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BST ekr 500 Operating Manual Download Page 8

 

Description

 

1 

12

 

ekr 500 web guiding controller 

EDV No.:  MD.299.01.06 

Chapter:  1 

with removable control panel 

Date: 

29.07.08 

Page: 

4/86 

1.4 System 

description 

 

1.4.1 System structure 

 

1.4.1.1 General 

The 

ekr 500

 consists of the controller and the removable control 

panel. 
 
The controller enclosure contains all of the control electronics and 
the connections for all of the necessary web guiding components 
(sensors, actuator, servo center transducer, remote control). 
 
 

1.4.1.2  Controller with mounted 

control panel 

Controller operation is carried out via the control panel

 

that was 

attached to the front of the controller in the factory. 
 
 
 
 
 
 
 
 
 
 

Controller with mounted control panel 

 
 

1.4.1.3  Controller with removed 

control panel 

If the installation requires a remote mounting of the control panel 
due to space or access limits in the machine, it can be removed 
und remotely mounted in the machine operator control station. 

 

In this case the connection between the controller and control 
panel is made using a cable extension that is available as an 
optional extra. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Controller with removed control panel 

 
 

The length of the cable used to connect the control 
panel to the controller must never exceed 20 m. 

Cable extension 

(2 m, 5 m, 10 m) 

Controller

 

Control panel

 

Summary of Contents for ekr 500

Page 1: ...al BST International GmbH Heidsieker Heide 53 33739 Bielefeld Germany Phone 49 5206 999 0 Telefax 49 5206 999 999 E Mail info bst international com The information and drawings contained in this document are the property of BST International GmbH Any reproduction of this document as a whole or in part without the written permission of BST International GmbH is prohibited ...

Page 2: ...13 2 1 2 Protection class 13 2 1 3 Power supply terminal strip X6 13 2 1 4 Analogue inputs terminal strip X1 X2 X3 13 2 1 5 Digital inputs terminal strip X14 14 2 1 6 Ouput motor output stage terminal strip X7 14 2 1 7 Output fault relay terminal strip X10 14 2 1 8 Control panel interface terminal strip X8 15 2 1 9 Weight dimensions 15 2 2 Control panel 16 2 2 1 Ambient conditions 16 2 2 2 Protect...

Page 3: ...ote control 43 6 Start up 44 6 1 Start up actuator 44 6 1 1 General 44 6 1 2 Determine sense of motor rotation 45 6 1 3 Determine guiding direction 45 6 1 4 Actuator without position feedback EMS 5 10 16 46 6 1 5 Actuator with position feedback EMS 17 EMS 21 EMS 22 48 6 2 Carry out material setup 52 6 3 Adjustment of gain 53 6 4 Start up electronic remote precision adjustment option 54 7 Operation...

Page 4: ...address of the control panel 76 9 2 Keyboard bus terminating resistors 77 9 2 1 Controller terminating resistor 77 9 2 2 Control panel terminating resistor 78 9 3 Generating the default settings 79 10 Trouble shooting 80 11 Maintenance 84 11 1 General 84 11 2 Controller 84 11 3 Control panel 84 11 4 Sensors 85 11 5 Electric motor driven actuator 85 12 Decommissioning 86 I Index A1 Annex 1 A1 Conne...

Page 5: ... by this type of warning without fail in order to protect yourself as the operator from life threatening injuries caused by electrical voltages Note This symbol is used to point out additional useful tips which will help you to make optimum use of all of the functions 1 1 2 Using the keys Using the keys is represented by the following symbols in this manual Press key Key combinations keys have to ...

Page 6: ...ust be observed by all persons working on or with the ekr 500 controller Before operating the system for the first time as well as before carrying out maintenance work you must read the safety information provided by chapter 1 7 of this manual Changing or loading firmware on this system must be carried out exclusively by BST personnel or personnel duely authorised to do so by BST Non observance of...

Page 7: ... listed in chapter 1 4 3 Connectable components BST web guiding systems have been designed and built in accordance with state of the art standards and the recognized safety rules Nevertheless its use may constitute a risk to life and limb of the user or of third parties or damage the BST web guiding systems and other equipment Therefore BST web guiding systems are only to be used if they are worki...

Page 8: ...ration is carried out via the control panel that was attached to the front of the controller in the factory Controller with mounted control panel 1 4 1 3 Controller with removed control panel If the installation requires a remote mounting of the control panel due to space or access limits in the machine it can be removed und remotely mounted in the machine operator control station In this case the...

Page 9: ...er transmits a correction signal to the actuator of the guiding device The actuator moves the guiding device rotating frame guide or swivel roll guide until the web of material is in its set position again 1 4 3 Connectable components The picture shows the components that can be connected to the controller Controller ekr 500 Actuator without position feedback Actuator with position feedback EMS 5 ...

Page 10: ...be marked on the control panel display by a white triangle being superimposed around the sensor symbol The relative coverage of the sensor scanning area will be displayed as a percentage beneath the sensor symbol Examples 0 covering No material within the sensor scanning area 50 covering Only one half of the sensor scanning area is covered 100 covering Sensor scanning area is fully covered Deviati...

Page 11: ...eb edge The following is valid in respect of the sensor mounting positions The sensor which is located to the left of the material in the web running direction when looking from the material top side is sensor 1 The material top side is the side of the material web which is not in direct contact with the deflection pulleys of the guiding device Example 1 Example 2 Example 3 As standard sensor 1 mu...

Page 12: ...ay The different operating statuses and all the relevant control parameters are displayed on the control panel s graphics display during operation The symbol significances are described in chapter 7 1 1 6 2 Control panel Located on the control panel are four different key groups that have the following functions Green keys Operating mode selection Grey keys Guiding mode selection Blue keys Setup m...

Page 13: ...b edge Sensor 2 Guiding to the right web edge Guiding mode selection Web center line guiding Manual positioning of the guiding device Arrow key left right Operating mode Manual Manual positioning of the guiding device to the left right Shifting of the guiding setpoint Arrow key left right Operating mode Automatic Shifting of the guiding setpoint to the left right SETUP Operating mode Manual Call u...

Page 14: ...ant building components causing the restrictions must be padded and a danger warning signs must be attached to them yellow black As a matter of course cable connectors e g between controller and sensors should only be disconnected when the system is no longer connected to the mains supply mains plug has been removed Any infringements will result in the warranty claim being invalidated In principle...

Page 15: ...ys carry out the following measures 1 Switch off 2 Prevent switching back on 3 Check the equipment is isolated 4 Earth 5 Cover or shield any adjacent parts that are still live Only then you can carry out the relevant work Please do not use the guiding frame as a tread or a Stepp ladder Do not remove any safety devices Positioning movements will be undertaken by the actuator during functional testi...

Page 16: ...st be taken to ensure that electrostatic charges are carefully discharged If making return shipments of electronic components or assemblies regulations in accordance with DIN EN 100 015 Protection of electrostatically endangered components must be observed You should therefore only use the electrically conductive ESD packaging provided for transport and label it correctly BST International GmbH is...

Page 17: ... ripple Power consumption max 4 A including actuator Connection plugged in from the outside using a 3 pin plug as per CEN 175301 803 DIN 43650 2 1 4 Analogue inputs terminal strip X1 X2 X3 Sensors terminal strip X1 X2 Signal input sensor 1 2 0 10 V 10 V or 0 20 mA selectable via DIL switch Power supply 12 V 5 50 mA 12 V 50 mA 12 V 24 V DC max Σ 0 5 A IR pulses for IR 2001 IR 2002 IR 2005 5 V lengt...

Page 18: ...itched via the hardware i e not via the processor or the software Galvanic isolation none Connection internal on cage clamp 2 1 6 Ouput motor output stage terminal strip X7 Voltage 24 V DC reduces the actuator s maximum actuating force if a lower supply voltage is used Power consumption max 1 2 A peak current 4 A Protection Automatic electric switching off after approx 400 ms if overcurrent occurs...

Page 19: ... interface terminal strip X8 Voltage 24 V DC corresponds to the supply voltage Power consumption max 0 5 A protected by Polyfuse Bus interface 500 kBaud no galvanic isolation Connection plugged in from the outside using a 4 pin micro style M8 connector 2 1 9 Weight dimensions Weight approx 1 18 kg controller without control panel Dimensions See page 17 ...

Page 20: ...10 C 70 C Air humidity in operation 5 90 without condensing Protection class IP 54 2 2 2 Protection class Protection class IP 50 If the controller is installed with mounted control panel the whole unit is classed as protection class IP 54 2 2 3 Power supply Voltage 24 V DC power supplied by the controller 2 2 4 Display Resolution 128 x 64 pixel LED background illumination 2 2 5 Weight dimensions W...

Page 21: ...9 01 06 Chapter 2 with removable control panel Date 29 07 08 Page 17 86 Dimensions details in mm Controller with mounted control panel Controller without control panel Control panel 45 61 6 182 130 169 6 182 130 169 6 45 61 6 182 130 169 6 45 55 93 105 93 105 6 21 ...

Page 22: ... mm 15 mm Output analogue Protection class IP 54 Ambient conditions Temperature Air humidity 0 to a max 45 C 5 90 no condensation 2 3 2 Ultrasonic sensors US 2003 US 2007 US 2008 US 2009 Power supply from the controller Gap standard 30 mm 40 mm 30 mm 40 mm 70 mm Measuring range typical 12 mm 12 mm 6 mm 12 mm 14 mm Max sensing range typical 15 mm 15 mm 7 mm 13 mm 15 mm Output analogue Protection cl...

Page 23: ...tuating force N Max actuating speed mm s 20 EMS 5 40 1 1 8 x 1 80 17 16 32 46 56 76 96 EMS 10 146 1 1 12 x 2 420 20 2 4 1 420 20 50 5 1 840 10 2 4 1 420 20 100 5 1 840 10 2 4 1 420 20 EMS 16 200 5 1 16 x 5 840 10 2 4 1 420 20 50 5 1 840 10 2 4 1 420 20 100 5 1 840 10 2 4 1 420 20 EMS 17 200 5 1 16 x 5 840 10 2 5 1 840 20 100 5 1 1680 10 2 5 1 840 20 EMS 21 200 5 1 20 x 5 1680 10 200 2 5 1 1125 20 ...

Page 24: ...ly the following power packs may be used Power pack supplied by Puls GmbH type ML100 100 BST order number 103 837 or Power packs with the following specifications Output voltage 24 V DC max 10 including ripple Output power max 100 W The power packs must meet all requirements of IEC 61010 1 for energy limited circuits section 9 3 If used in countries which have defined discrepancies from IEC 61010 ...

Page 25: ...s in standard cardboard boxes with cellular lining material The unit must only be transported when it is packed in the original BST transport packing BST International GmbH cannot be held liable for damage to the controller or control panel which is caused by an inappropriate transport packaging 3 2 Storage If the controller and the control panel will not be incorporated immediately they should be...

Page 26: ... sources must not cause reflections on the display The controller and the control panel must be installed on a vertical surface upright Installation on a horizontal surface horizontal is not permitted Upright installation Horizontal installation not permitted Strong electromagnetic fields in the vicinity of the controller the control panel or the sensors might cause operating failures Take note of...

Page 27: ... General This chapter describes the procedure for installing a controller with a mounted control panel 4 2 2 Mounting plan 4 2 3 Space needed to open the enclosure cover The necessary space around the enclosure must be maintained so that the enclosure cover can be fully opened see illustration 182 169 130 45 Controller housing M5 or Ø 6 Controller Enclosure cover ...

Page 28: ...en the cover carefully 3 Screw on the enclosure using two securing screws M5 hexagon socket screws 4 Wire in the electric cables if required or plug in the necessary cable connections see chapter 5 Take note of the EMC wiring instructions see chapter 5 3 5 Close the enclosure cover and screw it in place 6 If necessary you can position the control panel so that it is aligned with the controller ins...

Page 29: ... must be moved accordingly The relevant procedure is described in the following 1 Unscrew the four control panel securing screws 2 Pull the control panel carefully away from the front of the controller 3 Turn the control panel into the required position see illustration above 4 Feed the connecting cable into the new installation position on the back of the control panel There are four recesses in ...

Page 30: ...n versions The control panel enclosure enables the following installations versions to be used 1 Wall mounting Mount the control panel on a level surface See chapter 4 3 2 for the procedure 2 Control console mounting Mount the control panel in an existing on site control console or a control station See chapter 4 3 3 for the procedure The ekr 500 installation kit available as an option is required...

Page 31: ...ovable control panel Date 29 07 08 Page 27 86 4 3 2 Wall mounting 4 3 2 1 Mounting plan 4 3 2 2 Installation 1 Unplug the connecting cable connection from the control panel on the controller plug X100 Control panel connecting cable Plug X100 93 105 93 105 Control panel housing 4x M3 ...

Page 32: ...he plug carefully through the hole in the controller enclosure 4 Drill and thread the M3 holes as per the mounting plan see chapter 4 3 2 1 5 Use the four M3 screws to screw the control panel on The four hexagon screws that secured the control panel to the controller when the unit was delivered can be used for this 6 Fit the extension cable option to connect the control panel to the controller see...

Page 33: ...sole mounting 4 3 3 1 Installation cut out 4 3 3 2 Installation The optional installation kit is needed for the control console mounting BST order number 133 459 see chapter 4 3 1 1 1 Unplug the connecting cable connection from the control panel on the controller plug X100 101 1 101 1 Installation cut out Control panel connection cable Plug X100 ...

Page 34: ...panel into the cut out section 6 Use the two screws to screw the two securing plates part of the installation kit onto the back of the control panel The four hexagon screws that secured the control panel to the controller when the unit was delivered can be used for this 7 Screw the four threaded pins into the securing plates until the control panel is held in place firmly 8 Fit the extension cable...

Page 35: ...f the wiring sleeve must have a length of at least 8 mm Using cable without wiring sleeves For fine and multi core cable and for fine wired cable whose kink resistance is not sufficient due to its small diameter in order to overcome the contact force of the clamping springs the clamp must be correctly opened using a screwdriver Check that all the cables are fitted tightly after the connections hav...

Page 36: ...clamping insert from the intermediate supports 3 Strip cable back by 8 mm so that the screen braiding is uncovered 4 Pull the union nut onto the cable 5 Feed the cable into the cable clamp and bend the screening back over the cable clamp 6 Push the clamping insert to the intermediate support 7 Fit the screws Union nut Clamping insert Internediate supports Housing wall Attention Do not bend the cla...

Page 37: ...01 06 Chapter 5 with removable control panel Date 29 07 08 Page 33 86 5 4 Overview processor board The illustration below shows the position of the terminal strips X switches S and service LEDs H on the processor board of the controller Hardware version Type plate ...

Page 38: ... 17 21 22 Operating mode X3 Signal input electronic remote precision adjustment EFE 1 Operating mode X70 X6 Power supply 24 V DC X7 Actuator X100 X8 Connection control panel X10 Enable controller Servo center transducer OMG 8 Relay contact X14 Digital inputs Remote control electronic remote precision adjustment EFE 1000 X40 Programming interface Programming in the factory X41 RS232 interface Progr...

Page 39: ...on to terminal 8 3 IR pulse 5 V brown 4 IR pulse GND white 5 12 V pink pink Output 12 V 6 GND green green blue 7 12 V yellow yellow Output 12 V 8 Analogue input grey grey white 5 5 2 2 Terminal strip X2 Signal input sensor 2 Wire colours Terminal X2 Function IR US 2003 US 2007 US 2008 US 2009 Remarks 9 24 V brown 10 Synchronisation for US sensor brown black Internal connection to terminal 1 11 IR ...

Page 40: ...grey OMG 4 position feedback EMS 17 21 22 49 Analogue input remote precision adjustment EFE 1 grey The lines on terminals 45 and 47 must be swapped over to change the EFE 1 working direction 5 5 2 4 Terminal strip X6 Power supply Terminal X6 Function Wire colours Remarks 40 GND white 41 24 V brown Fed out through plug X70 5 5 2 5 Terminal strip X7 Actuator Terminal X7 Function Wire colours EMS 5 W...

Page 41: ...sed 56 Relay closed contact 57 Relay change over contact 58 Relay contact that opens white only EFE 1000 The open contact is normally closed when working correctly 5 5 2 8 Terminal strip X14 Digital inputs electronic remote precision adjustment EFE 1000 Terminal X14 Function Wire colour EFE 1000 Remarks 72 GND brown 73 GND GND for inputs 0 7 74 Input 0 75 Input 1 76 Input 2 77 Input 3 78 Input 4 7...

Page 42: ...ly authorised to do so by BST Non observance of this may cause the loss of the warranty rights 5 5 3 Plug assignments 5 5 3 1 Plug X70 Connection power supply The power supply is connected to the controller via a 3 pin connector as per CEN 175301 803 DIN 43650 Contact assignments in the plug connector Connector Coupling Contact Signal Wire colours Remarks 1 24 V brown 2 GND white Feeds in to termi...

Page 43: ...nnection control panel The control panel is connected to the controller via a 4 pin M8 micro style connector Contact assignments in the plug connector Socket female Plug male Contact Signal Wire colours Woodhead cable Remarks 1 Output 24 V brown 2 Bus_H white 3 Bus_GND green 4 Bus_L yellow Feeds in to terminal strip X6 X 1 2 3 4 View X X 1 2 3 4 View X ...

Page 44: ...cer that are being used DIL switch Reversion of the guiding direction activation EFE 1 S4 1 Reversion of the guiding direction for automatic mode sensor 1 sensor 2 web center line guiding S4 2 Reversion of the guiding direction for the servo center transducer S4 3 ON Electronic remote precision adjustment EFE 1 DIL switch S4 4 S4 5 S4 6 Selection of the used actuator OFF OFF OFF EMS 10 EMS 16 EMS ...

Page 45: ...rrent input 4 mA 20 mA S5 1 must be OFF OFF Voltage input see S5 2 S5 4 Sensor 2 ON Current input 4 mA 20 mA S5 2 must be OFF OFF Sensor 1 is not present Guiding mode cannot be selected S5 5 Sensor 1 ON Sensor 1 is present Guiding mode selectable OFF Sensor 2 is not present Guiding mode cannot be selected S5 6 Sensor 2 ON Sensor 2 is present Guiding mode selectable OFF Bright voltage dark voltage ...

Page 46: ... takes place BLINKER PREOPERATIONAL The device is in PREOPERATIONAL mode Initialization is completed The device can be started H1 RUN ON OPERATIONAL The device is in OPERATIONAL mode OFF NO ERROR The device runs OK No error is recognized 3x FLICKER SYNC ERROR No SYNC message was received H2 ERR ON BUS OFF The interface controller is in Bus OFF mode 5 7 2 LEDs Device status LED Name Status Signific...

Page 47: ...tus Signification H53 Enable OFF ON Controller is blocked motor output stage is switched off Controller is enabled H64 Relay OFF ON Error No error 5 7 5 LEDs Remote control LED Signification H9 Signal 1 24 V at terminal 74 H10 Signal 1 24 V at terminal 75 H11 Signal 1 24 V at terminal 76 H12 Signal 1 24 V at terminal 77 H13 Signal 1 24 V at terminal 78 H14 Signal 1 24 V at terminal 79 H15 Signal 1...

Page 48: ...r are set according to the application see chapter 5 6 6 1 Start up actuator 6 1 1 General Attention During the start up the actuator will carry out positioning movements The equipment must be protected in accordance with the machinery directives so that no danger of the personnel being injured exists e g by suitable barriers Actuator operation in generator mode The controller is not equipped with...

Page 49: ... sensors sensor 1 sensor 2 is described in chapter 1 5 2 6 1 3 Determine guiding direction During start up the assignment of the selection buttons for the guiding mode to the actuating direction sense of motor rotation of the actuator must be checked 1 Press key Sensor 1 or Sensor 2 The selected guiding mode is active The LED of the key lights 2 Press key Automatic The controller changes to automa...

Page 50: ...osition of DIL switch S4 2 on the processor board see chapter 5 6 1 6 1 4 2 Adjust gain of the servo center transducer OMG 4 OMG 8 If you are using a servo center transducer OMG 4 or OMG 8 preselect the adjustment of gain 1 Press key Servo center The LED of the key lights 2 Press key SETUP The set gain for the servo center transducer is shown graphically bar display and as numerical value on the l...

Page 51: ...ses stable guiding operation If a slower guiding reaction is desired the gain may still be reduced further Simultaneously pressing the two arrow keys will reset the gain to 0 5 5 Press key ENTER Adjustment of gain is completed The gain setting will be terminated automatically after a pre set time out period initiated after the last key operation has expired The gain setting has now been saved ...

Page 52: ...irection for operating mode center positioning must be checked 1 Press key Manual mode The controller changes to manual mode The LED of the key lights 2 Press arrow key left or right Observe position indicator in the display When pressing arrow key left the bar display must move to the left When pressing arrow key right the bar display must move to the right If the bar display moves in the opposit...

Page 53: ...e settings are sub divided into the following steps Step 1 Activating the setup menu 1 Press key Manual mode The controller changes to manual mode The LED of the key lights 2 Press key SETUP The controller changes to setup mode The setup selection menu appears in the display 3 Select the setup menu symbol for actuators EMS 17 EMS 21 and EMS 22 using the arrow keys 4 Press key ENTER The setup menu ...

Page 54: ... software limit switch 2 Actual position of the actuator graphical display Actual position of the actuator numerical display When the controller is delivered the position for software limit switch 1 will display 2048 and the position for software limit switch 2 will display 2047 The factory default settings will be overwritten by the new settings when teach in is run The relevant symbol sensor 1 s...

Page 55: ...ition for software limit switch 2 towards sensor 2 using the arrow keys The position indicator for software limit switch 2 shows the actual value supplied by the position feedback of the actuator 8 Press key Sensor 2 The position for software limit switch 2 is stored The symbol sensor 2 is represented inversely Step 4 Set servo center position 9 Move actuator to the desired center position for the...

Page 56: ...A material setup should be carried out during the first start up of the web guiding system in order to realise optimum guiding results During material setup an automatic adjustment of the controller to match the characteristics of the material to be scanned is carried out The procedure for carrying out a material set up is described in detail in chapter 7 2 ...

Page 57: ...isplay 4 Increase gain by means of the arrow key right until huntings appear the guiding device starts oscillating The display of the gain value rises step by step Pressing the arrow key longer than 3 seconds increases the pulse width until the key is released We recommend leaving the gain set to maximum if hunting does not occur 5 Decrease gain by using the left arrow key until the hunting ceases...

Page 58: ...de The LED of the key lights 2 Adjust the web set point as follows EFE 1 Turn the potentiometer clockwise in arrow direction EFE 1000 Press arrow key right Monitor the display on the control panel Turning the potentiometer clockwise EFE 1 or pressing the right arrow key EFE 1000 will move the guiding setpoint indicator to the right the displayed number value increases If the indicator moves in the...

Page 59: ...s in the following illustration Relative scanning area coverage of sensor 1 Relative scanning area coverage of sensor 2 Relative actuator position related to the stop positions only with actuator EMS 17 21 22 or servo center transducer OMG 4 8 Controller gain Guiding setpoint numerical display Guiding setpoint for sensor 2 Center of scanning area sensor 2 Actuator zero position only with actuator ...

Page 60: ...utomatically The symbol Active limit switch appears in the display above the actuator position indicator After driving the actuator into the opposite direction the symbol will be deleted automatically Also see chapter 10 position 7 7 1 2 2 Motor overcurrent If the actuator is blocked e g when the guiding device has moved into a stop position the warning symbol Motor overcurrent appears in the disp...

Page 61: ...ithin the permissible voltage range the symbol will be deleted automatically Also see chapter 10 position 15 7 1 2 4 Timeout motor activation If the actuator is run in the same direction for more than 50 seconds during operation of the web guiding system then the motor output stage is switched off The warning symbol Timeout motor activation appears in the display next to the actuator position indi...

Page 62: ...oller interlock is activated the output from the actuator s output stage is switched off The actuator will not carry out any guiding movements This is valid for all operating modes automatic guiding manual positioning center positioning Also see chapter 10 position 8 7 1 2 6 Keyboard interlock A key symbol will be displayed in the centre of the bottom edge of the display if the keyboard interlock ...

Page 63: ...th removable control panel Date 29 07 08 Page 59 86 7 1 2 7 Bus connection fault If a fault occurs in the bus connection between the controller and control panel the Bus connection fault warning symbol will be displayed Also see chapter 10 position 18 Symbol Bus connection fault ...

Page 64: ...her contrast characteristics e g film with a different material transparency With ultrasonic sensors US 2003 US 2007 US 2008 US 2009 After changing over to a material with different sound absorption properties After cleaning a dirty sensor Material setup can be carried out either automatically or manually Automatic material setup describes the standard procedure for storing the bright dark values ...

Page 65: ... type manual or automatic using the arrow keys The selected symbol will be displayed inversely Automatic material setup or Manual material setup 4 Press key ENTER Material setup is active The LED of the SETUP key lights The detected bright dark value for the selected sensor is shown in the display under the sensor symbol Dark value graphical display Actual value graphical display Bright value grap...

Page 66: ...in the setup selection menu see chapter 7 2 2 The display shows the accompanying screen here with sensor 1 selected The animation shows the required operation steps for creating the bright and dark value The hand moves the material into the sensor scanning area dark value and back out again bright value 4 Remove material from the selected sensor no material within the sensor scanning area The dete...

Page 67: ...tup selection menu see chapter 7 2 2 The display shows the required operation step for creating the bright value for the selected sensor here sensor 1 4 Remove material from the selected sensor no material within the sensor scanning area The detected bright value is shown in the display 5 Press key ENTER The bright value is stored The display shows the required operation step for creating the dark...

Page 68: ...panying screen for sensor 1 The animation shows the required operation steps for creating the bright and dark value for sensor 1 The hand moves the material into the sensor scanning area dark value and back out again bright value 4 Remove material from sensor 1 no material within the sensor scanning area The detected bright value is shown in the display 5 Cover scanning area of sensor 1 with the m...

Page 69: ...terial within the sensor scanning area The detected bright value is shown in the display 8 Cover scanning area of sensor 2 with the material to be scanned for at least 2 seconds The detected dark value is shown in the display 9 Press key ENTER The detected bright and dark values for sensor 2 are stored The material setup is completed The operating screen is displayed ...

Page 70: ... The LEDs of both keys light 3 Activate manual material setup in the setup selection menu see chapter 7 2 2 The display shows the required operation step for creating the bright value for sensor 1 4 Remove material from sensor 1 no material within the sensor scanning area The detected bright value is shown in the display 5 Press key ENTER The bright value for sensor 1 is stored The display shows t...

Page 71: ... sensor scanning area The detected bright value is shown in the display 9 Press key ENTER The bright value for sensor 2 is stored The display shows the required operation step for creating the dark value for sensor 2 10 Cover scanning area of sensor 2 with the material to be scanned and keep it covered The detected dark value is shown in the display 11 Press key ENTER The dark value for sensor 2 i...

Page 72: ...n this operating mode depending on the selected guiding mode The assignments of the guiding mode selector buttons are described in chapter 1 5 2 1 Select the desired guiding mode Guiding to the left web edge sensor 1 Press key sensor 1 The LED of the key lights Guiding to the right web edge sensor 2 Press key sensor 2 The LED of the key lights Web center line guiding Press keys Sensor 1 and Sensor...

Page 73: ...edge of the display 1 Select the desired guiding mode 2 Press key Automatic The controller changes to automatic mode The LED of the key lights 3 Press arrow key left or right The actual guiding setpoint is shown graphically bar display and as numerical value on the lower edge of the display 4 Shift the guiding setpoint to the desired position using the two arrow keys The new guiding setpoint will ...

Page 74: ...Operation 7 19 ekr 500 web guiding controller EDV No MD 299 01 06 Chapter 7 with removable control panel Date 29 07 08 Page 70 86 Note The guiding setpoint is saved separately for each guiding mode ...

Page 75: ...SETUP The set controller gain is shown graphically bar display and as numerical value on the lower edge of the display 4 Decrease gain by means of the arrow key left or increase gain by means of the arrow key right until the guiding operates stable The new setting will have an immediate effect on the control Press the arrow key down for longer than 3 seconds and the pulse width will be increased u...

Page 76: ...are and software versions ready Procedure 1 Press key Manual mode The controller changes to manual mode The LED of the key lights 2 Press key SETUP The controller changes to setup mode The setup selection menu appears in the display 3 Select the info symbol using the arrow keys The selected symbol will be displayed inversely 4 Press key ENTER The display shows the installed hardware and firmware v...

Page 77: ...iding setpoint is carried out exclusively via the potentiometer on the EFE 1 In automatic mode the arrow keys on the control panel are then out of function Pressing an arrow key on the control panel causes the message EFE to be displayed on the bottom edge of the display 1 Press key Automatic The controller changes to automatic mode The LED of the key lights 2 Adjust the guiding setpoint as follow...

Page 78: ...e processor board of the controller see chapter 5 7 5 Truth table remote control inputs Function Terminal 55 72 73 74 75 76 77 78 79 80 81 82 83 LED H53 H9 H10 H11 H12 H13 H14 H15 H16 Automatic guiding X 0 0 1 X X X X X Manual positioning X 1 0 0 X X X X X Center positioning X 0 1 0 X X X X X Web edge guiding sensor 1 X X X X 1 0 X X X Web edge guiding sensor 2 X X X X 0 1 X X X Web center line gu...

Page 79: ...o 1 by manufacturer delivery state You are only allowed to modify the device address if authorised to do so by the manufacturer The setting of the device address of the controller is carried out via the rotary switch S1 on the processor board Danger from mains voltage Never open the controller before switching off the mains Set device adress 1 Switch off controller line voltage 2 Open the controll...

Page 80: ... the device address if authorised to do so by the manufacturer Danger from mains voltage The plug of the control panel connection cable must be disconnected from the controller before you open the control panel Set device adress 1 Unplug the connecting cable connection from the control panel on the controller 2 Carefully remove stop B from the back of the control panel 3 Check the setting of the r...

Page 81: ... can be switched on or off using switch S3 on the processor board The terminating resistor should only be switched off after first obtaining agreement from the manufacturer Switch S3 Function OFF Internal terminating resistor switched off ON Internal terminating resistor switched on default setting Danger from mains voltage Never open the controller before switching off the mains Setting up the te...

Page 82: ...n enhancements S2 4 OFF ON Internal terminating resistor switched off Internal terminating resistor switched on Default setting Danger from mains voltage The plug of the control panel connection cable must be disconnected from the controller before you open the control panel Setting up the terminating resistor 1 Unplug the connecting cable connection from the control panel on the controller 2 Care...

Page 83: ...line voltage 2 Open the controller enclosure cover 3 Set rotary switch S1 on the processor board to 0 4 Switch on controller line voltage All of the relevant settings for the controller will be overwritten with the factory default settings 5 Switch off controller line voltage 6 Set S1 rotary switch S1 on the processor board to 1 7 Close the controller enclosure cover 8 Switch on controller line vo...

Page 84: ...he actuator see chapter 6 1 3 5 In operating mode Center positioning the actuator guiding device moves to an end position and remains there The actuator guiding direction has been set up wrongly The servo center transducer OMG 4 OMG 8 being used has been incorrectly installed Reverse guiding direction of the actuator see chapter 6 1 3 Check mounting position of the servo center transducer 6 The ac...

Page 85: ...anel and the display flash The supply voltage 24V DC has dropped out of the permitted voltage range due to the actuator s increased current consumption see chapter 2 1 3 Check the power supply 11 The center position of the guiding device is not correctly moved to If an actuator with position feedback EMS 17 21 22 is used then the servo center transducer OMG 4 was incorrectly selected Check adjustm...

Page 86: ...ontroller does not respond to any operation The display shows the following symbol see chapter 7 1 2 7 Fault in the bus connection between controller and control panel The device address of the controller or control panel is set incorrectly The internal terminating resistor in the controller and or in the control panel is not switched on Check cable connection between controller and control panel ...

Page 87: ...e length of the connection cable between controller and control panel is longer than 20 m The controller or the control panel has been installed close to a component that uses mains power or power lines Ensure that the maximum permitted length of the control panel connection cable is not exceeded Ensure that there is a minimum clearance of 100 mm from the component that uses mains power or the pow...

Page 88: ...e maintenance or cleaning intervals depend on the ambient conditions at the installation site If the customer is processing very dusty materials then the maintenance cleaning intervals must be reduced accordingly As a matter or course cable connectors e g between controller and actuator should only be disconnected when the controller is no longer connected to the mains supply Any infringements wil...

Page 89: ...enses of infrared sensors or the transmitter and receiver capsules of ultrasonic sensors have to be kept clean to ensure optimum guiding results A material setup must be run after the sensor lenses or receiver and transmitter capsules have been cleaned see chapter 6 2 11 5 Electric motor driven actuator The electric motor driven actuator is maintenence free ...

Page 90: ...gether with the entire machine The necessary procedures must be prepared by the manufacturer of the machine You must take into consideration that the web guiding equipment is generally considered to be an electrical electronic device which must be disposed of in accordance with the current legal requirements You might also be able to return the system to BST International GmbH but the correspondin...

Page 91: ... data 16 Terminating resistor 78 Turning the control panel 25 Wall mounting 26 27 Weight 16 Controller 4 Ambient conditions 13 Analogue inputs 14 Assembly 23 Control panel interface 15 Digital inputs 14 Dimensions 17 LEDs 42 Maintenance 84 Mounting 24 Mounting plan 23 Output fault relay 14 Output motor output stage 14 Plug assignments 38 Power supply 13 Processor board 33 Protection class 13 Servi...

Page 92: ... Utilisation 2 Operating modes 68 Automatic guiding 68 Center positioning 68 Manual positioning 68 Operation display 55 Overcurrent 56 Potentially explosive areas 3 Power pack 20 Power supply 20 Programming interface 38 Protection class 11 Remote control 8 74 Activate remote control 41 Interface conditions 74 Remote control inputs 74 Truth table 74 Remote precision adjustment 73 Start up 54 RoHS 1...

Page 93: ...299 01 06 Chapter A1 with removable control panel Date 29 07 08 Page 1 9 A1 Connecting plan Contact assignments in the plug connector Connector Coupling Contact Signal 1 24 V 2 GND Potential equalization Overview processor board Power supply plug X70 Type plate ...

Page 94: ...4 5 6 7 X1 8 DIL Switch S5 1 ON 3 OFF 5 ON 7 OFF 1 2 3 4 5 6 7 8 ON S5 IR 2001 IR 2002 IR 2005 brown white pink green yellow grey 5 8 7 6 3 4 DIL Switch S5 1 ON 3 OFF 5 ON 7 OFF 1 2 3 4 5 6 7 8 ON S5 pink green yellow grey brown US 2003 US 2007 US 2008 8 7 6 5 2 1 When connecting a second sensor X2 only type US 2009 is to be used blue white black brown US 2009 8 6 2 1 DIL Switch S5 1 2 3 4 5 6 7 8...

Page 95: ...alogue IN pink green yellow grey brown US 2003 US 2007 US 2008 16 15 14 13 10 IR 2001 IR 2002 IR 2005 brown white pink green yellow grey 13 16 15 14 11 12 DIL Switch S5 2 ON 4 OFF 6 ON 7 OFF 1 2 3 4 5 6 7 8 ON S5 DIL Switch S5 2 ON 4 OFF 7 OFF 1 2 3 4 5 6 7 8 ON S5 DIL Switch S5 2 OFF 4 OFF 7 ON 1 2 3 4 5 6 7 8 ON S5 blue white black brown US 2009 16 14 10 9 2 When connecting a second sensor X1 on...

Page 96: ...ee 6 1 3 X7 42 43 EMS 5 DIL Switch S4 1 2 3 4 5 6 7 8 ON S4 brown white pink grey 4 ON 5 OFF 1 6 OFF DIL Switch S4 1 2 3 4 5 6 7 8 ON S4 4 OFF 5 ON 1 6 OFF EMS 7 42 43 brown white DIL Switch S4 1 2 3 4 5 6 7 8 ON S4 4 OFF 5 OFF 1 6 OFF EMS 10 EMS 16 brown white 42 43 42 43 Actuator A Actuator B X7 For former applications the following wire colours are applicable brown brown white white pink grey ...

Page 97: ...ersion of the guiding direction AUTO see 6 1 3 2 Reversion of the guiding direction SC see 6 1 4 1 X7 X3 brown white EMS 17 X7 X3 pink green yellow grey 42 43 44 45 46 47 48 49 24V 12V GND 12V Analogue SC EFE 1 Actuator A Actuator B 1 2 3 4 5 6 7 8 ON S4 DIL Switch S4 4 OFF 5 OFF 6 OFF 7 OFF 8 OFF 2 1 42 43 45 46 47 48 EMS 21 22 1 2 3 4 5 6 7 8 ON S4 4 OFF 5 OFF 6 ON 7 OFF 8 OFF 2 1 ...

Page 98: ...06 Chapter A1 with removable control panel Date 29 07 08 Page 6 9 Actuator X7 Actuator 1 2 3 4 5 6 7 8 ON S4 7 ON 8 OFF Actuator A Actuator B 1 Reversion of the guiding direction AUTO see 6 1 3 X7 X7 42 43 CompactGuide brown white 42 43 DIL Switch S4 4 ON 5 ON 6 OFF 1 ...

Page 99: ...er transducer OMG 8 Namur X3 Servo center transducer OMG 4 X10 51 52 53 54 55 56 57 58 2 Reversion of the guiding direction SC see 6 1 4 1 X10 1 2 3 4 5 6 7 8 ON S4 DIL Switch S4 7 ON 8 OFF 2 brown blue 51 52 Namur A Namur B GND OMG 8 OMG 4 X3 1 2 3 4 5 6 7 8 ON S4 2 7 ON 8 ON DIL Switch S4 X3 44 45 46 47 48 49 24V 12V GND 12V Analogue SC EFE 1 45 yellow grey pink 47 48 ...

Page 100: ...ntact X10 Enable controller relay contact X14 72 73 74 75 76 77 78 79 80 81 82 83 Keyboard lock H9 H16 LED allocated to inputs 0 7 X10 X14 H9 H10 H11 H12 H13 H14 H15 H16 24V GND Input 0 24V GND Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 X10 51 52 53 54 55 56 57 58 Enable actuator output stage Namur A Namur B GND 24V Controller interlock Relay X14 Remote control ...

Page 101: ... 10 grey 49 Electronic remote precision adjustment EFE option X3 EFE 1 X14 EFE 1000 24V GND Input 0 24V GND Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 X14 72 73 74 75 76 77 78 79 80 81 82 83 H9 H10 H11 H12 H13 H14 H15 H16 X10 51 52 53 54 55 56 57 58 Namur A Namur B GND 24V Controller interlock Relay EFE 1000 pink 80 72 brown yellow 79 green 83 red efe 1000 2 6 4 3 1 white Either an EF...

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