 2 m (168 176) 2 m (131 993) 5 m (131 994) 10 m (131 995) ekr 500 digital Commander Connecting cable 3 m (118 447) 5 m (118 448) 10 m (118 449) ekr 500 digital...

  • Page 198: Application With Ccd Cameras

    Connection Diagram 16.2 Application with CCD Cameras 16.2.1 Application with CCD CAM 100 Extension cable or spiral cable 0.5 m / 2 m (168 176) 2 m (131 993) 5 m (131 994) 10 m (131 995) ekr 500 digital Commander Connecting cable 3 m (118 447)

  • Page 199: Application With Ccdpro 30000/5000

    Connection Diagram 16.2.2 Application with CCDPro 30000/5000 Extension cable or spiral cable 0.5 m / 2 m (168 176) 2 m (131 993) 5 m (131 994) 10 m (131 995) ekr 500 digital Commander Connecting cable 3 m (118 447) 5 m (118 448) 10 m (118 449) CAN bus distributor (167 205)

  • Page 200: Index

    ....  98 Connectable components....... 25 Connection cable .........  194 Connection cable .......... 194 maintenance ..........  187 Contacting BST International ...... 195 Position control..........  97 Contrast guiding.......... 22 Reverse the motor rotation direction..  82, 98 loss of the contrast transition to be scanned   122 select.............. ...
  • Page 201 Index installation positions........  48 Edge sensors maintenance ..........  186 installation position ........  26 message output SystemOK ......  33 maintenance ..........  187 output motor output stage......  32 Technical data ..........  37 power supply ..........  30 EFE 1000 ............ 169 Processor board ..........  67 EFE 1 ............. 169 protection category ........ ...
  • Page 202 Index select............  133 watchdog ............  22 Machinery Directive 2006/42/EC .... 10 web center-line guiding ......  22, 133 Magnet installation set ......... 194 web edge guiding...........  22 Guiding setpoint Maintenance Accept current position of the web edge as actuator ............  187 guiding setpoint........  138 CCD camera.......... ...
  • Page 203 Index Storage.............  8 Scope of delivery .......... 45 Operating mode Securing hole template Automatic ............  135 control panel..........  53 Center positioning........  135 controller ............  49 Manual mode..........  134 Sensor 1 select............  134 installation position ........  26 watchdog .............  146 Sensor 2 Operation display installation position ........ ...
  • Page 204 Index Target group ............. 8 Tear-off detection......... 153 Function ............  153 Use ...............  153 Technical data Edge sensors ..........  37 Sensors............  37 Technical specifications actuator ............  42 Ambient conditions........  30 control panel..........  35 power pack ............  36 Terminal assignment ........ 68 Terminal strips .......... 67 Terminating resistor ........ 87 control panel.......... ...

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Eltromat ekr 500 digital xt163 949163 428

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