BST ekrPro Com60 Operating Manual

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BST Web Guiding System

ekrPro Com60

with analog sensors

BST International GmbH Heidsieker Heide 53 33739 Bielefeld, Germany

Tel: +49 5206/999-0 Fax: +49 5206/999-999 e-mail: info@bst-international.com

ekrPro Com with analog sensors Date: 23.11.2007

web guide controller EDV-No.: MD.191.01.05/1.6.x

Symbols used in this operating manual

Warning signs

Symbols are used in this operating manual in order to clearly indicate particularly important places.

Attention!

Using the keys

Using the keys is represented by the following symbols in this manual:

You must obey this type of warning, in order to protect yourself, as the operator, from bodily injuries arising from mechanical movements.

Beware!

You must obey 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.

Press key.

LED operating status indications

1) 2)

Some keys on the front panel of the ekrPro Com60 controller have LED´s (light-emitting diodes) integrated in them. The different LED operating states are represented as follows:

LED off

LED constantly lit = activated phase

LED flashing

Key combinations, keys have to be pressed simultaneously.

Press keys in the specified order.

ekrPro Com with analog sensors Date: 23.11.2007

web guide controller EDV No.: MD.191.01.05/1.6.x

Contents

Symbols used in this operating manual Table of contents Section A General information Section B Commissioning Section C Operation Section D Appendix

ekrPro Com with analog sensors Date: 23.11.2007

web guide controller EDV No.: MD.191.01.05/1.6.x

ekrPro Com60

with analog sensors

Section A General information

A 1 Description A 2 Specifications A 3 Transport / Storage A 4 Decommissioning

ekrPro Com with analog sensors Date: 23.11.2007

web guide controller EDV No.: MD.191.01.05/1.6.x

Contents

Section A General information

Symbols used in this manual Table of contents

A 1 Description A1-1

A 1.1 General information A1-1 A 1.2 Utilisation A1-1 A 1.3 Housing versions A1-1 A 1.4 General definitions A1-2 A 1.4.1 Assignment of sensors to the guiding mode A1-2

selection keys A 1.4.2 Inverting of the sensor signal A1-3 A 1.4.2 Size of oscillation amplitude related to sensor

scanning area A1-3 A 1.4.2 Oscillation types and curves A1-4 A 1.4.2 Allocation of FVGs for a FVGPro 2MK A1-4 A 1.5 Connectable components A1-4 A 1.6 Safety information A1-5 A 1.7 Emissions A1-5

A 2 Specifications A2-1

A 2.1 ekrPro Com A 2.2 Optical edge sensor IR2001, IR2005 A2-3 A 2.3 Optical edge sensor IR2002 A2-3 A 2.4 IRS-U-2 A opto-electronic analog sensor A2-3 A 2.5 Ultrasonic edge sensor US2003, US2007, US2008 A2-4 A 2.6 Reflecting sensor TW 54 C 5 A2-4 A 2.7 Line sensor T 62 D 1 A2-5 A 2.8 Reflected light measuring light barrier R 42 D ... A2-5 A 2.9 Photoelectric fork sensor G 53 C2/5 A2-6 A 2.10 Switched power pack A2-7

A 3 Transport / Storage A3-1

A 4 Decommissioning A4-1

controller (version XT) A2-1

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Description A 1

The start-up, maintenance and installation

instructions described in this operating manual must be strictly adhered to!

A 1 Description

The aim of the operating manual is to enable you to use the guiding system rapidly by explaining the basic settings for initial start-up (start-up menu) and the conventional functions for operation. In addition, the complex functions will be described using selected examples for setting certain parameters.

A 1.1 General information

This family of control systems includes:

• ekrPro Com

• ekrPro Key

Devices in the controller family can be interconnected at different levels into a system network via a CAN-Bus.

A 1.2 Utilisation

The ekrPro Com

controller. Together with other BST components it may be used for:

• Web edge guiding (right or left)

: Controller with keyboard

: External control keyboard.

is a microprocessor controlled web guiding

A 1.3 Housing Versions

• Web center guiding

• Guiding on continuous or interrupted printed lines

• Guiding on continuous or interrupted printed edges (still

being prepared)

• Web width measuring

The controller includes a separate control unit that can directly control the sensor adjustment unit and it can be interconnected into the system.

Any other utilisation must first be authorised by the manufacturer.

There are also standard PLC compatible inputs and outputs as well as an OK-reporting system present.

The control unit ekrPro Com

is available in two different housing

versions:

• ekrPro Com60 XT: Mounting unit

(e.g. for wall mounting)

• ekrPro Key

Desk XT: Built-in unit

(e.g. for insertion in a control console)

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Description A 1

A 1.4 General

Settings

A 1.4.1 Assignment of sensors to the

to the scanning mode selection keys

In this operating manual, the edge sensors that are connected to the controller are designated with “sensor 1” and “sensor 2”. On the operating keyboard of the controller, the guiding mode selection keys have the lettering „SENSOR LEFT“ and „SENSOR RIGHT“ respectively.

According to the BST definition, the following link applies:

SENSOR LEFT = Sensor 1

SENSOR RIGHT = Sensor 2

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 movement direction (when looking from the material top side), is sensor 1.

Example 1:

The material top side is the side of the material web which is not direct contact with the deflection pulleys of the pivoting frame.

Example 2: Example 3:

Sensor right

(Sensor 2)

Sensor left (Sensor 1)

Sensor right

(Sensor 2)

Sensor left (Sensor 1)

As standard, sensor 1 (Sensor left) must be connected to connector X50 (terminal X1), while sensor 2 (Sensor right) must be connected to connector X51 (terminal X2) of the terminal board.

Sensor right

(Sensor 2)

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Description A 1

A 1.4.2 Inverting of the

sensor signal

If a BST edge sensor, of typical C-design, is mounted according to the BST definition (see section A 1.4.1) as "Sensor left" (sensor 1), then no inversion of the sensor signal is necessary. If a BST edge sensor is mounted according to the BST definition as "Sensor right" (sensor 2), then inversion should be activated via the setup menu (see section B 3.4.4.3.1).

When the control units is delivered, inversion of the sensor signal for sensor 2 is activated (factory setting).

Sensor left

Not permitted:

► Sensor:

Invert!

(Sensor looks to the left in the direction of travel.)

A 1.4.3 Size of oscillation amplitude

related to sensor scanning area

0 %

30 %

70 %

100 % Sensor coverage

Centre of sensor scanning area (visual range).

Oscillating web position

100 % of the sensor visual range

80 % of the sensor visual range = maximum oscillation amplitude

40 % of the sensor visual range

The maximum possible oscillation amplitude is 80% of the sensor visual range. As an example, the oscillating web position is shown herewith an attitude of 40% in "Sensor oscillation" mode.

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Description A 1

A 1.4.4 Oscillation types and curves

An oscillation can be implemented either as a sensor oscillation or an FVG oscillation. In the case of the sensor oscillation, the curve described is a delta function. The FVG oscillation describes a curve in accordance with a sine function.

Selections and settings are described under Point B 3.7.5.8.2.

A 1.4.5 Allocation of FVGs for a FVGPro 2MK

Traverse the FVG using the appropriate key in the menu window

<<< >>>

FVG 1

>>> <<<

internal

limit switch

external

limit switch

Web travel direction

>>> <<<

<<< >>>

FVG 2

A 1.5 Connectable

components

The general plan (annex C2) shows the components that can be

connected to the ekrPro Com

controller.

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EDV No.: MD.191.01.05/1.6.x Chapter: A 1

Description A 1

A 1.6 Safety information

The safety relevant information in accordance with DIN EN 294, DIN EN 349 and the industry specific safety regulations must be taken into consideration when installing the BST equipment in the production machine, these include:

• There must be a safe distance between the BST equipment and

the machinery already installed on-site, such as machine panels, building structure, etc.

• The interconnecting lines between the control equipment and the

control components or edge sensors must be laid so that nobody can trip over them, they are not taught and they are well anchored.

• Ensure that there is sufficient free headroom.

If the free passage is restricted, the relevant building components causing the restrictions must be padded and a danger warning signs must be attached to them (yellow/black).

Only trained specialist personnel are permitted to undertake the assembly, installation and

commissioning!

Before starting work, ensure the equipment is electrically isolated. To this end always 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.

The mains power must always be switched off before the equipment is opened. If it becomes necessary to work on the open equipment with voltage applied, then only Protection class IP 20 is provided. There is always increased danger because of the mains

• Any transport safety devices that were used must be removed

prior to commissioning.

voltage!

Do not use the chassis or machine frame as a climbing

aid or a stepladder. Do not remove any of the safety devices.

Positioning movements will be undertaken by the actuator during functional testing away from the production machine and/or during the commissioning! The relevant safety arrangements must implemented during performance checks! Monitor the overall safety concept of the production machine during commissioning!

A 1.7 Emissions

The A-rated equivalent continuous sound level of the equipment is less than 70 dB(A).

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EDV No.: MD.191.01.05/1.6.x Chapter: A 1

Specifications A 2

A 2 Specifications

A 2.1 ekrPro Com

Power supply 24V DC ± 5%

Power consumption 4W (without motor)

Input capacitance approx. 950µF

Controller inputs 2 x sensors, -9,75 V ...+9,75 V oder 0 V ...+9,75 V

FVG inputs 1x blocking, no

Digital inputs 12x digital inputs, no

Power supply outputs 2 x 24V (for CCD Pro camera)

controller (version XT)

12 bit selectable via software. 1 x sensor, -10,3 V to +10,3 V, 12 bit 1x EFE pot, -10,3 V to +10,3 V, 12 bit 1x pot return, -10,3 V to +10,3 V, 12 bit 1 x tacho, -9,0 V to + 9,0 V 1x blocking, input resistor 4.7 KΩ, operating points (<4 V (low) and >8 V (high)), but can only be used against “+“ switched sensors (pnp)

2x reference switch, no metallic separation

input resistor 4.7 KΩ, operating points (<4 V (low) and >8 V (high)), but can only be used against “+“ switched sensors (pnp), supply 24V DC

metallic separation

metallic separation,

Controller outputs Controller outputs -10.3V to -10 V, 12 bit 1x analog output

-10 V to +10 V, 2 mA 2x IR pulses 1x lamp supply 5 V, 1 A

Digital outputs 4 x digital outputs +24V, 1.0A per output, 1.5A

in total

No metallic separation.

Protected against feedback (positive voltage)

Controller output stage 1x DC motor 24V DC, max. 3 A, short circuit protected.

Select voltage, current or tachometer control (in preparation)

PWM 20 kHz

FVG output stage 1 x stepping motor, max. 1.5A; not

short circuit protected

CAN-bus 1x plug, 1x socket; no metallic separation

Screw connections / plugs

Variable through exchangeable connection plate; see Appendix D6

Protection class IP 54

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Specifications A 2

240

140

Display: LCD graphics module with 128 x 64 pixel and LED

background illumination

Ambient conditions: Temperature: 0° to 45°C max.

Humidity: 5% - 90%, no condensation

Weight: ekrPro Com

ekrPro Com

: approx. 2.1 kg

Desk: approx. 2.3 kg

Case dimensions ekrPro Com

(Mounting unit):

140

160

240

Installation ekrPro Com

Desk (Built-in unit)

225

125

105

205

max. 10

15115

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Specifications A 2

A 2.2 A2.2 Optical edge sensor

IR 2001, IR 2005

Power supplies: from the controller

Measuring range, typical: 12 mm

Visual range, typical: 15 mm

Output: analog

Protection class: IP 54

Ambient conditions: Temperature: 0 to a max. 45 °C

Humidity: 5% - 90%, no condensation

Case dimensions: (standard version)

A 2.3 Optical edge sensor

IR 2002

Power supplies: from the controller

Measuring range, typical: 8 mm

Visual range, typical: 13 mm

Output: analog

Protection class: IP 54

Ambient conditions: Temperature: 0° to 45°C max.

Case dimensions: (standard version)

A 2.4 IRS-U-2 A opto-electronic analog sensor

See the manufacturer’s data-sheet

W = 40 mm H = 95 mm D = 107 mm

Humidity: 5% - 90%, no condensation

W = 25 mm H = 57 mm D = 85.5 mm

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A 2

Specifications A 2

A 2.5 Ultra-sonic sensor

US2003, US2007, US2008

Power supplies: from the controller

Measuring range, typical: 15 mm (US 2008 = 4 mm)

Visual range, typical: 15 mm (US 2008 = 6 mm)

Output: analog

Protection class: IP 54

Ambient conditions: Temperature: 0 to a max. 45 °C

Humidity: 5% - 90%, no condensation

A 2.6 Reflection button

TW 54 C5

Case dimensions: (standard version)

Power supplies: 8V – 15V; from the controller

Lamp voltage: 5V; 0.8A; from the controller for:

Measuring range: 5.0 mm at 6 mm sensing distance

Output signal: Negative with black areas

Protection class: IP 65

Ambient conditions: Temperature: 0 to a max. 50 °C

Weight: 240 g

Case dimensions: W = 26 mm

B= 25 mm H = 76 mm D = 113 mm

maximum of one sensor

2.5 mm at 13 mm sensing distance

Positive with white areas

Humidity: 5% - 90%, no condensation

H = 54.5 mm D = 85.5 mm

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A 2

Specifications A 2

A 2.7 Line sensor T 62 D 1

Power supplies: from the controller

Lamp voltage: 5 V; 0.8 A

Sensing distance: 15 -30 mm

Measuring range: 3 -8 mm

Line widths: 0.5 -5 mm

Output voltage: 0 to ±10V

Protection class: IP 65

Ambient conditions: Temperature: 0 to a max. 50 °C

Humidity: 5% - 90%, no condensation

Weight: 1,100 g

Case dimensions: B= 67 mm

H = 105 mm D = 128 mm

A 2.8 Reflected light

measuring light barrier R 42 D, etc.

R 42 D 12 R 42 D 16

Power supplies: +12V, 12 mA or

±12V, 15 mA or

±15V, 20 mA

Lamp voltage: 5V, 4W; from the controller for a maximum of

one sensor

Max. distance: 1 m 2 m

Measuring range

15 mm 40 mm

in front of front lens:

Diameter of light beam

25 mm 55 mm

in front of front lens:

Diameter of light beam

40 mm 55 mm

at half distance

Output voltage:

at: U

= +12 V

= ±12 V

= ±15 V

Corresponding to change in illumination:

dark

light

8.5V 2V

8.5V 0V

10.5V 0V

Protection class: IP 65

Ambient conditions: Temperature: 0° – 70°C

(temperature compensation

only up to 50°C

Weight: 1,000 g 1,200 g

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Specifications A 2

A 2.9 Fork light barrier

G 53 C2/5

Power supplies: from the controller

Lamp voltage: 5V

Fork width: 29 mm

Measuring range: ± 3.5 mm

Diameter of light beam: 11 mm

Protection class: IP 65

Ambient conditions: Temperature: -20 to a max. 60 °C

Humidity: 5% - 90%, no condensation

Weight: 400 g

Case dimensions: B= 21 mm

H = 85 mm D = 87 mm

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A 2

Specifications A 2

A 2.10 Switched power pack

Supply of the ekrPro Com

including the BST components takes place over the switched power pack. There are two supply possibilities:

1. over a central power pack in the machine

2. over a power pack allocated to the BST part

The following details are based on a control system comprising a

control unit ekrPro Com

, analogue sensors, sensor adjustment unit and actuator (EMS1, EMS5, EMS10, EMS16, EMS17 or EMS20)

1. Central supply If supply takes place centrally from the machine the following

parameters are to be fulfilled:

• Output voltage: 24 V DC ± 5%

• Output current: 4.2 A DC

• Output power: 100 W

The power pack must be able to quickly charge (~ 5 sec) the input capacitance (approx. 950µF) of the control amplifier after switching on without recognizing this as a short circuit and so switching off again. The output should be permanently resistant to short-circuiting, overloading and idle running.

2. Separate power pack If a separate power pack is used for the BST components, we

recommend the use of units manufactured by PULS GmbH:

Input voltage: 85 - 264 V AC or 220 – 375 V DC Output voltage: 24 V DC ± 5% Output current: 4.2 A DC Output power: 100 W BST order number: 103 837

If a number of control systems are to be supplied from a single switched power pack, then, dependent on the total required power, the following power packs are also available:

Input voltage

85 – 264 V AC 220 -700 V DC 85 – 264 V AC 220 -700 V DC 340 – 479 V AC /3Ph. 450 -700 V DC

Output

voltage

24 V DC ± 5 % 10 A DC 240 W 118 661

24 V DC ± 5 % 20 A DC 480 W 109 365

24 V DC ± 5 % 20 A DC 480 W 116 679

Output current

Output

power

BST order

number

ekrPro Com

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Transport A 3

A 3 Transport

The equipment will be shipped in accordance with the details stipulated in the order:

• completely assembled and interconnected to the web guide

control system

• as component parts in standard cardboard boxes with cellular

lining material

If the unit will not be incorporated immediately, it should be stored in a dry room until installation.

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A 3

Decommissioning A 4

A 4 Decommissioning

Decommissioning (scraping) the systems must be carried out in together with the entire machine. The necessary procedures must be prepared by the manufacturer of the machine. You must take into consideration that the control system 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 corresponding agreement must be made first.

ekrPro Com

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ekrPro Com60

with analog sensors

Section B Commissioning

B 1 Installation B 2 Controls B 3 Commissioning B 4 Terminal assignments and service displays

ekrPro Com with analog sensors Date: 23.11.2007

web guide controller EDV No.: MD.191.01.05/1.6.x

Contents

Section B Commissioning

Symbols used in this manual Table of contents

B 1 Installation B1-1

B 1.1 Installation site requirements B1-1 B 1.2 Installation ekrPro Com B 1.2.1 Securing hole diagram B1-1 B 1.2.2 Installation B1-1 B 1.3 Installation ekrPro Com B 1.3.1 Installation dimensions B1-2 B 1.3.2 Cabling B1-2 B 1.3.3 Installation B1-3 B 1.4 Installation instructions for EMC-wiring B1-4 B 1.5 Installation contrast/line sensor B1-5 B 1.5.1 Sensor arrangement B1-5 B 1.5.2 Installation line sensor T 62 D 1 B1-6 B 1.5.3 Installation reflection sensor TW 54 C 5 B1-7

B 2 Display and operating controls B2-1

B 2.1 Control panel B2-1 B 2.2 Navigating within the system B2-2 B 2.2.1 Function keys (F-keys) B2-2 B 2.2.2 Arrow keys B2-5 B 2.2.3 Buttons B2-6

B 3 Commissioning B3-1

B 3.1 General information B3-1 B 3.2 Electrical connections B3-2 B 3.3 Commissioning with a CAN bus B3-3 B 3.3.1 Check unit address or set up if necessary B3-3 B 3.3.2 Terminator activation B3-5 B 3.4 Adjust password B3-7 B 3.5 Commissioning standard system B3-9 B 3.5.1 Select standard system B3-9 B 3.5.2 Carry out master setup B3-10 B 3.5.3 Setting the actuator guiding direction B3-11 B 3.5.4 Setting the actuator path limits B3-11 B 3.5.5 Servo centre position and amplification for the B3-12

“SC” operating mode B 3.5.6 Carry out material setup B3-13 B 3.5.6.1 Automatic material set-up B3-14 B 3.5.6.2 Manual material set-up B3-14 B 3.5.7 FVG - Sensor positioning device B3-15 B 3.5.8 Additional Functions B3-19 B 3.5.8.1 Tear Off Detection B3-19 B 3.5.8.1 Oscillation B3-23 B 3.6 Save settings B3-25

(Mounting unit) B1-1

Desk (Built-in unit) B1-2

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B 3.7 Set-up menu B3-26 B 3.7.1 Change User - User level selection B3-26 B 3.7.2 Material Setup - Sensor compensation B3-26 B 3.7.3 Sel. Std. System - Selection of a standard system B3-26 B 3.7.4 Save/Load settings- Load or save settings B3-26 B 3.7.5 General Set-up - System parameters B3-27 B 3.6.4.1 Setting the default values B3-27 B 3.6.4.2 Actuator –Actuator settings B3-28 B 3.6.4.3 Sensors/ EF E - Com m i s si o n i ng s e n so r s a n d EF E B3-35 B 3.6.4.4 Control Loop - Control loop settings B3-37 B 3.6.4.5 FVG - Sensor positioning device B3-38 B 3.6.4.6 Width Measure - Web width measurement B3-50 B 3.6.4.7 Edge Sources - Assignment of the sensors B3-54

to the guiding modes B 3.6.4.8 Add. Functions - Special functions B3-56 B 3.6.4.9 Dig. IO Config. - Configuration of the digital B3-60

inputs and outputs B 3.6.4.10 Special - Special device settings B3-69 B 3.6.5 Opt. Logic - Optional logic B3-72 B 3.6.6 Fieldbus - Field bus B3-72 B 3.6.7 Remote Device - Commissioning with a CAN bus B3-73 B 3.6.8 Test - Test program for service purposes B3-74

B 4 Terminal assignments and service displays B4-1

B 4.1 Board overview B4-1 B 4.2 Terminal diagrams B4-2 B 4.3 Service indicator displays B4-9

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Installation B 1

B 1 Installation

B 1.1 Installation site requirements

The ekrPro Com

free area.

Ambient conditions: Temperature: 0 to a max. 45°C Humidity: 5 - 90%, no condensation

B 1.2 Installation ekrPro Com

(mounting unit)

B 1.2.1 Securing hole diagram

B 1.2.2 Installation

Attention! A free area of at least 300 mm in front of the housing

must be guaranteed so that it can be opened.

controller must be installed in a dry, vibration-

ekrPro Com

housing

5 2 1

1. Drill the securing holes as shown in the mounting plan.

2. Use the four screws to attach the housing.

3. Wire in the electric cables (if required) or plug in the necessary cable connections.

securing

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Installation B 1

B 1.3 Installation

ekrPro Com60 Desk (built-in unit)

B 1.3.1 Installation dimensions

B 1.3.2 Cabling

Attention!

A space of at least 140 mm must be guaranteed for the cabling in order to ensure that the cables are laid correctly (see illustration).

Section

min. 140

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: B 1

Installation B 1

B 1.3.3 Installation

max. 10

1. Cut out the insertion hole and drill four mounting holes (installation dimensions see chapter B 1.3.1).

2. Slide the ekrPro Com

Desk into the recess.

3. Use the four securing screws to secure the

controller ekrPro Com

Desk in place.

4. Wire in the electric cables or plug in the

necessary cable connections.

Attention!

A free area of at least 300 mm in front of the housing must be guaranteed so that it can be opened.

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Installation B 1

B 1.4 Installation instructions for EMC-wiring

housing wall

Union nut

Intermediate supports

Cable insert

1. Unscrew in the union nut for the cable screw-in cable glands.

2. Pull out the clamping insert from the intermediate supports. Attention! Do not press down on the cable insert.

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.

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Installation B 1

B 1.5 Installation

contrast / line sensor

B 1.5.1 Sensor arrangement

The sensors must be arranged as follows in order to ensure clear allocation of the two keys on the front foil of the controller to the corresponding contrast transitions:

• The sensor connection cable points in the direction of sensor 1.

Sensor 1

This sensor arrangement results in the following key allocation:

Connection cable

Material web

→

TW 54 C 5

T 62 D 1

Sensor 2

web running direction

Contrast transition BRIGHT/DARK

Contrast transition DARK/BRIGHT

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: B 1

Installation B 1

°5°

B 1.5.2 Installation

line sensor T 62 D 1

T 62 D 1

ø8

Deflection roller

Scanning arrangement T 62 D 1

The following points must be adhered to during installation of the

T 62 D 1 in order to realise optimum guiding results:

• The line sensor should be mounted on a torsionally rigid base.

• The line / contrast must be placed at right angles to the

longitudinal axis of the sensor (see drawing).

• The scanning should be carried out on a deflection roller. This will ensure that any material web height fluctuations are eliminated at the scanning point.

• The distance between the sensor scanning optics and the material web must be set so that there is a light spot with a diameter of approximately 8 mm (corresponding to a scanning distance of approximately 17 mm) on the web.

• We recommend that the sensor angle is reduced by 5° - 15° in the web running direction when using very reflective materials

…15

5°…15

Web running direction

The light spot diameter can be reduced in size by altering the distance from the web in order to optimise the system when working with poor contrast or narrow lines. The scanning distance clearance must never exceed 30 mm

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Installation B 1

B 1.5.3 Installation

reflection sensor TW 54 C 5

5°…15°

TW 54 C 5

6…12

web running direction

You must abide by the following points when installing the

TW 54 C 5 reflection scanner in order to realise optimum guiding

results:

• The line sensor should be mounted on a torsionally rigid base.

• The line / contrast must be placed at right angles to the

longitudinal axis of the sensor (see drawing).

• The scanning should be carried out on a deflection roller. This will ensure that any material web height fluctuations are eliminated at the scanning point.

• The distance between the sensor scanning optics and the material web has to be 6 - 12 mm, depending on the required measuring range (diameter of the light spot).

The measuring range (light spot diameter) depends on the distance between the contrast transitions.

Only one

contrast transition may be located within the light spot.

correct

wrong wrong

Distance scanning optics D material web: 6 - 12 mm Light spot diameter: 7.5 – 4 mm

• We recommend that the sensor angle is reduced by 5° - 15° in the web running direction when using very reflective materials

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with analog sensors Date: 23.11.2007 Page: 7/7

Controls B 2

B 2 Display and operating controls

B 2.1 Control panel

Graphics display

A contrast-rich LCD display with LED background illumination. Display has 6 lines, each of 28 characters. The graphics display is used for displaying the operating hours, parameters and the set-up menus.

Keypad

The controller can be configured for operation using this keypad.

Key Function

Automatic guiding

Manual positioning

Centring the guiding device (servo-center)

Left web edge guide

Right web edge guide

Web center guiding

Edge / contrast control: Contrast transition: light / dark

Edge / contrast control: Contrast transition: dark / light

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: B 2

’Automatic’ operating mode:

• Moves the setting to the left/right

’Manual’ operating mode:

• Manual left/right positioning of the guiding device

• Change between the operating status displays

Controls B 2

Key Function

B 2.2 Navigating within the system

Use the arrow keys and the F1 – F4 function keys to navigate within the system. The different functions are explained in the following.

If incorrect entries are made, or if functions are active which, for example, prevent entering of parameters (e.g. keyboard lock) the appropriate message windows are shown on the display for 5 seconds This gives the user information about which error is present in the current case. The message can be deleted using the "OK" key.

Menu navigation:

In editing box:

Jump back by one level

Cancels the last entry

Select controller settings or controller gain for change the settings

Saves the settings at the end of the set-up functions

Activates special functions (e.g. oscillation)

(not used at the present moment)

Menu selection

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Controls B 2

B 2.2.1 Function keys (F-keys)

The F-keys functions are assigned in different dialog windows. The associated abbreviated names are displayed at the bottom edge of the screen. Press the relevant F-key several times to select the required numerical value. The time interval in between pressing the button twice must never exceed 0.5 seconds.

Shortcut functions

The function keys are assigned numbers in the equipment menu. Therefore a menu option can be selected by using the arrow keys to navigate to the required menu sub-option or it can be selected directly by using the shortcut number instead.

For example:

Selecting the actuator

The associated menu sub-option is 611

(see navigation overview as well).

1. Press key . This will display the set-up menu.

Current position in device menu

Assignment of allocated function keys

To enter the shortcut number:

2. Press F2 key 3x = 6.

The "General setup" menu including the first "Actuator" submenu is called up.

3. Press the F1-key once = 1

Materia l Setup

Actuator

Sel. Std. System Save/Load Settings

General Setup

opt. Logic

123 45 6 789 0

Type (EMS&Hydr.)

Sensors/EFE

Hydraulics Add-on

Control Loop

Direction

FVG

SC-Transducer

511

The required dialog will be displayed and you can now use the arrow keys to select the parameter that has to be modified.

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Controls B 2

Entries in the editing box

The parameter values are entered directly in the editing box. This can also be realised using the F-keys.

1. Open the required sub-menu and then press the ENTER key to activate the editing box.

2. Use the horizontal arrow keys to mark the initial position for the settting.

Width Measure Offset current width:

enter ref.width

123 456

3. Enter the number. For example: press F4 x 1 = 0. The actual position will jump automatically by 1 place to the right after 0.5 seconds without an entry being made.

4. Now enter the next number in the same way as described above in Section 3.

5. Press the ENTER button to import the modified value.

6. Press the ESC button to cancel the value.

Editing box

The arrow keys can also be used to enter a value in the editing box in addition to using the F-keys.

Width Measure Offset current width:

enter ref.width

123 456

Use the horizontal arrow keys to position the cursor on the number to be modified. Now use the vertical arrow keys to increase or decrease the number. Press ENTER to import the entered value. Press the ESC button to cancel the value if you do not want to save it.

789 0

78.5

789 0

Opened editing box

Selected digit

Opened editing box

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web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: B 2

Controls B 2

Entering negative numbers

Use the horizontal arrow keys to mark the initial position for the setting.

Now use the vertical arrow keys so that the minus sign is entered or removed.

After this, enter the digit sequence as described above.

B 2.2.2 Arrow keys

Various entries can be made and options can be selected from the menu mode dialog windows. The procedure for the various controls and lists is as follows:

Control elements

Use the arrow keys to mark the required control if there are several control elements displayed in the same dialog window. For example:

sens.mode W XP

0 0 0 0

5.00

Use the ’right’ arrow key to scroll forward and

use the ’left’ arrow key to scroll backwards.

The vertical arrow keys do not have a function here.

Option lists

An entry from a default list can be selected from an option list. This is realised by pressing the ENTER button to open the selected option list.

Example:

Select an actuator type

EMS 17

Select an actuator type

EMS 10 EMS 16

EMS 17

123 456 789 0

The “▼“ or “▲“ symbols displayed on the right of the option list indicate that there are more entries in list than are displayed on the screen.

Use the vertical arrow keys to mark the position in the list. Confirm the selection by pressing ENTER.

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Controls B 2

Checkbox

Use the vertical arrow keys

Arrow keys option using the checkbox control element.

Example:

(de)activate speed control

active

X = Option active

= Option inactive

Read-only Checkbox

Read-only checkboxes only have a display function. These give the operator reports about the current status of the components (e.g. stop switch statuses).

Example:

= activated

= not activated

B 2.2.3 Buttons

Button control elements are present in certain dialog windows

Select a sensor type sensor1

<<<

dark

-2048 abs. 1775

auto

IR 2005

dark

Inv.

bright

2047

bri.

If a button is marked and the ENTER button is pressed afterwards, an action will be executed (e.g. traversing the actuator). The button will be displayed as being pressed down and the action will continue to be executed all the time that the ENTER button is kept pressed down.

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Commissioning B 3

B 3 Commissioning

B 3.1 General information

The controller ekrPro Com

the control system (connected sensors, actuator, sensor adjustment unit, ...) using the system parameters in the individual setup menus. The required parameters have already been entered if the control system is an integral part of a projected BST system. You do not have to reset anything with regard to this. A new system configuration is required if components or the controller have been exchanged on-site. The range of the settings and therefore the set-up menus that have to be taken into consideration depend on the system being used.

To simplify commissioning, the commissioning staff can select his system from a list of the most common standard systems (see chapter B.3.5). Following the selection, all of the basic settings are automatically entered in the setup menu. Finally the commissioning staff has only to check a few applicationrelated settings and if necessary adjust them accordingly.

The procedures to be used with the separate menus are described

in section B 3.7.5 General set-up.

Danger from mains voltage!

Never open the controller before switching off the mains!

is matched to the actual configuration of

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Commissioning B 3

B 3.2 Electrical connections

The system must be wired according to the accompanying connection diagram or plugged into the appropriate cable sockets.

Standard wiring sleeves with collars (DIN 46228/Part 4) must be used with all cable connections up to 0.75 mm². Wiring sleeves must not be used with cables from 0.75 mm² up to a maximum of 1.5 mm².

Using wiring sleeves:

The spring-loaded terminals have been optimised for square crimping. This can be realised using, for example, ‘WAGO’ variocrimp pliers. This type of crimping also enables the connection to be connected and disconnected without any problems. The crimping is also gas-tight, i.e. there is no space inbetween the conductor and the wiring sleeve.

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 have been made (in both cases).

The ekrPro Com connection. If the supply voltage was inversely connected to terminals 42 and 43 of the controller, this inverse polarity would also be connected to the 24 V output socket. This could lead to damage to components connected to this socket.

Attention! Applications with a sensor adjustment unit!

controller is protected against incorrect

The stepping motor output stages are not

protected against short circuits. You must check, without fail, using a suitable test unit (ohmmeter) that no short circuits or cross-connections between the two windings exist before starting the commissioning.

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Commissioning B 3

B 3.3 Commissioning

with a CAN Bus

B 3.3.1 Checking the unit address

and setting up if necessary

If the ekrPro Com setting of the CAN device address must be checked. The CAN device address setting up is carried out via the S1 BCD switch on the processor board:

The ekrPro Com state).

• Set the S1 BCD switch to "1" if the ekrPro Com

device connected to the CAN bus.

controller is operated via a CAN bus, then the

BCD switch S1

address is preset to "1" in the factory (delivery

is the only

• If you want to run several

ekrPro... family devices on one CAN bus system, then different device addresses (1 – 8) must be set for the devices. One of the devices must be set to device address "1" without

fail! Device addresses 0 and 9 are reserved.

Each device address can only be used once per guiding system!

Procedure:

1. Switch-off the power to the controller.

2. Open controller’s front cover.

3. Set S1 BCD switch to the required device address (1 – 8).

4. Close the controller’s front cover.

5. Restore the power.

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Commissioning B 3

ekrPro Key

(if fitted) :ekrPro Key60:

There are several plugs on the rear side of the

ekrPro Key

The BCD switch S1 for setting the address (node

number) is behind these plugs.

Procedure:

S1 BCD switch

1. Switch-off the power to the controller.

2. Remove the plug.

3. Check setting of BCD switch S1. If necessary, set

device address to S1 = 1.

4. Refit the plug.

5. Restore the power.

FVGPro Module (if fitted

) :FVGPro Module”

The device address setting up is also crried out via the

S1 BCD switch mounted on the board:

Procedure:

1. Switch off the power to the FVG Pro module.

2. Open housing’s front cover.

3. Check the setting of the BCD switch S1. If

necessary, set device address to S1 = 1.

4. Close the controller’s front cover.

5. Restore the power.

S1 BCD switch

The device address modification will be effective after the power has been restored

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Commissioning B 3

B 3.3.2 Terminator activation

The terminator must be activated on each of the physical first

and last CAN bus participants. The possible settings are described below.

In the ekrPro Com

, the activation is carried out using switch S3 on

B 3.3.2.1 ekrPro Com

the processor circuit board. Set the switch to "ON“.

Terminator S3

Procedure:

B 3.3.2.2 ekrPro Key

(if fitted)

1. Switch-off the power to the controller.

2. Open controller’s front cover.

3. Activate terminator S3 (switch position ON)

4. Close the controller’s front cover.

5. Restore the power.

In the ekrPro Key

activation

is carried out via switch S3.

Remove plug on the back side. Set the switch to "ON“.

Switch S3

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Commissioning B 3

B 3.3.2.3 BST ProLogic

(if fitted)

In the BST ProLogic activation takes place using the DIP switch segment 1 (S1 = ON) for the CAN 1.

CAN 2

B 3.3.2.4 FVGPro Module

(if fitted)

In the FVGPro Module activation is carried out via switch S3 on the processor circuit board. Set the switch to "ON“.

Switch S3

Procedure:

1. Switch-off the power to the module.

2. Open module’s front cover.

3. Activate terminator S3 (switch position ON)

4. Close the module’s front cover.

5. Restore the power.

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Commissioning B 3

B 3.4 Adjust password

User administration in the ekrPro Com

differentiates between four different user levels with different user rights. The individual user levels are each protected by a password. Dependent on the selected user level, more or fewer paths are activated in the setup menu. Non-activated entries are greyed out in the menus and cannot be selected. The user levels with the corresponding user rights are shown in the following table.

User level Rights Default Password Operator

(Operator)

Mainten.

Maintenance personnel

Admin.

Administrator

BST Support

(BST-Service

• No rights to make changes in the setup menus.

• Unlimited changing rights in the menu

“Material Setup”.

• Unlimited rights to make changes in the setup menus.

• As for “Admin.” (only for BST servicing purposes)

The unit is supplied with the user level Admin set.

The indicated default password should only be used for the first access to the setup menu and then an application-appropriate

password entered. This is also true for the Mainten. user level. This

protects the system against unauthorized access. Make sure these new passwords are only known to the authorized personnel! BST International GmbH is not liable for damage arising from the incorrect use of the password(s).

An automatic logout time can be set for all user levels (timeout time). If no key is pressed for the set time, the user is automatically logged

out and the controller changes to the user level Operator.

Changes to passwords and the timeout time is undertaken from the

menu General Setup > Special > Change Pwd

All passwords can be reset to the default passwords up to 20 seconds after switching on of the controller by pressing the key

combination F4” + “ESC.

When the controller is switched-off, the last active user level is stored and automatically activated after a reboot.

The procedure for selecting the user level is described in the following pages.

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Commissioning B 3

Selection of user level is undertaken from the Change User menu.

1. Select Change User menu and press ENTER.

Enter user level & password User level Password 0 Current user level: Admin.

logout

Operator

2. The user level selection window appears. In the lower part of the window the active user level is

displayed (Admin. in the example).

Enter user level & password User level Operator Password Current user level BST Support

123 456 789 0

Mainten.

Admin.

Press the ENTER button and the user level option list will then be opened. Select the desired user level with the up and down arrow keys. Confirm the selection by pressing ENTER.

Enter user level & password User level Mainten. Password Current user level: Admin

123 456 789 0

00000

3. Use the right and left arrow keys to select the Password

editing box and press ENTER.

Enter user level & password User level Mainten. Password Current user level: Admin

logout

Enter the password and confirm the entry with ENTER.

4. Press the F3-key (login).

The controller changes to the selected user level. The Setup menu selection window appears. Entries, for which there are no user rights in the selected user level are shown greyed out.

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Commissioning B 3

B 3.5 Commissioning standard system

To simplify commissioning, the commissioning staff can select his own system from a list of the most common standard systems listed

under the menu Sel. Std. System.

B 3.5.1 Select standard system

F1 for fa ct. def aults Choose standard system …

select a standard config.

… & press F2 to acti vate

Set.Def.

F1 for fa ct. def aults Choo se st andar d sys tem …

sele ct a sta ndard conf ig.

… & pr ess F2 to activate

Set.Def.

Following the selection, all of the basic settings are automatically entered in the setup menu and the system is switched to the

operating mode MAN.

1. Press the MENU button.

The setup menu of the controller appears in the display.

2. Select menu "Sel. Std. System“ and press ENTER.

3. The selection window for the standard system will appear.

4. Press the ENTER button. The option list opens with the most common standard systems. Individual entries each contain the following information:

Type of connected

sensor(s)

Type of connected

actuator

Type of the

sensor positioning device

(if fitted)

5. Use the vertical arrow keys to select the system that matches the present system. Confirm the selection with the ENTER key. The selected system is displayed.

6. To import the standard system configuration, press

function key F2 (set.). The selection is confirmed by the message window Standard System Set.

The base settings in the setup menu are automatically entered by the system. After this, the selection window is displayed again.

7. Press the ESC button to exit the window.

Attention!

After selecting the standard system, adjustment for a particular application (e.g. material properties) must take place. Accordingly, the following steps should be carried out:

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Commissioning B 3

B 3.5.2 Carry out master setup

The sensor type will already have been set when the standard system was set.

The procedure is described for Sensor 1. The master set-up for Sensors 2 and 3 is the same.

1. Select Sensors/EFE in General set-up and then select the Sensor 1 sub-directory afterwards. Confirm the respective

selection by pressing ENTER.

2. Select the type of sensor that is connected to the system from the option list displayed in the new window that has opened up and then enter it.

Attention!

If the mounting position of the selected sensor differs from the BST setting (see chapter A 1.4) or if the sensor outputs an inverted signal (e.g. another manufacturer’s sensor is being

used), then the checkbox Inv. must be checked.

A master set-up will be carried out afterwards.

Master set-up can be run automatically or manually.

dark

Inv.

bright

2047

bri.

3. Automatic master set-up:

► Press the F1 button and then cover the sensor’s scanning

window with an opaque material for two seconds afterwards.

Select a sensor type sensor1

<<<

dark

-2048 abs. 1775

auto

IR 2005

► Remove the material from the scanning window and press

the F2 button two seconds later.

► This completes the master set-up for this sensor.

4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque

material and then press the F3 button.

► Remove the material so that the window is completely

uncovered and press the F4 button.

5. Run the master set-ups for Sensors 2 and 3.

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Commissioning B 3

B 3.5.3 Setting the actuator

guiding direction

For standard systems, the EMS17 is registered as the actuator. The direction has to be set for it.

1. Select the sub-directory Direction from the menu Actuator.

Confirm the selection by pressing ENTER.

If necessary, the actuator guiding direction for manual mode

can be reversed by activating the checkbox Mot. Dir. Inverted.

The rotational direction can be checked on the spot.

Drive the actuator using the F2 or F3 key. If key F2 is pressed, the actuator must move the material web

Toggle Man Dir. until F2 moves to sensor 1

Mot. Dir. Inverted

in the direction of sensor 1, if F3 is pressed it must move it

towards sensor 2!

Pressing F2 or F3 automatically changes the controller to

“manual” operating mode. The sensor allocation can be checked on the spot. Press the

MENU button. The operating display is shown.

Cover one sensor. The change to the coverage range shows the allocation.

After this, press the MENU key to ENTER to the settings

menu.

2. Press the ESC button to exit the window.

B 3.5.4 Setting the actuator

path limits

From here it is possible to limit the adjustment travel of the actuator.

Change User

Actuator

Material Setup Sel. Std. System

General Setup

opt. Logic

123 456 789 0

Type (EMS&Hydr.)

Sensors/EFE Control Loop FVG

Type & Dir.

Hydraulics Add-on

Pos. Limit

Directions

SC W & XP

SC-Transducer

1. Select Actuator in General Setup, then the sub-directory SC-Component and finally Pos. Limit.

Confirm the respective selection by pressing ENTER.

2. Use the vertical arrow keys to deactivate the checkbox active.

This deactivates the function of both limit switches.

The settings can only be entered in the deactivated state.

3. Use the F2 key to drive the actuator until it reaches the

required left limit switch position. The actual position of the actuator supplied by the position

feedback is shown in the middle above the F2 and F3 keys.

4. Confirm this position by pressing the F1 key.

The limit switch position is stored. The corresponding position value is shown below the checkbox.

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Commissioning B 3

5. Use the F3 key to traverse the actuator until it reaches the

required right limit switch position.

6. Confirm this position by pressing the F4 key.

7. Reactivate both limit switches.

Select (x) checkbox active to do this.

The description is given in section 2. Import of the limit switch position is indicated by a black circle

in the read-only checkbox above the F1 and/or F4 key.

Confirm the selection by pressing ENTER.

8. Press the ESC button to exit the inputting menu.

B 3.5.5 Setting centre position

and gain for “SC” operating mode

From here the centre position and the amplification for operating

mode SC are set.

1. Select Actuator in General Setup, then the sub-directory SC-Component and finally SC W & XP.

2. Press ENTER to open the inputting menu and enter the parameters.

3. The current actuator position will be displayed in the field

mot.pos..

4. Use the F2 and F3 keys in MAN operating mode to traverse

the actuator into the required position.

5. Press the F4 key if you want to save the current position as

the setpoint value for the centring position.

The setting from mot.pos. will be imported into set-point W.

6. The setpoint value setpoint W and the gain gain XP can also

be entered directly in the relevant window.

7. The settings can be checked on the spot by switching over to

the SC operating mode.

8. Press the ESC button to exit the window.

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Commissioning B 3

B 3.5.6 Carry out material setup

Automatic adjustment of the controller to match the characteristics of the material to be scanned is carried out during material set-up (e.g. different material transparency at the optical sensors or different sound absorption in the case of ultrasonic sensors). The material set-up is the same for all three sensors. The procedure for sensor 1 is used as the example here:

1. Press the MENU button to open the set-up menu.

2. Select Material set-up and confirm by pressing ENTER.

3. Select Sensor 1 and confirm by pressing ENTER.

This will open the Sensor 1 material set-up window.

Material Setup - Sensor 1

<<<

dark

-2048 abs. 1775

auto

dark

bright

2047

bri.

Material set-up can now be carried out either automatically or manually.

The manual procedure should always be used if the contrast that has to be scanned is critical.

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Commissioning B 3

B 3.5.6.1 Automatic material set-up

1. Press the F1-key.

2. Completely cover the sensor’s scanning window with the material to be scanned for approx. 2 seconds.

3. Completely remove the material from the sensor scanning window (no material over the sensor).

4. Press the F2-key.

This completes the material set-up for this sensor. Material set-up is finished when the same procedure has been carried out for any other sensors connected to the controller.

B 3.5.6.2 Manual material set-up

1. Completely cover the sensor’s scanning window with the material to be scanned.

2. Press the F3-key.

3. Completely remove the material from the sensor scanning window (no material over the sensor).

4. Press the F4-key

The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or the bright setting (steps 3 and 4) can be made first.

For sensors TW54 and T62, you must use the special

Material-Setup – Sensor 3 (see Point C 2.3.4).

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Commissioning B 3

B 3.5.7 FVG - Sensor positioning device

The stepping motor output stages are not

The connection cable from the ekrPro Com

control unit to the sensor adjustment unit must not exceed the maximum cable length of 20 m.

Power is continuously applied to the stepping motor output stage, even when stopped. Therefore any work undertaken on the interconnections must only be carried out with the power switched off.

B 3.5.7.1 Default values set

Depending on the configuration selected under Select Standard System, various default settings are carried out in the FVG

submenu.

B 3.5.7.1.1 Configuration-dependent default values

1. Selection IR2005:EMS 17 or US2007:EMS 17

For this selection, the sensor positioning device connection

entitled "not connected" is selected and entered. No additional

entries have to be carried out.

2. Selection IR2005:EMS17:1MK60 or IR2005 EMS17:1MK75 resp. US2007:EMS17:1MK60 or US2007:EMS17:1MK75

If one of these configurations is selected, the FVG 1MK Op. sensor

positioning device connection is selected and entered. The following settings-dependent parameters are selected and entered:

- Homing Direction – retraction direction and limit switch assignment

• at the first setting after switching on: not reversed

- Offset 1:

• at the first setting after switching on:

Offset = 0

Inverted = no

- Offset 2:

• at the first setting after switching on:

Offset = 2000

Inverted = yes

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- Range – Traversing range limits

• at the first setting after switching on:

min = 0.0 max = 5000.0

- Feed – Feed for stepping motor / gearing combination

This setting is treated as the feed per motor revolution for the stepping motor / gearing combination. The respective value is automatically entered when the FVG type is selected: for FVG 1MK60 = 20088 for FVG 1MK75 = 61666. The manufacturer has entered this default setting and you are only permitted to modify it (if necessary) after having obtained the manufacturer’s agreement. The relevant procedure then has to be agreed. All warranty claims will be invalidated in any other case.

3. Selection IR2005:EMS17:2MK60 or IR2005 EMS17:2MK75

resp. US2007:EMS17:2MK60 or US2007:EMS17:2MK75 If one of these configurations is selected, the "FVG 2MK Op.“

sensor positioning device connection is selected and entered. The following settings-dependent parameters are selected and entered for the FVG 1 (Slide 1)and the FVG 2 (Slide 2):

Slide 1

- Homing Direction – retraction direction and limit switch assignment

• at the first setting after switching on: not

reversed

- Offset - positional offset to FVG position

• at the first setting after switching on: Offset = 2000

Inverted = no

- Range – Traversing range limits

• at the first setting after switching on:

min = 0.0 max = 5000.0

- Feed – Feed for stepping motor / gearing combination

This setting is treated as the feed per motor revolution for the stepping motor / gearing combination. The respective value is automatically entered when the FVG type is selected: for FVG 2MK60 = 20088 for FVG 2MK75 = 61666. The manufacturer has entered this default setting and you are only permitted to modify it (if necessary) after having obtained the manufacturer’s agreement. The relevant procedure then has to be agreed. All warranty claims will be invalidated in any other case.

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Slide 2

- Homing Direction – retraction direction and end switch assignment

• at the first setting after switching on: not

reversed

- Offset - positional offset to FVG position

• at the first setting after switching on: Offset = 2000

Inverted = yes

- Range – Traversing range limits

• at the first setting after switching on:

- Feed – Feed for stepping motor / gearing combination

This setting is treated as the feed per motor revolution for the stepping motor / gearing combination. The respective value is automatically entered when the FVG type is selected: for FVG 2MK60 = 20088 for FVG 2MK75 = 61666. The manufacturer has entered this default setting and you are only permitted to modify it (if necessary) after having obtained the manufacturer’s agreement. The relevant procedure then has to be agreed. All warranty claims will be invalidated in any other case.

B 3.5.7.1.2 Configuration-independent default value

The following values are general settings, which can be selected and entered as default values independently of the FVG selected.

- Retract Mode – free-running mode

min = 0.0 max = 5000.0

• at the first setting after switching on: SC & Man

- Norming Mode – Standardization Mode

Setting of the standardization mode is dependent on the type of sensor being used.

Infrared sensors: The mode is always set to "bright/dark“. Ultrasonic sensors: The mode is always set to "no norming“.

- Width Adjust – FVG operating mode for center line guiding

• at the first setting after switching on: Level Outer

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- Repositioning – repositioning of the material after certain events

The current position of the material web is saved once an event takes place (e.g. web tear). Once the event has been rectified, the material is repositioned to this position. This functionality is only effective once pre-positioning has been activated.

- Velocities – adjustment of positioning speeds

• at the first setting after switching on:

Retract velocity: 60 mm / s Edge push velocity: 5 mm / s Slow manual velocity: 1 mm / s Fast manual velocity: 60 mm / s Norming velocity: 60 mm / s

- Special – Special settings for driving the FVG slides

• at the first setting after switching on:

Mode after error: Man

Carry out setting according to point B 3.7.5.5, if the settings listed above, for the sensor adjustment unit, do not corresponding to the operating requirements.

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B 3.5.8 Add. Functions – Special functions

Useful additional functions can be realised using the ekrPro Com

These functions can be accessed quickly under this menu point.

These functions deal with the Tear Off Detection and Oscillation.

B 3.5.8.1 Tear-Off Det. – Tear-off detection

Tear-off detection enables, dependent on the selected sensing

type (edge / contrast guiding) the following functions:

1. With web edge guiding:

Detection of torn off sections on the web edge using edge sensors IR2001/2005, US2007, …

This function is activated during web edge guiding, if during operation of the web guiding system errors arise from the web edge that is being scanned. The function detects both tears into the material web (inward tear) as well as projecting material (outward tear).

2. With contrast guiding:

Guiding on interrupted printed or contrast edges with contrast sensors T62D1 or TW54C5.

Interrupted printed or contrast edge

Light spot of the contrast sensor

Tear-off inwards

Tear-off outwards

Tear-off detection can be implemented using the same sensors that are used for web guiding. Alternatively a second sensor can be used.

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Criteria for detecting a tear: To detect a tear, at least one of the two following criteria must be

fulfilled:

1. Exceeding / undershooting of the preset threshold value

If the sensor signal exceeds or falls below the set threshold value

(threshold), then this is recognised as a tear. After a preset delay time (delay) has elapsed, the web guiding

system is automatically blocked. Blocking of the guidance system is lifted, as soon as the sensor signal again lies above/below the set threshold value and the set

run-on time (hold time) has elapsed.

2. Exceeding of the preset maximum rate of change of the sensor

signal. The system continuously checks the rate of change speed of the

sensor signal in both positive and negative directions. If the

preset maximum permissible rate of change (sig. chg. lim.) is

exceeded, then this is recognized as a tear.

After a preset delay time (delay) has elapsed, the web guiding

system is automatically blocked. If the set rate of change is undershot, then blocking of the guiding

system is not

lifted.

Lifting of the blocking is only implemented if the preset threshold

value (threshold) is again undershot (see point 1).

Conditions for guiding on interrupted printed or contrast edges

For trouble-free operation of the control unit, the following conditions must be fulfilled:

1. Minimum mark length

The printed or contrast edge to be sampled must not fall below

the minimum mark length L depends on the maximum web speed, v

. The minimum mark length

min

, the sampling cycle, t,

max

and the diameter, d, of the light spot of the contrast sensor used.

It can be calculated using the following formula.

Light spot

min

[m/min]

[m] = * 3 * t [s] +

max

60 s/min

d [mm]

1000 mm/m

= minimum mark length [m]

min

= max. web speed [m/min]

max

t = sampling cycle [s] = 0.004 s d = light spot diameter [mm]

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Example calculation:

At a maximum web speed v diameter d = 8 mm the resultant minimum mark length L

= 300 m/min and a light spot

max

min

equals:

300 m/min

= ¹ 3 ¹ 0,004 s ¬

min

60 s/min

8 mm

1000 mm/m

= 0,068 m = 68 mm

min

2. Alignment of the contrast sensor:

When scanning an interrupted line

, correct alignment

of the contrast sensor must be observed:

• The contrast sensor must be aligned so that the edge

of the line is located in the sensor light spot.

• Only one

edge may be located within the light

spot.

correct

wrong wrong

3. Operating mode setting for the contrast sensor T 62 D 1

The operating mode selection switch on the sensor must be set

to the position Kante (edge).

Operating mode selection switch

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Parameter settings

Setting of the parameters for the function tear-off detection is made

separately for each guiding mode. If necessary, a different sensor can be allocated as the tear-off detection sensor for each guiding mode. It is also possible to allocate two different guiding modes with different parameters to a single sensor.

1. Select Add. Functions in General Setup and then select the Tear Off Det. sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3, Center 1&2) from the option list.

Confirm the selection by pressing ENTER.

3. This will open up the inputting window for the selected guiding mode. The following separate parameters can be set:

► Sensor:

Selection of the sensor with which tear-

off detection is to be implemented.

► threshold [%]: Percentage covering of the sensor

measuring band, above which a change is detected as a tear. For the example value entered here (80/20), this means that the function detects a tear, if more than 80% or less than 20% of the sensor measuring band is covered.

► sig. chg. limit. [%/4ms]: Maximum permissible rate of

change of the sensor signal in % per 4 ms (Scanning cycle = 4 ms, i.e. the sensor measurements are read every 4 ms). A tear is detected, if the rate of change of the sensor signal exceeds the percentage per 4 ms set here. The values to be set are calculated according to the formula on the following page.

► delay [ms]: Delay time in ms from detection of a tear

until blocking of the guiding system.

► hold [ms]:

Blocking hold time in ms after the

detected end of the tear until the blocking is lifted, i.e. until the guiding system is activated.

4. If necessary, set parameters for further guiding modes (see points 2 and 3).

5. Press the ESC button to exit the window.

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Calculation of the maximum allowable rate of change of the sensor

signal (parameter sign. chg. limit) The maximum permissible rate of change sig. chg. limit of the

sensor signal, depends of the minimum web speed v

min

and

diameter d, of the contrast sensor light spot and can be calculated

using the following formula.

sig. chg. limit [%/4ms] = 2 ¹ * ¹ 100

[m/min]

min

60 s/min * d [mm]

sig. chg. limit = permissible rate of change [%/4ms]

= min. web speed [m/min]

min

d = light spot diameter [mm]

Example calculation:

At a minimum web speed v

= 30 m/min and a light spot diameter

min

d = 10 mm the resultant maximum rate of change of the sensor signal equals:

sig. chg. limit [%/4ms] = 2 ¹ ¹ 100

30 m/min

60 s/min * 10 [mm]

sig. chg. limit [%/4ms] = 10 % /4ms

B 3.5.8.2 Oscillation

This special function enables the position of the web to be displaced within the sensor´s visual range using adjustable amplitude (size of the lateral displacement) and frequencies (displacement speed).

The format of the web displacement when the controller is operated without a sensor positioning device follows a delta curve ( ). When operated with a sensor positioning device, a sine-wave ( ) web displacement takes place. See also chapter A1, Point A 1.4.4‚ Oscillation types and curves’.

Osc. Mode – determine operating mode for oscillation mode

1. Select Add. Functions in General Setup and then select the Osc. Mode sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. The set value for the web width (Nominal Width) is entered in this window. Activation then takes place in the operating

status display using the F1 key.

The following settings are possible:

• • OFF:

Oscillation is deactivated

(factory setting)

• Auto:

Activation in operating mode

Automatic

Repositioning of material web is carried out within the sensor visual area with adjustable amplitude.

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• SC:

Activation in operating mode SC

using the servo-center component.

• FVG Auto:

Oscillation with connected FVG An FVG oscillation with sine-shaped web repositioning.

3. Press the ESC button to exit the window.

Osc. Params. – Set oscillation parameters

The oscillation parameters, i.e. amplitude and frequency, are set in this submenu.

1. Select the Osc. Params submenu and confirm by pressing

ENTER.

2. The parameters have the following meanings:

► Amplit. Auto [%]:

Amplitude of the oscillation in operating

mode Automatic.

The percentage value relates to the size of the sensor scanning area. Setting range: 1 % to 99 %

► Amplit. SC [%]:

Setting up the amplitude for the SC

operating mode The percentage wise input of the amplitude relates to the distance between the software limit switches. One limit switch represents 0 % and the other 100 %. Setting range: 1 % to 99 %

► Amplit. FVG [mm]

Amplitude of oscillation when using a

sensor positioning device. The sample value shown here of 10 mm results in repositioning of the web by ± 5 mm. Setting range: 0 to 999.9 mm

► Frequency [Hz]:

Oscillation frequency.

Setting range: 0.016 … 1.000 Hz

3. Press the ESC button to exit the window.

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Osc. Params Add-on – Additional functions for oscillation (can only be used for the sensor oscillation)

Additional specifications can be set for the sequence of the oscillation in this sub-menu.

1. Select the sub-menu Osc. Params Add-on and

confirm with ENTER.

2. The parameters displayed in the setting menu have the following meanings:

Oscillation Add-on:

► start/stopp at act.pos:

When the function is activated, the oscillation will continue at the position

>> NOT FOR FVG OSC.!<<

where it was stopped.

► start osc. after restart:

When the function is activated, the oscillation is immediately started when the system is switched back on.

B 3.6 Save settings

Once the parameters have been determined for the current system, they can be saved. This enables the facility to access them again at any time in the case that modifications have been carried out unintentionally or by unauthorized persons.

1. Press the MENU button.

The Setup menu appears in the display.

2. Select Save/Load Settings menu and press ENTER.

3. Saving or loading the settings can now be carried out using

keys F2 or F3. F2 = Save the entered setting

F3 = Load saved values

4. Press the ESC button to exit the window.

Attention! This setting cannot be copied to another

controller or saved externally.

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B 3.7 Setup menu

The system parameters are saved in the Setup menu and they can also be modified from here. The menu structure is shown in Appendix D1.

B 3.7.1 Change User Selection of user level-

User administration in the ekrPro Com

different user levels with different user rights. The individual user levels are each protected by a password.

The procedure for selecting the user level is described in detail in chapter B 3.4.

B 3.7.2 Material Setup - Sensor co mpensation

The procedure for material setup is described in chapter C 2.3.

B 3.7.3 Sel. Std. System – Selection of a standard system

To simplify commissioning, the commissioning staff can select his own system from a list of the most common standard systems listed under the menu "Sel. Std. System". Following the selection, all of the basic settings are automatically entered in the setup menu.

differentiates between four

B 3.7.4 Save/Load Settings

The procedure for selecting a standard system is described in detail in chapter B 3.5.

You can use this function to save user-defined settings in the system and call them up again. This gives you the facility for accessing them at any time in the case that modifications have been carried out unintentionally or by unauthorized persons.

The procedure for selecting a standard system is described in detail in chapter B 3.6.

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B 3.7.5 General Setup - System parameters

All of the parameters that have to be set up once when aligning the

system are contained in the General set-up.

The following procedures are provided for the different operating modes. However, the default values should be loaded before the special parameters are set up. This will meet the condition for a standardised basic output.

B 3.7.5.1 Setting the default values

1. Go to the General set-up menus and then select Sel. Std. System

F1 for fa ct. defaul ts Choo s e st andar d system …

sele c t a sta ndard config .

… & press F2 to activate

Set.Def.

2. Press the F1-key. The default settings will be loaded.

3. Press the ESC button to exit the window.

4. The application specific parameters can be set up now.

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B 3.7.5.2 Actuator – Actuator settings

B 3.7.5.2.1 Type (EMS&Hydr.) – Actuator selection

The relevant servo center component must be entered before starting the commissioning (see chapter B 3.7.5.2.4 ”servo-center component settings“). Any remote control which may possibly be running, must be deactivated!

The preset actuator is the EMS 17.

Actuator path limits and the servo-center component have to be adjusted.

If a different motor-driven or hydraulic actuator is being used it should first be selected from the option list. The actuator selection procedure is shown on the left.

1. Press the MENU button, select General Set-up from the sub-

menu and then press ENTER.

2. Select Actuator in General Setup and then select the Type (EMS&Hydr.) sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

Mate rial Set up

Actuator

Sel. Std. System Save/Load Settings

General Setup

opt. Logic

123 45 6 789 0

Type (EMS&Hydr.)

Sensors/EFE

Hydraulics Add-on

Control Loop

Direction

FVG

SC-Transducer

3. The default actuator will be displayed on the screen. Press the ENTER button and the actuator option list will then be opened. Now use the vertical arrow keys to select the actual actuator that is connected to the system.

Motor-driven actuators: EMS …

Select an actuator type

EMS 17

Hydraulic actuators: hyd. … mA

If a hydraulic actuator is used, then additional

Note:

hydraulic settings must be made in the menu

Hydraulics Add On (see the following page).

Confirm the selection by pressing ENTER.

Select an actuator type

EMS 10 EMS 16

EMS 17

Press the ESC button to exit the window.

123 456 789 0

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B 3.7.5.2.2 Hydraulics Add-on – Hydraulic settings

If a hydraulic actuator is used, then additional hydraulic settings

must be made in the menu Hydraulics Add On.

1. Select Actuator in General Setup and then select the Hydraulics Add-on sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. This will open an inputting window, in which the settings for the connected hydraulic actuator have to be entered. The relevant settings are listed in the following table:

Zero elevation [%] Dither amplitude [mA] Use teach table Specific current control

Teach

0 0

Unit

name

Actuator

Type

Dither

amplitude

[mA]

Zero

elevation

[%]

Specific

current

control

SV 1-10/4 300 mA 10 0 No

SV 1-10/8 300 mA 10 0 No

SV 1-10/16 300 mA 20 0 No

SV 1-10/32 300 mA 20 0 No

SV 1-10/48 1000 mA 40 0 No

SV 1-6 300 mA 20 0 No

HR 024 300 mA

HR 040 300 mA 20 0 No

EH-St 9/3 300 mA 25 5 No

The dither frequency is 50Hz.

1* This setting is dependent on the fitted continuously operated

valve SV 1-10/x.

3. The system must be optimized to the actual settings after the parameters have been entered. This is realised by an integrated self-teach function.

Press the F3 key to start this function.

This will import the throughput curve for the hydraulic actuator. The measured values are saved in table as nonvolatile settings.

Attention! The hydraulic actuator will traverse during the

teach process. The relevant safety arrangements

Zero elevation [%] Dither amplitude [mA] Use teach table Specific current control

Teach

0 0

The flow curve determined for the controller must be activated in the window if it is to be used.

must be implemented.

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Digital blocking output (oil blocking)

If a hydraulic actuator is used, then a blocking valve can be connected to terminal 67 (X15), in order to interrupt the oil flow.

Oil blocking is only active with a hydraulic actuator and when one of the following conditions is fulfilled:

• Man output = 0 and position controller deactivated.

• A limit switch position is reached.

• An over-temperature and a short circuit exist.

• Missing enable for the actuator:

(see actuator enable terminal 53)

Behaviour when oil blocking is switched on:

• PWM and analogue output are blocked.

• Blocking is activated after a 150 ms delay

(OV at terminal 67 (X15)

Behaviour when oil blocking is switched off:

• Blocking is deactivated (24 V DC at terminal 67 (X15))

• Blocking is deactivated after a 150 ms delay.

B 3.7.5.2.3 Direction – setting the

actuator guiding direction

1. Select the sub-directory Direction from the menu Actuator.

Confirm the selection by pressing ENTER.

If necessary, the actuator guiding direction for manual mode

can be reversed by activating the checkbox Mot. Dir. Inverted.

The rotational direction can be checked on the spot.

Drive the actuator using the F2 or F3 key.

Toggle Man Dir. until F2 moves to sensor 1

Mot. Dir. Inverted

If key F2 is pressed, the actuator must move the material web in the direction of sensor 1, if F3 is pressed it must move it

towards sensor 2!

Pressing F2 or F3 automatically changes the controller to manual operating mode.

The sensor allocation can be checked on the spot. Press the

MENU button. The operating display is shown.

Cover a sensor. The change to the coverage range shows the allocation. After this, press the menu key to ENTER to the settings menu.

2. Press the ESC button to exit the window.

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B 3.7.5.2.4 SC Transducer -

Servo-center component settings

Type & Dir. – Selecting the servo-center component

1. Select the sub-directory SC-Transducer from the Actuator menu and then select Type & Dir..

Confirm the respective selection by pressing ENTER.

not connected

2. Use the horizontal left or right arrow keys in the newly

opened window to select the servo-center component selection window and confirm it by pressing ENTER.

3. Select and mark the relevant servo-center component from the option list. For actuators with integrated position feedback (EMS 17, EMS 20B, EMS 21 and EMS 22) there is a common

servo-center component. In this case EMS_Pot. has to be

selected.

Select not connected if a servo-center component is not

connected to the system.

4. Confirm the selection by pressing ENTER. The screen will ENTER to the previous window.

5. Drive the actuator using the F2 key, while monitoring the bar

indicator in the display. Position feedback via the servo-center component must be configured so that when the actuator is driven, the black bar on the left side gets smaller.

If the length of the black bar increases when the F2 key is

pressed, inverting is to be switched on by selecting the check

box Inv.. Pressing key F3 must cause the black bar to increase towards

the right side.

The absolute position value supplied by the servo-center component is displayed beneath the bar display.

Press the ESC button to exit the window.

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Pos. Limit – Setting the actuator path limits (software limit switches)

This sub-directory is only be used if an actuator with position feedback (for example, EMS 17) is connected to the system. This enables you to limit the actuator paths.

1. Select Actuator in General Setup, then the sub-directory SC-Transducer and finally Pos. Limit.

Confirm the respective selection by pressing ENTER.

2. Use the vertical arrow keys to deactivate the checkbox active.

This deactivates the function of both limit switches.

The settings can only be entered in the deactivated state.

3. Use the F2 key to drive the actuator until it reaches the

required left limit switch position. The actual position of the actuator supplied by the position feedback is shown in the middle above the F2 and F3 keys.

4. Confirm this position by pressing the F1 key.

The limit switch position is stored. The corresponding position value is shown below the checkbox.

5. Use the F3 key to traverse the actuator until it reaches the

required right limit switch position.

6. Confirm this position by pressing the F4 key.

7. Reactivate both limit switches.

Select (x) checkbox active to do this.

The description is given in section 2. Import of the limit switch position is indicated by a black circle

in the read-only checkbox above the F1 and/or F4 key.

8. Press the ESC button to exit the inputting menu.

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SC W & XP –

Setting the centre position and the gain for the SC operating mode

This sub-directory is only be used if an actuator with position feedback (for example EMS 17) is connected to the system. In this case the centre position setting option and the gain have to

be set up for the SC operating mode.

1. Select Actuator in General Setup, then the sub-directory SC-Transducer and finally SC W & XP.

2. Press ENTER to open the inputting menu and enter the parameters.

3. The current actuator position will be displayed in the field

mot.pos..

4. Use the F2 and F3 keys in MAN operating mode to move the

actuator into the required position.

5. Press the F4 key if you want to save the actual position as the

set point for the servo-center position.

The setting from mot.pos. will be imported into setpoint W.

6. The setpoint value setpoint W and the gain gain XP can also

be entered directly in the relevant window.

7. The settings can be checked on the spot by switching over to

the SC operating mode.

8. Press the ESC button to exit the window.

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B 3.7.5.2.5 Man Pos Control – Activation of the Position Controller

The position controller for ”manual” mode can be activated for actuators with position feedback (e.g. EMS 17). With the position controller activated, the actuator keeps the actual

position when in manual mode, independently of any external forces

acting on the drive (self-locking).

When using an OMG 4, OMG 8 or CK 37 servo-center component, the position controller must be deactivated!

1. Select Actuator in General Setup and then select the Man Pos. Control sub-directory afterwards.

2. Press the ENTER button to enter the inputting menu.

3. To switch on the position controller activate checkbox active

using the vertical arrow keys.

To test the position controller the actuator can be moved in

manual mode to a desired position using the F2 and F3 keys.

If the position controller is activated, the function can be

interrupted by pressing the F4 key (e.g. to prevent damage to

the material web).

4. Press the ESC button to exit the window.

B 3.7.5.2.6 Man Speed – adjustment speed for

manual mode

This sub-menu is used to set the positioning speed of the actuator in

manual operating mode.

1. Select Actuator in General Setup and then select the Man Speed sub-directory afterwards.

2. Press the ENTER button to enter the inputting menu.

3. Enter the desired positioning speed in the editing box

MAN speed [1/1000].

Input of the positioning speed is as a percentage of the maximum positioning speed.

The example value of 700 entered here means a positioning

speed of 700 per thousand = 70 percent of the maximum speed.

To test the set positioning speed move the actuator using the

F2 and F3 keys.

4. Press the ESC button to exit the window.

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Commissioning B 3

B 3.7.5.3 Sensors/EFE – Commissioning sensors and remote electronic fine adjustment

B 3.7.5.3.1 Sensor 1, 2, 3 – Commissioning sensors

The types of the sensors that are actually connected can be set up in the sub-menus Sensor 1, Sensor 2 and Sensor 3.

The following must be undertaken before running the master set-up so that the correct guiding results and the correct importing of the sensor reference setting for checking the amount of dirt can be guaranteed:

a) Clean the lenses if using optical scanning with infrared

edge sensors

b) Clean the transmitting and receiving capsules if

scanning with ultrasonic edge sensors

The commissioning of the sensor (master set-up) only has to be run once during the initial start up of the respective sensor.

Setting up the sensor and operation

Select a sensor type sensor1

<<<

dark

-2048 abs. 1775

auto

IR 2005

bright

dark

Inv.

2047

bri.

The procedure is described for Sensor 1. The master set-up for Sensors 2 and 3 is the same.

1. Select Sensors/EFE in General set-up and then select the Sensor 1 sub-directory afterwards. Confirm the respective

selection by pressing ENTER.

2. Select the type of sensor that is connected to the system from the option list displayed in the new window that has opened up and then enter it.

Attention!

If the mounting position of the selected sensor differs from the BST setting (see chapter A 1.4) or if the sensor outputs an inverted signal (e.g. another manufacturer’s sensor is being

used), then the checkbox Inv. must be checked.

A master set-up will be carried out afterwards.

Master set-up can be run automatically or manually.

3. Automatic master set-up:

► Press the F1 button and then cover the sensor’s scanning

window with an opaque material for two seconds

► Afterwards remove the material from the scanning window

and press the F2 button two seconds later.

► The master set-up for this sensor is finished.

4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque

material and then press the F3 button.

► Remove the material so that the window is completely

uncovered and press the F4 button.

5. Run the master set-ups for Sensors 2 and 3.

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Commissioning B 3

Attention! If a reflection sensor is being used as Sensor 3

then only this sensor must be selected and entered from the option list. You do not have to run a master set-up.

B 3.7.5.3.2 EFE Remote Adj. –

Commissioning of remote electronic fine adjustment (EFE)

A remote electronic fine adjustment unit is not identified automatically by the controller. It must be entered in the set-up menu.

1. Select Sensors/EFE in General Setup and then select the EFE Remote Adj. sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. Not connected is the default factory setting. Select EFE 1 if a remote adjustment device is available.

3. Press the ESC button to exit the window.

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B 3.7.5.4 Control Loop - Control loop settings

The parameters for the control circuit are set up in this sub-menu.

B 3.7.5.4.1 Gain & Offset – Amplification & setpoint values

1. Select Control Loop in General Set-up and confirm by

pressing ENTER afterwards.

2. Mark Gain & Offset in the selection window and then confirm

by pressing ENTER.

3. This will open up a window for the set point value and gain settings. The set value (W) for the web position and the gain setting (XP) can be set up separately here for each of the guiding modes. We recommend that you should use the factory default settings for standard controllers.

Setting range: 0 – 999.99

sens.mode W XP

0 0 0 0

5.00

4. Press the ESC button to exit the window after you have

entered the settings.

B 3.7.5.4.2 Adj. done Limits – Bearing position controlled

This function is only relevant when being used together with a Profibus DP module for exchanging data with the customers

PLC. The corresponding protocol is Protocol 1049.

Using the specifications (notification threshold), evaluations are made in this sub-menu as to when a new position that has been approached is termed as controlled. This can then be used as the start position for the following working sequence. This notification threshold must be determined empirically and individually for each application. You can only influence the message and not to the controlling of the system.

1. Mark Adj.done Limits in the selection window and then

confirm by pressing ENTER.

2. Determine the values.

Note that: Larger values require an earlier message.

3. Press the ESC button to exit the window.

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B 3.7.5.4.3 Speed Control – Speed regulation

When speed control is activated, speed variations, which can be caused by varying loading of the actuator, are automatically compensated. This activation of this function is a default setting. It must be deactivated if a tacho-generator is being used.

1. Select Speed control in the selection window and then

confirm by pressing ENTER.

2. Activate speed control using the vertical arrow keys:

3. Press the ESC button to exit the window.

(de)activate speed control

active

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B 3.7.5.5 FVG –

Sensor positioning device

The control unit integrated in the controller for running the sensor positioning device can be parameterised in this sub-menu. A stepping motor drives the sensor adjustment unit.

The stepping motor output stages are not short circuits. You must check, without fail, using a suitable test unit (ohmmeter) that no short circuits or cross-connections between the two windings exist before starting the commissioning.

The connection cable from the ekrPro Com sensor adjustment unit must not exceed the maximum cable length of 20 m.

Power is continuously applied to the stepping motor output stage, even when stopped. Therefore any work undertaken on the interconnections must only be carried out with the power switched off.

The FVG function has been set to not activated in the factory, i.e.

no further settings are required if an FVG is not connected to the system.

The required setting must be entered if the FVG function will be used.

B 3.7.5.5.1: Connection – Activating of the sensor positioning

device (FVG) connected

1. Select FVG in General Setup and confirm by pressing ENTER

afterwards.

2. Select Connection in the selection window and then press

ENTER to open the inputting menu.

3. Select the desired operating mode from the option list.

• Not Connected:

• FVG eco:

• FVG 1MK Op.:

• FVG 2MK Op.:

Move the sensors/FVG slides manually

Sensor positioning device with stepping

Sensor positioning device with two

4. Press the ESC button to exit the inputting menu.

protected against

control unit to the

The sensor positioning device is

deactivated (default setting).

by means of the controller arrow keys.

motor. The FVG slides are moved by the controller.

stepping motors. It is fitted with a hoist. The FVG slides are moved by the controller.

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Once the selection has been made, specific settings must be carried

out for the FVG eco, FVG 1MK Op. and FVG 2MK Op. modes.

B 3.7.5.5.2 FVG eco

The FVG eco mode allows the sensors/FVG slides belonging to the

FVG connected to be moved using the controller arrow keys. It effectively represents manual operation of the FVG. For this reason, automatic edge search functions and web width adjustment are inactive

in this mode.

The specific settings are analogue to those in the Internal FVG. The

procedure is described under point 3.7.5.5.3.

B 3.7.5.5.3 Internal FVG

The Int. FVG submenu is used when the FVG 1MK Op. mode has

been selected (normally when using a FVG 1K or FVG 1MK).

Homing Direction – Retraction direction and limit switch assignment

The sensor’s retraction direction and the assignment of the limit switches are set up in the next steps.

1. Mark Int. FVG in the FVG selection window and then confirm by pressing ENTER. Select Homing Dir. from the sub-

directory and then press ENTER to open the inputting menu.

Change User

Actuator

Material Setup Sel. Std. System

General Setup

opt. Logic

123 456 789 0

Connected

Sensors/EFE

Homing Dir.

Control Loop

Retract Mode

FVG

Err. Behaviour

2. Press the F1 key to check the selected retraction direction. By pressing the F1 key, the FVG slide must move outwards

(into the homing position). After the homing position is reached, the limit switch with the

outer label must be activated ( ).

Exit the window without making any changes if the homing direction and limit switch assignment are correct.

If the FVG slide moves inwards when the F1 key is pressed, then the checkbox Homing dir. inv. should be activated. If the limit switch with label inner is activated in the homing position, then the checkbox Ref. switch inv. should be

activated.

If the limit switch is activated but no checkbox

Note:

(outer or inner) is activated, then the limit switch

requires testing.

3. Press the ESC button to exit the inputting menu after you

have entered the setting.

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Commissioning B 3

(

The outside FVG1 limit switch has been determined as the reference point for the FVG slide (offset = 0.0 mm)

Offset

Offset 2 (FVG)

FVG 1

Web running

direction

FVG 2

Offset 1 – position offset to FVG1 slide position

You can use the position offset to, for example, set the home position (= 0.0 mm) to a fixed point, e.g. machine wall or a specific point within the machine. The offset value is added to the current FVG position, which results in the "Abs. slide pos.“

absolute position

. machine wall e.

Fixed point in the machine

offset

Home position

[Dist. from home = 0.0 mm]

actual FVG position

Offset 2 – position offset to FVG2 slide position

The meaning of the entry and display fields is equivalent to those of

Offset 1.

2000 mm has been set as the default value for the FVG2 offset. When carrying out initial start-up, this value must be adapted to the actual FVG length.

If Sensor 2 moves in the opposite direction to Sensor 1, and if the distance information is based on the same fixed point, you should

activate the Inverted checkbox.

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Range – Traversing range limits

The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the operating status screen.

1. Select Range from the sub-directory and then press ENTER

to open the inputting menu.

2. Press the F1 to start the retraction of the slides to the park

position (home position). After this position has been reached, the FVG stops.

3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch

has been reached, press key F4 (set). This completes the

adjustment procedure.

4. Press key F1 to run the sensor to the park position so that you

can draw in the web at a later point.

5. Press the ESC button to exit the inputting menu after you

have entered the settings.

If material has already been placed in the FVG adjustment range, you can also enter the inside limit position directly into the editing box.

If you are now working with a position offset, this does not need to be referred to in this dialog window.

The following arises from the representation in the operating display.

The value shown gives the absolute distance from the fixed point entered in the offset dialog. In other words, the position offset is included in the numerical representation.

The relative position (bar representation) relates to the range value entered. In other words, the position offset is not included.

Feed – Feed for stepping motor/gearing combination

This setting is treated as the feed per motor revolution for the stepping motor / gearing combination.

The manufacturer has entered this default setting and you are only permitted to modify it (if necessary) after having obtained the manufacturer’s agreement. The relevant procedure then has to be agreed. All warranty claims will be invalidated in any other case.

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B 3.7.5.5.4 FVG Pro

The FVG Pro submenu is used when the FVG 2MK Op. mode has

been selected (usually when using an FVG 2MK). In this case, each

FVG needs to be adjusted separately. The terms used here FVG 1 (Slide 1) and FVG 2 (Slide 2) relate to the arrangements in

accordance with Point A 1.4.5.

The safety features are identical for both FVGs. The procedure for

FVG 1 (Slide 1) is used as the example here:

Homing Direction – Retraction direction and limit switch assignment

The retraction direction of the sensors and the assignment of the limit switches are set up in the next steps.

1. Mark FVG Pro in the FVG selection window and then confirm by pressing ENTER. Select Slide 1 and confirm by

pressing ENTER.

2. Select Homing Dir. from the sub-directory and then press

ENTER to open the inputting menu.

3. Press the F1 key to check the selected retraction direction. By pressing the F1 key, the FVG slide must move outwards

(into the homing position). After the homing position is reached, the limit switch with the

outer label must be activated ( ).

Exit the window without making any changes if homing direction and limit switch assignment are correct.

activated.

If the limit switch is activated but no checkbox

Note:

(outer or inner) is activated, then the limit switch

requires testing.

4. Press the ESC button to exit the inputting menu after you

have entered the setting.

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Offset – positional offset to position of first FVG slide

You can create a reference system with an absolute reference point using the positional offset. This reference point can, for example, be the machine wall or another obvious point on the machine. It is also possible to use an outer position or the centre of the FVG. If the centre of the FVG is used, one of the FVG slides will move in a negative direction. The offset value is added to the current FVG position and results in

the absolute distance to this reference point (Abs. slide pos.).

The setting up of an absolute reference system is necessary for use

of the Pre-positioning function.

Example:

FVG 1

Offset FVG 1

Reference point

(zero position)

Offset FVG 2

FVG 2

Tape measure

1. Press the F1-key. The FVG slides move to the home

position.

2. Measure offset FVG1 (distance between reference point Î centre sensor measurement window) and enter the value

under offset [mm].

3. Use the F2 and F3 buttons to traverse the FVG a short path.

FVG 1

path travelled (Dist. from home)

absolute position measured

4. Now compare the value shown under Abs. slide pos. with

the measured value. If the measured value is larger and the displayed value

smaller, then you must activate the inverted checkbox.

5. Carry out settings for the second FVG slide (Slide 2) in the

same manner.

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The standard operating display now shows the position of the centre of the measurement window belonging to the appropriate sensor based on the reference point.

Range – Traversing range limits for first FVG slide

The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the operating status screen.

1. Select Range from the sub-directory and then press ENTER

to open the inputting menu.

2. Press the F1 to start the movement of the slide to the park

position (home position). After this position has been reached, the FVG stops.

3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch

has been reached, press key F4 (set). This completes the

adjustment procedure.

4. Press key F1 to move the sensor to the park position so that

you can draw in the web at a later point.

5. Press the ESC button to exit the inputting menu after you

have entered the settings.

If material has already been placed in the FVG adjustment range, you can also enter the inside limit position directly into the editing box.

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Feed – Feed for stepping motor/gearing combination

This setting is treated as the feed per motor revolution for the stepping motor / gearing combination.

In addition to the specific settings which depend on the FVG used, you should also carry out general settings for the FVG application in the menu.

B 3.7.5.5.5 - Retract Mode – free-running mode

The retract mode determines when the FVG will traverse into the park position (home position) after a specific operating mode change.

Change User

Actuator

Material Setup Sel. Std. System

General Setup

opt. Logic

123 456 789 0

Connected

Sensors/EFE

Homing Dir.

Control Loop

Retract Mode

FVG

Err. Behaviour

1. Select Retract Mode from the sub-directory and then press

ENTER to open the selection menu.

2. The following retract modes are available in the selection menu:

• SC: The sensor positioning device will traverse into

the park position after switching over to the

Select a full retract mode

SC Man.

SC & Man.

123 456 0789

SC mode

• Man.: The sensor positioning device will traverse into

the park position after switching over to the

MAN mode

• SC & Man.: The sensor positioning device will traverse into

the park position after switching over to the

SC or MAN mode.

3. Press the ESC button to exit the inputting menu after you

have made the selection.

B 3.7.5.5.6 - Norming Mode – Standardization Mode

The method for standardizing the FVG sensor can be selected in Norming mode. The sensor will be automatically adjusted to the material characteristics during norming. This will occur immediately if norming is active and the controller is

switched over to AUTO mode.

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1. Select Norming Mode from the sub-directory and then press

ENTER to open the selection menu.

2. The following norming modes are available in the selection menu:

• Bright:

Only a bright setting standardisation will be

carried out.

Select a norming mode

Bright

Bright/Dark No Norming

123 456 0789

This standardisation mode is normally used

for the infrared sensor IR 2002 with reflection bar.

• Bright/Dark:

Both bright and dark setting standardisations will be carried out. This standardisation mode is normally used

for infrared sensors with film material.

• No norming:

Sensor standardisation will not be carried out.

This standardisation mode is normally used

for ultrasonic sensors.

3. Press the ESC button to exit the inputting menu after you

have made the selection.

B 3.7.5.5.7 - Width Adjust – FVG operating mode for center line guiding

Use Width Adjust to select FVG operating mode for center line

guiding.

1. Select Width Adjust from the sub-directory and then press

ENTER to open the inputting menu.

2. The standard values are already entered in the settings menu. These should be adapted in accordance with the application.

The sensor positioning unit follows the material web if more

than the portion set in the editing box Width adj. Level [%] of

the sensor scanning area is covered. The example setting entered her (75%) means that the sensor will follow the material web if less than 25% or more than 75% of the sensor scanning area is covered.

3. Press the ESC button to exit the window.

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25% covering

Start of sensor tracking

50% covering

End position

75% covering

Start of sensor tracking

• Lvl. Outer:

The approach of the sensor towards the

material web generally occurs from the outside.

The FVG operating mode can be carried out in the MAN mode, in the Automatic mode as well as the SC mode.

However, the change will only become effective in the controller after the operating mode has been changed again. If, for example, you want to change over and you are in

Automatic mode then you must change over to MAN mode and then back to Automatic mode again. Only then will the

change become effective.

4. Press the ESC button to exit the window.

B 3.7.5.5.8 - Repositioning – repositioning of the material

after certain events

1. Select “Repositioning“ from the sub-menu and then press

ENTER.

2. Activate the required behaviour in the settings menu.

The web/sensor position is saved after a web tear has occurred.

The web/sensor position is saved at the time of switching

over from Automatic operating mode to Manual or SC

operating mode.

3. Press the ESC button to exit the inputting menu after you

have made the selection.

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B 3.7.5.5.9 - Velocities – adjustment of positioning speeds

This function can be used to adapt the positioning speeds for various actions.

1. Select Velocities from the sub-menu and then press

ENTER.

2. The standard values are already entered in the settings menu. These can be accepted as is or adapted to the application.

3. Press the ESC button to exit the window.

The parameters have the following meanings:

Retract mode [mm/s]:

This parameter is used to determine the sensor positioning device retraction speed.

Edge push vel. [mm/s]:

This parameter is used to match the traversing speed of the sensor positioning device to the displacement speed of the actuator. This prevents the sensor mounted on the FVG slide from being pushed into the more slowly sideways moving material web during edge searching during web centerline guiding.

Slow Man. vel. [mm/s]:

Speed which should be used when shifting the material web manually in automatic operation (for example shifting the web using remote-control arrow keys).

Fast Man. vel. [mm/s]:

Speed which should be used when moving the FVG slides in

the Manual operating mode (for example when moving the

FVG slides using a menu dialog box keys).

This parameter is only relevant for FVG eco application.

Norm. vel. [mm/s]:

Speed which is run during norming.

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B 3.7.5.5.10 - Special – Special settings for moving the FVG slides

during edge searching

1. Select Special from the sub-directory and then press ENTER

to open the inputting menu.

2. Standard values have already been entered. These can be accepted as is or adapted to the application.

3. Press the ESC button to exit the window.

Mode after Error:

Operating mode which the system switches to after an error occurs (e.g. web tear).

Sensor-cover-guarding:

This monitoring function prevents destruction of the material web due to unwanted contact with the sensors. If the coverage of the sensor scanning area, with the checkbox activated, exceeds 90 % of full coverage, then the FVG slides are automatically stopped.

This monitoring function is only active when oscillation is activated or during sensor positioning.

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B 3.7.5.6 Width Measure - Web width measurement

The parameters required when using a width-measuring unit are set up in this sub-menu.

B 3.7.5.6.1 Ref. Width – Width of the calibration sheet

A piece of material with a known width must be used once as a reference for adjusting the web width measurement.

1. Select Width Measure in General Set-up and confirm by

pressing ENTER afterwards.

2. Ref. Width is marked in the following selection window. Press

the ENTER button to call up the inputting window.

3. Insert calibration sheet and start width measurement. To do

this you must switch over to centerline guiding and then select Automatic operating mode.

Width Measure Offset current width:

enter ref.width

set ref

4. Enter the width under enter ref. width after the sensors have reached the edges of the calibration sheet and press the F3

button to take over the entered value.

5. The adjustment procedure is finished.

The actual measured value (current width) and the entered reference value (ref. width) must both show the same size.

6. Press the ESC button to exit the window.

The reference width value last entered remains saved when the device is switched off.

Inserting the calibration sheet:

First check the dimensions of the calibration sheet.

Important:

The calibration sheet reference dimension can change marginally due to the effects of heat. Information relating to various temperatures is given on the calibration sheet. To obtain the best results, use the reference dimension for the temperature which is nearest to the actual temperature, or interpolate the dimension between these two temperatures.

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B 3.7.5.6.2 Limits – Set width, error and warning limits

The set value for the web width (Nominal Width) is entered in this window. The lower and upper error limits (E+, E-) and the lower and upper warning limits (W+, W-) are also set up here. The measuring unit is mm. These are the entries which form the basis for the operating display when the web width measurement is active. Five conditions are indicated.

a) Material width is in valid range.

b) Material width is too wide when related to the upper warning limit; it lies in the W+ area (24V DC at output 66).

W+

c) Material width is too small when related to the lower warning limit; it lies in the W- area (24V DC at output 65).

W-

d) The material width lies outside the absolute tolerance. It lies in the error limit areas E+ (24 VDC at output 66)

E+

e) The material width lies outside the absolute tolerance. It lies in the error limit areas E- (24 VDC at output 65)

E-

Digital message outputs are available for the limits. The meaning and allocation of messages relating to digital outputs are described under Point B 3.7.5.9.2.

Material width

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Commissioning B 3

1. Select Limits in the selection window and press the ENTER

key. This will open up the input window.

2. Enter the nominal value for the material width in the edit field

Nominal Width.

3. Enter selected values for the error and warning limits in the

80.0

-5.0

5.0

-2.0

2.0

corresponding edit fields.

4. Press the ESC button to exit the window after you have

entered the settings.

B 3.7.5.6.3 Opmodes – Operating modes in which the width measurement should be active

You can use this window to determine in which operating modes the width measurement is able to be implemented. This makes it also possible to carry out a web width measurement without an FVG if the checkbox has been activated for the corresponding operating mode.

If an FVG is connected, the condition is that retraction has been deactivated for the selected operating mode(s).

1. Mark Opmodes in the selection window and then press the

ENTER button. This will open up the input window.

2. Select the desired mode(s).

3. Press the ESC button to exit the window after you have

entered the settings.

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B 3.7.5.7 Edge Sources - Assignment of the sensors

to the scanning modes

The ekrPro Com

controller allows the free assignment of the connected sensors to different scanning modes. Therefore each scanning mode can have the input signal of any sensor allocated to it. For example, it is possible to assign the "sensor right" sample mode selection key to the sensor connected as "sensor left". If the controller is operated via a CAN bus, the scanning modes can also be assigned to the input signals of sensors which are connected to another controller of the BUS-system.

1. Select Edge Sources in General Setup and confirm by

pressing ENTER afterwards.

2. A sample type selection window opens. The following selection types can be selected:

Guiding

Control input Key

Mode

Edge 1

Edge 2

Edge 3

Src. SC

Edge 1

Edge 2

Edge 3 (contrast transition)

Centre position control encoder

Src. EFE

Electronic remote fine

—

adjustment unit

3. Select sample mode using the vertical arrow keys and press ENTER.

4. The input window appears for the selected sample mode.

5. If the selected sample mode is to be assigned to the input signal of a sensor that is connected to another CAN bus unit,

then select the option list device and press the ENTER key to

open it. All the units connected to the CAN bus are displayed in the opened option list.

6. Select the desired CAN bus unit and press ENTER.

7. Select the option list edge using the horizontal arrow keys and

press ENTER.

8. Select the sensor from the option list to whose input signal the selected sample mode is to be assigned and press ENTER.

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Commissioning B 3

9. The input value supplied by the selected sensor can be shown in this window as either an absolute or normalized (percentage) value.

To activate normalized display, select checkbox norm..

10. If necessary, the checkbox inv. is used to invert the input

signal delivered by the sensor. Inverting is necessary, if the input value delivered by the sensor changes in the wrong direction when material is brought into the sensor measurement area.

11. Use the function keys F2 and F3 to drive the actuator in Manual operating mode.

This enables checking of the change in the sensor signal with an inserted material web.

12. Press the ESC button to exit the window.

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Commissioning B 3

B 3.7.5.8 Add. Functions – Special function

Explanations for the requirements and function of both special functions can be obtained under point 3.5.8. The parameter settings are carried out as follows:

B 3.7.5.8.1 Tear Off Det. – Tear Off Detection

Setting of the parameters for the function Tear-off detection is

made separately for each guiding mode. If necessary, a different sensor can be allocated as the tear-off detection sensor for each guiding mode. It is also possible to allocate two different guiding modes with different parameters to a single sensor.

1. Select Add. Functions in General Setup and then select the Tear Off Det. sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3, Center 1&2) from the option list.

Confirm the selection by pressing ENTER.

3. This will open up the inputting window for the selected guiding mode. The following separate parameters can be set:

► Sensor:

Selection of the sensor with which tear-

off detection is to be implemented.

► threshold [%]: Percentage covering of the sensor

► sig. chg. limit. [%/4ms]: Maximum permissible rate of

► delay [ms]: Delay time in ms from detection of a tear

until blocking of the guiding system.

► hold [ms]:

Blocking hold time in ms after the

detected end of the tear until the blocking is lifted, i.e. until the guiding system is activated.

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Commissioning B 3

4. If necessary, set parameters for further guiding modes (see points 2 and 3).

5. Press the ESC button to exit the window.

B 3.7.5.8.2 Oscillation

This special function enables the position of the web of material to be displaced within the sensor´s visual range using adjustable amplitude (size of the lateral displacement) and frequencies (displacement speed).

Osc. Mode – determine operating mode for oscillation mode

1. Select Add. Functions in General Setup and then select the „Osc. Mode“ sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. The set value for the web width (Nominal Width) is entered in this window. Activation then takes place in the operating

status display using the F1 key.

The following settings are possible:

• • OFF:

Oscillation is deactivated

(factory setting)

• Auto:

Activation in operating mode

Automatic

Repositioning of material web is carried out within the sensor visual area with adjustable amplitude.

• SC:

Activation in operating mode SC

using the servo-center component.

• FVG Auto:

Oscillation with connected FVG An FVG oscillation with sine-shaped web repositioning.

3. Press the ESC button to exit the window.

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Commissioning B 3

Osc. Params. – Set oscillation parameters

The oscillation parameters, i.e. amplitude and frequency, are set in this submenu.

1. The Osc. Params submenu Select Sensor 1 and confirm by

pressing ENTER.

2. The parameters have the following meanings:

► Amplit. Auto [%]:

Amplitude of the oscillation in operating

mode Automatic.

The percentage value relates to the size of the sensor scanning area. Setting range: 1 % to 99 %

► Amplit. SC [%]:

Setting up the amplitude for the SC

operating mode The percentage wise input of the amplitude relates to the distance between the software limit switches. One limit switch represents 0 % and the other 100 %. Setting range: 1 % to 99 %

► Amplit. FVG [mm]

Amplitude of oscillation when using a

sensor positioning device. The sample value shown here of 10 mm results in repositioning of the web by ± 5 mm. Setting range: 0 to 999.9 mm

► Frequency [Hz]:

Oscillation frequency.

Setting range: 0.016 … 1.000 Hz

3. Press the ESC button to exit the window.

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Commissioning B 3

B 3.7.5.9 Dig. IO Config. - Configuration of the

digital inputs and outputs

B 3.7.5.9.1 Configure –

selection of digital input table and activation of inputs/outputs

You can select from two tables in this dialog window. Both contain various assignments for the digital inputs (see Point B 3.7.5.9.3). The tables are created so that they cover most of the applications controllable using digital inputs, which helps avoid time-consuming configurations. Specific adjustments can, however, still be carried out if required. The procedure is described under Point B 3.7.5.9.2.

1. Select Dig. IO in General Setup and then select the Configure sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. Select the required input table. The Dig.In Table 1 (Default Table) and Dig.In Table 2 (Special Shifted

Center) tables are available for selection. The input assignment for each table is represented in

Point B 3.7.5.9.3. Confirm the selection with the F2 (Set.)

key.

3. Press the ESC button to exit the window.

Both digital inputs and outputs can be switched off for initial startup. Please deactivate the appropriate checkboxes to do this.

Attention!

Any activated Ext.Lock functionality will be

cancelled by deactivating the IN ena. checkbox.

Thus, the actuator can carry out positioning movements. The controller release is, however, not influenced.

B 3.7.5.9.2 Inputs –

Digital inputs

When necessary this sub-menu permits changing of the assignment of various functions to the digital inputs of the controller. Moreover the respective signal pattern (bit mask), which must be applied to the digital inputs (terminals 74 – 85) in order to activate a particular function, can be changed.

The procedure for changing the factory-set standard configurations of the digital inputs is explained in the following two examples,

based on the Dig.In Table 1 (Default Table).

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Commissioning B 3

Example 1: The function Tear-off detection is to be assigned to

the digital inputs (lines 29 and 30). In so doing, the standard bit-pattern for lines 29 and 30 must not

be changed.

1. Select Dig. IO in General Setup and then select the Inputs sub-directory afterwards.

Confirm the respective selection by pressing ENTER.

2. The digital inputs setting window opens.

Truth Tabl e Pattern no. assigned function 29 Keyb.Lock ON Bitmask 85 74

deact.

3. Use the function keys F1 (next row) or F2 (previous line) to

select the stored truth table.

The option list displays the factory assigned function (Keyb. Lock ON) for row 29.

Truth Tabl e Pattern no. assigned function 29 Tear Out ON Bitmask 85 74

deact.

4. Select the option list using the horizontal arrow keys and open by pressing ENTER. The option list contains all the available functions.

5. Select the function Tear Out ON (tear-off detection ON) using

the vertical arrow keys and press ENTER.

Truth Tabl e Pattern no. assigned function 30 Keyb.Lock OFF Bitmask 85 74

deact.

6. Select line 30 using function key F2.

The option list displays the factory assigned function ("Keyb. Lock OFF) for line 30.

7. Select the option list using the horizontal arrow keys and open

Truth Tabl e Pattern no. assigned function 30 Tear Out OFF Bitmask 85 74

deact.

by pressing ENTER.

8. Select the function Tear Out OFF (tear-off detection OFF)

using the vertical arrow keys and press ENTER.

Assignment of the function Tear-off detection to the digital

inputs is now completed.

9. Press the ESC button to exit the window.

By pressing function key F3 (deact.) within the menu, all

bits of the selected bit pattern are set to “1”.

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Commissioning B 3

Example 2: The function Tear-off detection is to be assigned to

the digital inputs (lines 21 and 22).

The following section of the truth table shows that lines 21 and 22 belong to a bit-block with a total of 8 lines (lines 21 to 28).

Factory allocation of functions with the corresponding standard bit-patterns

Terminal

Line

Significance

20 FVG stop X X X 1 1 1 X X X X X X 21 Set Lim.Sw. 1 X

22 Reset Lim.Sw. 1 X

23 Reset Lim.Sw. 1 X

24 Set Lim.Sw. 2 X

25 Reset Lim.Sw. 2 X

26 Reset Lim.Sw. 2 X

27 Set Overtemp. X

28 Reset Overtemp. X

29 Keyb.Lock ON 1 X X X X X X X X X X X

85 84 83 82 81 80 79 78 77 76 75 74

1 0 0 0 1 1 0 1 0 0 1 1 1 1 0 0

X X X X X X X X X

User defined allocations - function Tear-off detection on lines 21 and 22

Terminal

Line

Significance

20 dig. Left/Right Stop X X X 1 1 1 X X X X X X 21

Tear Out ON

Tear Out OFF

23 Do Nothing 1

24 Do Nothing 1

25 Do Nothing 1

26 Do Nothing 1

27 Do Nothing 1

28 Do Nothing 1

29 Keyb.Lock ON 1 X X X X X X X X X X X

85 84 83 82 81 80 79 78 77 76 75 74

1 X

0 X 1 1 1 1 1 1 1 1 1 1 1 1

X X X X X X X X X

1 1 1 1 1 1 1 1 1

The procedure for changing the allocations can be divided into three steps, which are described on the following page.

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Commissioning B 3

Step 1: Cancel the factory allocations of functions.

As the function tear-off detection requires only lines 21

and 22 of the bit block, the factory-side allocation of functions to the remaining lines of the block (lines 23 to

28) must be cancelled.

Accordingly the function Do Nothing is allocated to lines

23 to 28 from the option list. The procedure for doing this is described in example 1.

Moreover the values of all bits in the non-required lines 19 to 24 must be set to “1”.

Procedure:

1. Use the function keys F1 and F2 to sequentially

select the individual block lines.

2. Use the horizontal arrow keys to the change the bit pattern (Bitmask) display.

3. Sequentially select the individual bits using the horizontal arrow keys and use the vertical arrow keys to set the value of the selected bit to “1”. The values of all 12 bits must be set to "1”.

Step 2: Assign new function

The function Tear Out ON (tear-off detection ON) is assigned to the line 21 and the function Tear Out OFF

(tear-off detection OFF) is assigned to the line 22. The procedure for doing this is described in example 1.

Step 3: Adjust bit pattern

In line 21 the bit for terminal 84 is assigned the value ”1“ (24 V signal applied to terminal 84). In line 22 the bit for terminal 84 is assigned the value ”0“ (0 V signal applied to terminal 84).

The value for all the non-relevant bits (terminal 83) of the two lines 21 and 22 must be set to the value "X" (not relevant).

The procedure for changing the bit values is described in step 1.

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Commissioning B 3

B 3.7.5.9.3 Truth table

Default values for digital input allocation: Dig. InTable 1

Terminal

Line Significance 85 84 83 82 81 80 79 78 77 76 75 74

1 set Auto

(automatic mode)

2 set MAN

(manual mode)

3 set SC

(servo center position)

4 opmode clear

(defined zero state operating mode)

5 set Edge1

(edge 1)

6 set Edge2

(edge 2)

7 set Center1&2

(center 1/2)

8 set Edge3

(edge 3)

9 set Edge3 Inv. (inverse edge 3)

10 guid.mode clear

(defined zero state guiding mode)

11 Motor stop

12 Motor stop

13 FVG stop

14 FVG stop

15 Motor left

16 FVG left

17 Motor right

18 FVG right

19 Motor stop

20 FVG stop

21 Set Lim.Sw. 1

(stop switch 1)

22 Reset Lim.Sw. 1

(reset stop switch 1)

23 Reset Lim.Sw. 1

(reset stop switch 1)

24 Set Lim.Sw. 2

(stop switch 2)

X X X X X X X X X

X X X X X X

X X X

1 0

0 0

1 1

0 1

0 0 0

0 0 1

0 0 0

0 0 1

0 1 0

0 1 1

1 0 0

1 0 1

1 1 0

1 1 1

X X X X X X X X X

0 0 1

0 1 0

0 1 1

1 0 0

1 0 1 0 0 0

X X X X X X

1 0 0

0 0 1

0 1 0

0 0 0

X X X

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Commissioning B 3

Terminal

Line Significance 85 84 83 82 81 80 79 78 77 76 75 74

25 Reset Lim.Sw. 2

(reset stop switch 2)

26 Reset Lim.Sw. 2

(reset stop switch 2)

27 Set Overtemp.

(over-temperature)

28 Reset Overtemp.

(reset over-temperature)

29 Keyb.Lock ON

(keyboard interlock on)

30 Keyb.Lock OFF

(keyboard interlock off)

31 -

Do Nothing

(reserved)

0 0

1 1

0 0

X X X X X X X X X X X

1 1 1 1 1 1 1 1 1 1 1 1

X X X X X X X X X

Alternative digital input allocation: see Dig. In Table 2:

Terminal

Line Significance 85 84 83 82 81 80 79 78 77 76 75 74

1 set Auto

(automatic mode)

2 set MAN

(manual mode)

3 set SC

(servo center position)

4 opmode clear

(defined zero state operating mode)

5 set Edge1

(edge 1)

6 set Edge2

(edge 2)

7 set Center1&2

(center 1/2)

8 set Edge3

(edge 3)

9 set Edge3 Inv. (inverse edge 3)

10 guid.mode clear

(defined zero state guiding mode)

11 Shifted Center OFF

12 Reset Prepos. Center

(reset pre-positioning to centre)

13 Shifted Center ON

14 Set Prepos. Center

(pre-positioning to centre)

15 set Center1&2

(center 1/2)

16 FVG left

17 FVG right

18 FVG stop

19 FVG stop

X X X X X X X X X

X X X X X

X X X X X X

X X X X X

X X X

X X

0 1 1 0 1 1 0 0

0 0 0 1

0 0 1 0

0 1 1

1 0 0

1 0 1 0 0 0

X X X X X X

X X X X X X X

1 0 0

0 0 1

0 1 0

0 0 0

X X X

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Commissioning B 3

Terminal

Line Signification 85 84 83 82 81 80 79 78 77 76 75 74

20 Set limit switch 1 X

21 Reset Lim.Sw. 1

Reset Lim.Sw. 1

23 Set Lim.Sw. 2

Reset Lim.Sw. 2

Set Overtemp.

Reset Overtemp.

Ext. Unlock

Ext. lock

30 -

Do Nothing (reserved)

1 0

0 0

1 1

0 1

0 0

1 1

0 0

X X X X X X X X X X X

1 1 1 1 1 1 1 1 1 1 1 1

X X X X X X X X X

0 = 0 V signal 1 = 24 V signal X = not relevant

Controller interlock The controller interlock is generally activated. The function can only

be deactivated by application of a "1” signal (24 V=) to terminal 53. If the controller block is activated, the output of the output stage is switched off. The actuator will not carry out any guiding movements. This is valid for all

operating or guiding modes (AUTO, MAN, SC).

Keyboard interlock All of the controller’s keys are locked by a “1“ (24 VDC) on

terminal 85. The controller can be controlled via the keyboard when this signal is no longer set.

The individual lines in the truth table can each be allocated the following meaning:

Significance

• Do Nothing

• set AUTO

• set MAN

• set SC

• opmode clear

• set Edge 1

• set Edge 2

• set Center 1&2

• set Edge 3

• set Edge 3 inv.

• guid. mode clear

Significance

• Motor Left

• Motor Right

• Motor Stop

• FVG Left

• FVG Right

• FVG Stop

• Set Lim.sw. 1

• Reset Lim.sw. 1

• Set Lim.sw. 2

• Reset lim.sw. 2

• Set Overtemp.

Significance Significance

• Reset Overtemp.

• Keyb. Lock ON

• Keyb. Lock OFF

• Osc. ON

• Osc. OFF

• Tear Out ON

• Tear Out OFF

• ext. Lock

• ext. Unlock

• Set W.

• Set Prepos. E1

• Reset Prepos. E1

• Set Prepos. E2

• Reset Prepos. E2

• Set Prepos. C1&2

• Reset Prepos. C1&2

• Set Prepos. Center

• Reset Prepos.

Center

• Copy cur.pos. to Prepos.

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BST ekrPro Com60 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual