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Summary of Contents for EVO 150

Page 1: ...P O Box 7816 Madison Wisconsin 53707 7816 Instruction Manual EVO 150 Web Guide Control System...

Page 2: ......

Page 3: ...een 17 Parameters 21 Appendix 1 Parameter Summary 37 Appendix 2 Parameters Download Upload 40 Appendix 3 Centerline Guiding with One Detector 41 Appendix 4 Super Centerline Guiding 42 Appendix 5 Fusio...

Page 4: ...p 84 Maintenance 84 Remote Station Guide Point Adjust 88 Introduction 89 Installation 89 Operation 90 Parameters 91 Keypad Lock 95 Troubleshooting 96 Remote Station Auxiliary 97 Introduction 98 Instal...

Page 5: ...of this manual match the first two digits of the version numbers displayed by your controller digital line guide or remote station If they do not match contact AccuWeb to obtain the correct manual Acc...

Page 6: ...EVO 150 Controller 4 EVO 150TM Web Guide Control System...

Page 7: ...able with gap widths ranging from 1 5 to 4 38mm to 102mm Fully compensated for temperature humidity dust and most other process contaminants Immune to passline variation and web flutter Suitable for l...

Page 8: ...inputs Potentiometer input for electronically adjustable limits Limit switch inputs for fixed limits Inhibit input Input voltage 24 DC 3 EVO 150 Enclosure Low profile Environmentally sealed function...

Page 9: ...ith a remote PLC or computer through a fieldbus network Compatible with many fieldbus protocols including Ethernet IP PROFINET Modbus TCP IP Provides control of operating mode guide point position and...

Page 10: ...slightly on the ball rod ends to accommodate minor actuator mounting misalignment Note Motor contains no temperature sensing device to protect motor from excessive temperature due to failure to start...

Page 11: ...utton e Jog the IN button repeatedly until the actuator automatically stops at its end of travel limit Caution If the actuator or web guide mechanism hits a mechanical obstruction before the actuator...

Page 12: ...observe how the guide reacts The guide should move the web so that it follows or chases the movement of the sensor Edge detector The guide should move the web so that the edge of the web is always al...

Page 13: ...button Place detector B near the opposite edge of the web Move detector B towards the web until its null indicator LED turns off Note The scribed lines on the edge detector indicate the approximate lo...

Page 14: ...o Center mode Check items 20 21 and 22 in the table below While in Automatic mode the web guide or actuator moves too fast or slow in response to large changes in the position of the edge of the web s...

Page 15: ...go out and the EDGE A or EDGE B LED will blink indicating the polarity change 7 Servo gain is too high Decrease the value of parameter 5 Refer to page 21 for more information about setting controller...

Page 16: ...ator or return the actuator for repair 18 Actuators with limit switches MX Limit switch failure The end of travel limit switches in the MX series actuators directly control the motor circuit and canno...

Page 17: ...outputs The controller s main features include the following Compatible with all ultrasonic and infrared PointSource and WideArray edge detectors and AccuBeam 3 digital line guide These sensors are de...

Page 18: ...9 do not use 192 168 0 5 On most Windows based systems the TCP IP settings can be modified by navigating to the Windows Control Panel selecting the Network Connections icon right clicking on the netw...

Page 19: ...is located on the lower left corner of the navigation bar that is located at the bottom of every screen When the wrench icon is pressed the Settings screen appears From left to right the Settings scre...

Page 20: ...be adjusted via the arrow buttons located to the left and right of each parameter s respective indicator bar 2 The Edge Detector Settings button allows selection of the edge detector model being used...

Page 21: ...ally the center of stroke of the linear actuator The Out Limit sets the maximum distance that the actuator can move OUT extend The Current Position box displays the current position of the actuator Th...

Page 22: ...to the positive option the actuator will move out when edge detector A is blocked This is the default setting Note For typical center line guiding applications the Edge Polarities are set opposite to...

Page 23: ...accept the change To leave the data value at its original value press Exit button Note The Enter button must be pressed in order for a change in a parameter s value to be saved in the controller The...

Page 24: ...t is to the left of the line or edge it is following 4 1 The actuator will move Out when edge detector B is blocked or the digital line guide s sight point is to the right of the line or edge it is fo...

Page 25: ...Actuator Settings Screen button Out End of Travel Limit 1 0 1 8 9 This parameter works only with actuators that have potentiometer feedback TA MTB SFB MT SF HF and MA It sets the maximum distance that...

Page 26: ...eadband is a zone around the sensor guide point that the web edge or line must enter before the motor drive is turned off Once the web edge or line position enters this zone it must then move outside...

Page 27: ...area of a WideArray detector change parameter 77 Range 2 to 128 Note This value is set by the Setting Screen Edge Detector Settings button Actuator Position Display This parameter displays the positi...

Page 28: ...will be selected All inputs are momentary 2 7 7 The system will power up in Manual mode and Line Input C will be selected All inputs are momentary 2 7 8 The system will power up in Manual mode and Ed...

Page 29: ...switchpad LEDs and edge detector null indicator LEDs are enabled In this mode each edge detector null LED indicates the position of the web sensed by that detector alone and both null LEDs are always...

Page 30: ...ameter 5 Auto Mode Speed Limit is controlled by parameter 7 This is the default setting 4 8 1 Servo Gain and Auto Mode Speed Limit are controlled by the optional Fieldbus Interface see page 103 Input...

Page 31: ...o the current web position This is typically done only during job set up when the system is in Manual or Servo Center mode Note To reset Offset 1 to its default value select parameter 60 then press th...

Page 32: ...tor Note This value is set by the Setting Screen Edge Detector Settings button Sensor B Type 5 6 0 Sensor B is an ultrasonic edge detector This is the default setting 5 6 1 Sensor B is an IR edge dete...

Page 33: ...dicate that the web is not at the downstream guide point 6 3 3 This mode is used for dampening the response of the slave guide in chaser slave systems The chaser sensors are connected to Integrator In...

Page 34: ...grator output will change at a rate of 0 2 inches per second The default value is 01 Range 001 to 255 Integrator Limit 6 9 1 0 0 This parameter sets the maximum rate that the integrator output can cha...

Page 35: ...Beam 1 is located at the end of the transducer closest to the pigtail wiring 7 4 1 Beam 1 is located at the end of the transducer farthest from the pigtail wiring Sensor B Transducer Orientation This...

Page 36: ...t swapped 7 8 1 This is the default setting The data bytes are swapped Parameters 79 through 83 have not yet been implemented Maximum Motor Current 8 3 1 5 This parameter is used to adjust the availab...

Page 37: ...s 4th Octet 8 9 8 This parameter sets the 4th Octet of the controller boards IP Address The default value is 8 Range 0 to 255 Note This is not the address for the fieldbus see page 103 Web Server Subn...

Page 38: ...ote This is not the gateway for the fieldbus see page 103 Web Server Gateway 3rd Octet 9 6 2 5 5 This parameter sets the 3rd Octet of the controller boards Web Server Gateway The default value is 0 Ra...

Page 39: ...ignal level see note 1 16 Edge detector A transmit level see note 1 17 Edge detector B transmit level see note 1 18 Minimum deadband 0 100 5 19 INHIBIT input mode 0 3 1 20 Calibrate edge detector A se...

Page 40: ...t used see note 1 52 AUXILIARY input function 0 14 0 53 Oscillation minimum speed not used 54 not used not used 55 Sensor A type 0 1 0 56 Sensor B type 0 1 0 57 not used not used 58 not used not used...

Page 41: ...it 0 1 0 86 Web Server IP Address 1st Octet 0 255 192 87 Web Server IP Address 2nd Octet 0 255 168 88 Web Server IP Address 3rd Octet 0 255 0 89 Web Server IP Address 4th Octet 0 255 8 90 Web Server S...

Page 42: ...rs Download Upload screen also enables the end user to upload the parameters from the controller and save them to a file The Parameters Download Upload screen is used to set all of the parameters on t...

Page 43: ...edge detector This feature can be used for applications that do not allow for standard centerline guiding with two edge detectors To select Centerline Guiding with One Detector set parameter 98 to a v...

Page 44: ...overlay for Super Centerline Guiding 1 Calibrate the edge detectors see page 57 2 Insert a narrow material 1 25 4mm to 4 101 6mm wide into the edge detector array 3 Slowly less than one inch per seco...

Page 45: ...the controller The most likely causes are Parameter 2 is set to the wrong value Refer to page 21 for more information about setting controller parameters The actuator cable is disconnected or has loo...

Page 46: ...ne aligned with the fixed guide point When the oscillation function is turned on the guide point moves at a programmed speed over a programmed travel distance The system moves the web continuously to...

Page 47: ...ies actuators Oscillation Total Travel 3 2 7 5 0 This parameter sets the guide point s range of travel distance This range is symmetrical around the system s fixed guide point The position of the fixe...

Page 48: ...be inactive Note The INHIBIT input is not opto isolated If your application requires an opto isolated INHIBIT input then set parameter 72 to 1 Refer to page 21 for more information about setting contr...

Page 49: ...es a non isolated AUXILIARY input then set parameter 72 to 1 Refer to page 21 for more information about setting controller parameters Electrical Specifications PLC I O Board Inputs per input On state...

Page 50: ...n about setting controller parameters The control inputs are either maintained or momentary depending on the setting of parameter 27 In the maintained mode deactivating all inputs will cause the actua...

Page 51: ...T 7 x x Select Manual mode and Out mode move actuator out EDGE A 3 selects AUTO mode x Select Input A other function x Select Input A and Automatic mode EDGE B 4 selects AUTO mode x Select Input B oth...

Page 52: ...s off during normal operation AUTO MODE 5 This output is on when the controller is operating in Automatic mode and is off during all other modes of operation NO FAULT 6 This output is on when the cont...

Page 53: ...ler board straighten any bent pins 6 Align the socket on the underside of the Serial I O board with header P2 on the controller board 7 Push the Serial I O board firmly onto header P2 8 Secure the Ser...

Page 54: ...he Remote Station or web browser To configure the EVO 150 system for chaser follower operation set the controller parameters as shown in the table below Refer to page 21 for more information about set...

Page 55: ...53 66 Integrator input 1 polarity 0 1 0 0 67 Integrator input 2 polarity 0 1 0 1 68 Integrator rate 001 255 010 100 69 Integrator rate limit 01 1 00 1 00 1 00 1 Refer to page 56 for more information...

Page 56: ...PointSource and WideArray Edge Detectors 54 PointSource and WideArray Edge Detectors...

Page 57: ...with sensing areas ranging from 0 2 to 18 6 wide 5mm to 472mm Available with gap widths ranging from 1 5 to 4 38mm to 102mm Fully compensated for temperature humidity dust and most other process conta...

Page 58: ...36 1 2 30 1 10 1 0 1 5x5U 4511 XX 2 6 66 2 4 61 1 16 0 0 4x5U 4500 XX 2 6 66 2 4 61 1 16 1 0 1 5x9U 4524 XX 6 6 168 6 4 163 1 36 0 0 4x9U 4520 XX 6 6 168 6 4 163 1 36 1 0 4x14U 4530 XX 11 4 290 11 2...

Page 59: ...calibrated individually The calibration is performed by accessing the edge detector setting button on the Setting Screen see page 17 The Detector Settings screen is where the applicable edge detector...

Page 60: ...Beam box will count down to 1 Then the Lowest Beam box will show a number between 100 and 204 3 Place the web material that is being calibrated in the detector gap and completely cover the transducer...

Page 61: ...etectors For best performance clean the black optical windows if they become dusty or dirty Use a clean soft non abrasive cloth dampened with a mild soap solution or a cleaning solution suitable for c...

Page 62: ...AccuBeam 3 Digital Line Guide Sensor 60 AccuBeam 3 Digital Line Guide Sensor...

Page 63: ...controllers and remote station MICRO 1000 MICRO 4000 NET or EVO 150 Controllers The Digital Line Guide requires an interface cable to connect to these controllers Cables are available in standard leng...

Page 64: ...ows on the switchpad select the Calibrate parameter 5 Rotate the backup roller and or move the sensor laterally until the test pattern is approximately centered under the sensor 6 Press the ENTER key...

Page 65: ...to the format described above A c c u B e a m 3 D L G x x x x Front panel keys The front panel keys are defined as follows UP DOWN ENTER To select a parameter press the ENTER key until the cursor is i...

Page 66: ...sor s graphic display and that the guide point indicator a dot is located under the line or edge you want to track If the pattern or guide point indicator is not visible perform the auto calibration r...

Page 67: ...ch line or edge the sensor should track This feature is particularly useful if there are multiple lines or edges in the sensor s field of view 4 Move the selection window over the line or edge you wan...

Page 68: ...just the selection window if there is only one line in the sensor s field of view and the sensor has been centered over it d As you adjust the window size and position the sensor will continuously ana...

Page 69: ...d Max Right are both set to 127 These parameters define the maximum widths of the white areas adjacent to the registration line Setting them to 127 removes any restriction on the maximum width of thes...

Page 70: ...not be necessary to adjust the selection window if there is only one edge in the sensor s field of view and the sensor has been centered over it d As you adjust the window size and position the senso...

Page 71: ...s step Setting them to 127 removes any restriction on the maximum width of these areas so either one could extend beyond the edge of the sensor s field of view e Max Center and Min Center are set to t...

Page 72: ...hin its field of view Edge Patterns Edge patterns are defined by two regions The Left region is the area located to the left of the edge to be tracked and the Right region is the area located to the r...

Page 73: ...instantly recalled The Digital Line Guide s parameters are described below Job Profile J O b P r o f i l e 1 The Digital Line Guide can store up to 25 unique parameter configurations called job profil...

Page 74: ...ing Parameter L E D A n g l e D i f f Diffuse Use this setting for materials with a dull non glossy finish This is the default value L E D A n g l e R e f l Reflective Use this setting for highly refl...

Page 75: ...rection Tracking Parameter S C a n D i r R t o L Right to Left Scan the pattern from right to left The sensor will evaluate objects in its field of view beginning with those on the far right This is t...

Page 76: ...fault value is 0 Range 0 to 127 pixels Note A setting of 0 disables this Min Max rule Note A pixel is equivalent to 0 0049 0 124mm Maximum Right Tracking Parameter M a x R i g h t 1 2 7 This parameter...

Page 77: ...irst when the Digital Line Guide is powered up Refer to the table below for the numeric code that corresponds to each parameter The default value is 18 Job Profile Range 0 to 18 Parameter Start Up Val...

Page 78: ...0 0000 0000 1111 This pattern hides the Offset Backlight Hidden Read Only and Start Up parameters Range 0 to FFFFF Read Only R e a d O n l y 0 This parameter can be configured to prevent accidental or...

Page 79: ...Hexadecimal hex conversion Bit field Hex digit 0 0 0 0 0 0 0 0 1 1 0 0 1 0 2 0 0 1 1 3 0 1 0 0 4 0 1 0 1 5 0 1 1 0 6 0 1 1 1 7 1 0 0 0 8 1 0 0 1 9 1 0 1 0 A 1 0 1 1 B 1 1 0 0 C 1 1 0 1 D 1 1 1 0 E 1...

Page 80: ...parameters are activated The Hidden parameter hides unused parameters if a parameter is Hidden it cannot be selected or displayed and the Read Only parameter prevents changes to parameters if a param...

Page 81: ...item 5 in the table below Item Description Repair Procedure 1 Bad cable connection If the display is not working check the interface cable and replace if bad 2 Keypad is disabled Refer to page 78 for...

Page 82: ...0 Maintenance For best performance clean the optical window on the underside of the unit if it becomes dusty or dirty Use a clean soft non abrasive cloth dampened with a mild soap solution or a cleani...

Page 83: ...0 0 000 Calibrate LED Color Blue Red Green Blue LED Angle Diff Refl Side Diff Filter 4 8 16 4 Threshold 1 to 127 4 Pattern Lt Dk Lt Dk Lt Dk Lt Dk Dk Lt Lt Dk Lt Scan Dir L to R R to L L to R Max Left...

Page 84: ...Digital Line Guide Sensor 82 Appendix 2 Line Guide Test Pattern Use this test pattern to verify the proper installation and operation of the Digital Line Guide Test pattern Web direction Sensor cable...

Page 85: ...AccuWeb Linear Actuators 83 AccuWeb Linear Actuators...

Page 86: ...o be changed in order to prevent mechanical jamming of the actuator or guide mechanism Use the following table to set the initial values of the In Limit Out Limit and Servo Center Position parameters...

Page 87: ...F and HF LUBRICATION 1 Remove the actuator from the machine 2 Extend the actuator to its Out end of travel limit 3 Remove the three Allen nuts and end cap Be careful not to damage the rubber seal 4 Re...

Page 88: ...minals of the new potentiometer as the old potentiometer 7 Install the new potentiometer onto the mounting bracket and reinstall the worm gear on the potentiometer shaft 8 Turn the potentiometer to it...

Page 89: ...NUAL button then press the OUT button to drive the actuator to its Out limit 2 Remove the actuator from the positive displacement guide PDG 3 Gain access to the lead screw through the top of the actua...

Page 90: ...Remote Station Guide Point Adjust 88 Remote Station Guide Point Adjust...

Page 91: ...Point Adjust Remote Station also requires a Serial I O board AUX 4249 to connect to the EVO 150 Controller Note The Remote Station guide Point Adjust cannot be used on EVO 150 controllers with the fi...

Page 92: ...l page 91 At power up a software identification message is displayed for several seconds then the display reverts to the format described above R e m o t e S t a t i o n R M T 0 3 G P x x x x Front pa...

Page 93: ...other parameters as needed To recall a job profile select the profile number Note When AC power is turned on the system will automatically reload the job profile that was selected and in use when AC...

Page 94: ...ode is 0 1 millimeter The default value is ENGLISH U n i t s M E T R I C Backlight B a c k l i g h t O N This parameter controls the LCD display backlight The default value is on B a c k l i g h t O F...

Page 95: ...10 1111 This pattern hides the Offset 2 Backlight Hidden Read Only and Start Up parameters Range 0 to FFFFF Read Only R e a d O n l y 0 This parameter can be configured to prevent accidental or unauth...

Page 96: ...xadecimal hex conversion Bit field Hex digit 0 0 0 0 0 0 0 0 1 1 0 0 1 0 2 0 0 1 1 3 0 1 0 0 4 0 1 0 1 5 0 1 1 0 6 0 1 1 1 7 1 0 0 0 8 1 0 0 1 9 1 0 1 0 A 1 0 1 1 B 1 1 0 0 C 1 1 0 1 D 1 1 1 0 E 1 1 1...

Page 97: ...rameters are activated The Hidden parameter hides unused parameters if a parameter is Hidden it cannot be selected or displayed and the Read Only parameter prevents changes to parameters if a paramete...

Page 98: ...The system does not respond to parameter changes entered through the Remote Station keypad Check item 1 in the table below The display shows EEPROM error Set defaults Check item 3 in the table below...

Page 99: ...Remote Station Auxiliary 97 Remote Station Auxiliary...

Page 100: ...board AUX 4249 to connect to the EVO 150 Controller AccuBeam 3 Digital Line Guide Sensor The Auxiliary Remote Station requires an interface cable and T box assembly CON 1000 to connect to the Digital...

Page 101: ...tification message is displayed for several seconds R e m o t e S t a t i o n R M T 0 3 A R x x x x After a delay of several seconds the Auxiliary Remote Station will then mirror the other remote stat...

Page 102: ...ters are activated The Hidden parameter hides unused parameters if a parameter is Hidden it cannot be selected or displayed and the Read Only parameter prevents changes to parameters if a parameter is...

Page 103: ...ure 1 Bad cable connection If the display is not working check the interface cable and replace if bad 2 Keypad is disabled Refer to page 100 for more information about this feature 3 Non volatile memo...

Page 104: ...Fieldbus Interface 102 Fieldbus Interface...

Page 105: ...ion Utility and example Module Properties configuration Installation To install the Fieldbus interface card in the EVO 150 controller follow the steps below 1 Field installation of the Fieldbus interf...

Page 106: ...only be one Fieldbus master per network Fieldbus Slave The unit that receives commands over the Fieldbus network from the master This unit responds to commands when requested by the master There may...

Page 107: ...ector Fusion Mode Super Center line Normal Mode Osc Auxiliary Input Null Indicator 1 2 Guide Point Offset Lower byte 0 255 0 FFh 3 Upper byte 0 255 0 FFh 2 4 Servo Gain Lower byte 0 40 0 28h 5 Upper b...

Page 108: ...Servo Center mode move actuator to Servo Center position 0 No change 5 Manual 1 Select Manual mode stop actuator 0 No change 4 In 1 Select Manual mode and In mode move actuator in 0 No change 3 Out 1...

Page 109: ...parameter 52 Refer to page 19 for more information about setting controller parameters 0 Activate the AUXILIARY input 0 Null Indicator 1 Use the default value of parameter 35 to control the switchpad...

Page 110: ...rmed 4 0 40 0 28h Sets parameter 5 Servo Gain to this 8 bit value To use this feature parameter 48 Servo Gain and Speed Limit Source must be set to 1 Refer to page 19 for more information about settin...

Page 111: ...ine 1 Auto Servo Center Manual In Out Input A Input B Input C 1 2 Actuator Position Lower byte 0 255 0 FFh 3 Upper byte 0 255 0 FFh 2 4 Edge A Position Lower byte 0 255 0 FFh 5 Upper byte 0 255 0 FFh...

Page 112: ...e inhibit input is not asserted 3 No Fault 1 The controller is operating correctly There are no operating faults 0 The controller is not operating correctly Refer to page 23 for more information about...

Page 113: ...Input A is selected 0 This mode not selected 1 Input B 1 Input B is selected 0 This mode not selected 0 Centerline 2 detectors 1 Centerline mode 2 detectors is selected 0 This mode not selected Input...

Page 114: ...Bytes 6 and 7 Edge B Position Byte Value Status Indicated 6 Lower byte 0 255 0 FFh This 16 bit value indicates the current position of the web in sensor B Refer to Table 1 on page 59 for the range of...

Page 115: ...U 4530 XX 11 200 284 48 10784 2A20 21984 55E0 11 400 289 56 10684 29BC 22084 5644 4x21U 4540 XX 18 400 467 36 7184 1C10 25584 63F0 18 600 472 44 7084 1BAC 25684 6454 PointSource Infrared E D 1 5x3L 40...

Page 116: ...rk to indicate the center of their sensing areas WideArray detectors have two scribe marks to indicate the boundaries of their sensing areas and the center of their sensing areas is the point exactly...

Page 117: ...Ethernet networks in the world and is widely used in a variety of industries The IP address subnet mask default gateway hostname and BOOTP enable disable option of the EtherNet IP card can be configur...

Page 118: ...nsumer model Every module within a PROFINET network has three addresses An IP address a MAC address and a station name The IP address subnet mask default gateway and station name of the PROFINET IO ca...

Page 119: ...120 deg F 48 9 deg C Humidity 0 90 non condensing Modbus is a simple networking protocol that allows for control and data transfer between two industrial devices The Modbus TCP uses Ethernet Modbus TC...

Page 120: ...electronic components are secured for shipping If you are returning mechanical equipment make sure all clamps and spreaders are re installed If you are returning electronic equipment make sure all cir...

Page 121: ...eller s plant and shall carry a minimum 30 restocking charge This is required because of the continued modification and redesign of standard components and parts e Fabricated items such as positive di...

Page 122: ...m an accident misuse or abnormal condition of operation NO other warranty is expressed or implied including warranties or merchantability and fitness for any particular purpose We are not liable for i...

Page 123: ...cation drawing AC 6844 This application drawing shows the Digital Line Guide mounting hole pattern 8 Application drawing for various PDG web paths C 7634 This drawing shows the different web path conf...

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