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Web Guiding System

ekr 500 Plus


with CLS Pro 600

Translation of the
Original Quick Reference Guide

Quick Reference Guide EDV no.: MD.341.01.01


ekr 500 Plus with CLS Pro 600 Issue Date: 31.03.2009
Quick Reference Guide QRG

General information

This Quick Reference Guide describes the assembly and the


commissioning of the web guiding system ekr 500 Plus with
CLS Pro 600.

The web guiding system ekr 500 Plus with CLS Pro 600 should
only be commissioned after you have acquainted yourself with the
corresponding more detailed operating manual of the controller
ekr 500 Plus and the line and contrast sensor CLS Pro 600. This
will help to avoid hazards and prevent damage to the system due
to improper commissioning or operation.

Prior to commissioning and before performing any maintenance


work, you must read, without fail, the safety instructions in the
corresponding operating manual!

The detailed operating manual for the devices specified above are
a part of the delivery. They can also be found in internet under the
following address:

http://www.bst-international.com

BST International GmbH


Heidsieker Heide 53
33739 Bielefeld, Germany
Telefon: +49 5206 999-0
Telefax: +49 5206 999-999
info@bst-international.com

Our service department is available for special queries


under the telephone number 0049 (0) 5206 999760 or under
service@bst-international.com.

Quick Reference Guide EDV no.: MD.341.01.01


ekr 500 Plus with CLS Pro 600 Issue Date: 31.03.2009
Quick Reference Guide QRG

Contents
1 General information 1
1.1 System overview ................................................................... 1
1.2 Used terms ............................................................................ 1
2 Start-up ekr 500 Plus 3
2.1 Set DIL switches.................................................................... 3
2.2 Start-up of the EMS actuator ................................................. 5
2.2.1 Determine sense of motor rotation .........................................5
2.2.2 Determine guiding direction....................................................5
2.2.3 Actuator without position feed back
(EMS 5 / EMS 10 / EMS 16) ...................................................5
2.2.3.1 Determine guiding direction for operating mode
Servo-center (OMG 4, OMG 8) 5
2.2.3.2 Adjust gain of the servo-center component
(OMG 4, OMG 8) 6
2.2.4 Actuator with position feed back
(EMS 17, EMS 21, EMS 22) ...................................................7
2.2.4.1 Determine guiding direction for operating mode
Servo-center 7
2.2.4.2 Adjust stroke limitation and servo-center position 8
3 Setting up the CLS Pro 600 11
3.1 General ................................................................................ 11
3.2 Requirements ...................................................................... 11
3.3 Adjust password level.......................................................... 12
3.4 Configuration ....................................................................... 13
4 Material Setup 15
4.1 at the controller.................................................................... 15
4.2 at the sensor........................................................................ 15
4.3 Edge set-up mode ............................................................... 16
4.4 Line setup mode .................................................................. 17
5 Optimise gain 18

Quick Reference Guide EDV no.: MD.341.01.01


ekr 500 Plus with CLS Pro 600 Issue Date: 31.03.2009
Quick Reference Guide QRG

1 General information
1.1 System overview
Use this Quick Reference Guide if the system you use has the
following configuration:

controller ekr 500 Plus


with removed control panel

or

controller ekr 500 Plus


with fitted control panel

connector X101

Actuators with position feed back


EMS 17, EMS 21, EMS 22
Line and contrast sensor
CLS Pro 600 or

Actuators without Servo-center


Edge sensor position feed back component
EMS 5, EMS 10, EMS 16 OMG 4, OMG 8

1.2 Used terms


According to BST definition, the following relation applies between
the selection buttons fort he guiding mode and the sensors:

= Sensor 1 (left web edge)

= Sensor 2 (right web edge)

= Sensor 3 (line / contrast scanning)

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The following is valid in respect of the sensor mounting positions of


the analogue edge sensors (Sensor 1, Sensor 2):
The sensor, which is located to the left of the material in the
web running direction (when looking from the material top
side), is sensor 1.

The following is valid in respect of the sensor mounting position of


the line and contrast sensor:

The connecting cable of the line and contrast sensor points in


the direction of Sensor 2.

CLS Pro 600

Connecting
cable
Sensing roller

Sensor 3

Sensor 2

Sensor 1
Printed line

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2 Start-up ekr 500 Plus


Requirements:
The guiding system is wired completely that means all
cables between the system components (controller, sensors,
actuator, servo-center component, etc.) are installed
(see manual ekr 500 / ekr 500 Plus).
The controller is connected to the voltage supply.
After that proceed as follows:

2.1 Set DIL switches


1. The DIL switches on the controllers processor board must be
set up for the relevant application prior to commissioning.

ON DIP DIL switch S4 is used to reverse the guiding direction, to activate


the electronic remote precision adjustment EFE 1 and to select the
actuator and servo-center component that are being used.
1 2 3 4 5 6 7 8
Dont change the settings of the DIL switches S4.1 to S4.3 (the
DIL switch S4 default settings are used).
Set the DIL switches S4.4 to S4.8 according to the actual system
configuration.

DIL switch Selection of the used actuator


S4.4 S4.5 S4.6

OFF OFF OFF EMS 10, EMS 16, EMS 17

ON OFF OFF EMS 5

OFF OFF ON EMS 21, EMS 22

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DIL switch Seelction of the used


S4.7 S4.8 servo-center component

OFF OFF Position feed back EMS 17, EMS 21, EMS 22
(potentiometer)

ON OFF OMG 8

OFF ON No servo-center component


(center position cannot be selected)

ON ON OMG 4

ON DIP DIL switch S5 matches the control parameters to the sensors that
are being used.
The system recognizes the CLS Pro 600 sensor automatically.
1 2 3 4 5 6 7 8 Therefore dont carry out here any settings.
DIL-Schalter S5
The operating display of the ekr 500 Plus is displayed as follows:

CLS Pro 600


recognized

The edge sensors are displayed only if they are really connected
resp. the DIL switches are set accordingly.
Within the above example, one edge sensor (sensor 1) is
connected.
Setting is carried out according to the manual ekr 500 / ekr 500
Plus.

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2.2 Start-up of the EMS actuator

2.2.1 Determine sense of motor rotation


During start-up the assignment of the arrow keys to the actuating
direction (sense of motor rotation) of the actuator must be checked.

1. Press key MAN.


The controller changes to manual mode.
The LED of the key lights.

oder 2. Press arrow key left or right.

Observe guiding device!


When pressing arrow key right the guiding device must move
towards the sensors cable connection.

If the guiding device moves in the opposite direction then the


motor connection lines on terminal strip X7 (terminal 42 and 43)
must be swapped over. (see manual ekr 500 / ekr 500 Plus).

2.2.2 Determine guiding direction


Setting the guiding direction for line or contrast guiding is carried
out on the CLS Pro 600 line and contrast sensor (see point 3.4).

2.2.3 Actuator without position feed back


(EMS 5 / EMS 10 / EMS 16)

2.2.3.1 Determine guiding direction for


operating mode Servo-center (OMG 4, OMG 8)
If you are using a servo-center component OMG 4 or OMG 8 the
guiding direction for the operating mode servo-center must be
checked.
1. Press key Servo-center.
The LED of the key lights.

Observe the guiding device!


The guiding device must move towards its center position.
If the guiding device moves to one of its stop positions, then
change position of DIL switch S4.2 on the processor board.

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2.2.3.2 Adjust gain of the servo-center component


(OMG 4, OMG 8)
If you are using a servo-center transducer OMG 4 or OMG 8,
preselect the adjustment of gain.

1. Press key Servo-center.


The LED of the key lights.

2. Press key SETUP.


The set gain for the servo-center transducer is shown
graphically (bar display) and as numerical value on the lower
edge of the display.

Gain Gain
(graphical display) (numerical display)

3. Increase gain by means of the arrow key right, until hunting


occurs (the guiding device starts oscillating).
The display of the gain value rises step by step.
Pressing the arrow key longer than 3 seconds increases the
pulse width until the key is released.
We recommend setting the gain to maximum if hunting does not
occur.

4. Decrease gain by using the left arrow key, until the hunting
ceases (stable guiding operation).
If a slower guiding reaction is desired, the gain may still be
reduced further.

Simultaneously pressing the two arrow keys will


reset the gain to 0.5.

5. Press key ENTER.


Adjustment of gain is completed.

The gain setting will be terminated automatically


after a pre-set time-out period initiated after the
last key operation has expired.
The gain setting has now been saved.

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2.2.4 Actuator with position feed back


(EMS 17, EMS 21, EMS 22)

2.2.4.1 Determine guiding direction


for operating mode Servo-center
If you are using an actuator with position feedback the guiding
direction for operating mode Servo-center must be checked.

1. Press key MAN.


The controller changes to the manual operating mode.
The LED of the key lights.

oder 2. Press arrow keys left or right.

Observe position indicator in the display!

When pressing arrow key left the bar display must move to the
left.
When pressing arrow key right the bar display must move to
the right.
If the bar display moves in the opposite direction then change
position of DIL switch S4.2 on the processor board.

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2.2.4.2 Adjust stroke limitation


and servo-center position
The actuator stroke limitation (adjustment of the software limit
switches) and the adjustment of the servo-center position are
carried out using a special setup menu.
The settings are sub-divided into the following steps:

Step 1: Activating the setup menu

1. Press key MAN.


The controller changes to manual operating mode.
The LED of the key lights.

2. Press key SETUP.


The controller changes to setup mode.
The setup selection menu appears in the display.

Setup menu
EMS 17 / 21 / 22

or 3. Select the setup menu symbol for actuators EMS 17, EMS 21
and EMS 22 using the arrow keys.

4. Press key ENTER.


The setup menu is active.
The LED of the key SETUP lights.

The significances of the individual display symbols are:

1 2 3

4 5 6

7
8

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1 Symbol Sensor 1 (software limit switch 1)


2 Symbol Servo-center position
3 Symbol Sensor 2 (software limit switch 2)
4 Set position for software limit switch 1
5 Set servo-center position
6 Set position for software limit switch 2
7 Actual position of the actuator (grapfical display)
8 Actual position of the actuator (numerical display)

When the controller is delivered the position for software


limit switch 1 will display -2048 and the position for
software limit switch 2 will display 2047.
The factory default settings will be overwritten by the new
settings when teach-in is run.
The relevant symbol (sensor 1, sensor 2 or servo-center
position) will be displayed as inverted after the teach-in of
a new setting has been run.

Inverted symbol display

Step 2: Set position for software limit switch 1

5. Move guiding device to the desired position for software limit


or
switch 1 (towards sensor 1) using the arrow keys.

The position indicator for software limit switch 1


shows the actual value supplied by the position
feedback of the actuator.
Range of values: -2048 +2047.

6. Press key Sensor 1.


The position for software limit switch 1 is stored.

The symbol sensor 1 is represented inversely.

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Step 3: Set position for software limit switch 2

or 7. Move guiding device to the desired position for software limit


switch 2 (towards sensor 2) using the arrow keys.

The position indicator for software limit switch 2


shows the actual value supplied by the position feed
back of the actuator.
Range of values: -2048 +2047.

8. Press key Sensor 2.


The position for software limit switch 2 is stored.

The symbol sensor 2 is represented inversely.

Step 4: Set servo-center position

or 9. Move actuator to the desired center position for the guiding


device using the arrow keys.

The position indicator for the servo-center position


shows the actual value supplied by the position feed
back of the actuator.
Range of values: -2048 +2047.

10.Press key Servo-center.


The actual position is stored as servo-center position.

The symbol servo-center is represented inversely.

Step 5: Exiting the settings

11.Press key ENTER.


The setup menu will be closed.
All modified parameter values are stored.

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3 Setting up the CLS Pro 600


3.1 General
The display area in the graphic display of the keypad has
differently coloured borders. The different colours show which
mode you are in at present.
There are the following possibilities:

Operating mode AUTOMATIC Operating mode MANUAL


(green) (grey)

SETUP mode Error (flashes red)


(blue) (line/edge not recognized)

3.2 Requirements
1. The controller ekr 500 Plus must be in the MAN operating
mode.
2. The distance between sensor and material of web / scanning
roller has to be set correctly.
(See also manual CLS Pro 600, section 2.2.4)

Sensor enclosure
Protective packaging
(adjustment tool)
Sensing
roller

20

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3.3 Adjust password level


The password level Operator is set after switching on the sensor.
You have to be logged in as Administrator to carry out sensor set-
up and the sensor must be in set-up mode (blue border strip).

The procedure for selecting the password levels is described in the


following, e.g. for commissioning or operating.

1. Press the button MENU on the commander of the sensor for at


least 3 seconds.

2. Afterwards the menu will be displayed. Mark the change user


entry and press ENTER for confirmation.

3. Use the up or down arrow keys to select the password level


Administrator and press ENTER for confirmation.

4. You will be asked to enter the password afterwards.


Enter the valid password 00002.
Use the arrow key right to select the last place of the
password. Now press the arrow keys up or down as often as
the 2 appears at this place.

5. Confirm the entry by pressing ENTER.

You are now logged into the selected user level. You can now
adapt the parameters that can be accessed from this level.

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3.4 Configuration
\\configuration\mounting position\ Open the Mounting-Position in the Configuration sub-menu and
teach-in the sensors mounting position.
The system must be in operating mode MAN.
This procedure consists of 4 sub-steps.

Use the teach-in model shown in the operating manual (annex 5)


to carry out the teach-in process.

Mounting position A is shown as the example in this procedure:


Note that mounting positions B, C and D must first be activated
before you can use them.

1. Call up and open the sub-memnu configuration.

2. Select config positon A.

3. Start the teach-in process fort his mounting position.


Select the teach in parameter and confirm your selection by
pressing ENTER. The teach-in process has now started.

3a) The first step is to set up the manual adjustment.


Use the left / right arrow keys to move the guiding
device.
The actuator has to be moved in the respective
direction.
! The settings can be inverted from here if the arrow
key assignments are incorrect. This is realized by
using the up / down arrow keys.
Press ENTER to confirm your settings.
arrow key left
moving direction of
the actuator
arrow key right
moving direction of
the actuator

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3b) The window for the second step is now open.


Position the teach-in model linein the green field and
then press ENTER to confirm the process:
teach-in model
Material to be
scanned

Laser line

The line identification process will now be run.

3c) Move the line some millimetres to the left by hand in


step 3 afterwards.
Now press the arrow key left once.
The system will now calculate all of
the parameters automatically.

3d) Press key ENTER. Set-up is now complete.

The settings are displayed summarised again in the


window Step 4.
If necessary, you can make changes to the parameters
displayed here.
However, we recommend that you do not change the
factory default settings.

4. Press key Menu to leave the set-up menu.

5. Switch off the sensor now (pull the connector X101) and
switch it on shortly after. The sensor is reset to the password
level Operator now.

6. This completes the commissioning of the sensor connected


to the ekr 500 Plus controller.
Now you can carry out the material set-up.

The last activated mounting position is loaded with every further


system restart.

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4 Material Setup
The set-up of the CLS Pro 600 sensor is only possible in the
operating mode MAN.

Switching the controller to the operating mode MAN

You can switch on the MAN mode at the controller keyboard or via
the sensor keyboard.

4.1 at the controller

Press key MAN. The LED of the key lights.

4.2 at the sensor

2 Use the arrow keys up / down to select the operating


mode MAN.
1 The selected mode with a green border stripe
will be displayed in the bottom left corner.

Confirm the selection by pressing ENTER.

2 Then the current operating mode will be


displayed in the right upper corner.

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4.3 Edge set-up mode

1. Press key SET-UP EDGE to call up the set-up mode.

The LEDs inside the SET-UP key will illuminate. The LED
inside the ENTER key will flash.
The sensor light will be switched on and it will flash. The laser
line will be visible simultaneously.

2. Use the laser line to position the sensor on the required edge.
Use the mechanical adjustment device to fix the position.

Laser line

The screen display


of the commander is
as follows:

3. Press the ENTER button.


The LEDs inside the ENTER nad SET-UP keys will be
extinguished.
The display will change over from set-up mode to the scanning
mode.

4. Press the ENTER button.


The system will now switch back to AUTO mode (operating
mode).

The edge set-up is finished.

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4.4 Line setup mode

1. Press key SET-UP LINE to call up the set-up menu.

The LEDs inside the SET-UP key will illuminate.


The LED inside the ENTER key will flash.
The sensor light will be switched on and it will flash. The laser
line will be visible simultaneously.

2. Use the laser line to position the sensor on the required line.
Use the mechanical adjustment device to fix the position.

Laser line

The screen display


of the commander is
as follows:

3. Press the ENTER button.


The LEDs inside the ENTER and SET-UP keys will be
extinguished.
The display will change over from set-up mode to the
scanning mode.

4. Press the ENTER button.


The system will now switch back to AUTO mode
(operating mode).

The line set-up is finished.

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5 Optimise gain
Requirements: - web of material is fed in
- the guiding device has not operated a limit
switch
- basic setup and material setup of the
CLS Pro 600 is carried out

1. Select guiding mode Line /contrast scanning (sensor 3).


Press key Sensor 3.
The LED of the key lights.

2. Press key Automatic.


The controller changes to automatic mode.
The LED of the key lights.

3. Press key SETUP.


The set controller gain is shown graphically (bar display) and as
numerical value on the lower edge of the display.

Controller gain Controller gain


(graphical display) (numerical display)

4. Increase gain by means of the arrow key right until hunting


occurs (the guiding device oscillates).
The display of the gain value rises step-by-step.
Pressing the arrow key longer than 3 seconds increases the
pulse width until the key is released.
We recommend setting the gain to maximum gain if hunting does
not occur.
5. Decrease gain by means of the arrow key left until the hunting
ceases (stable guiding operation).
You can continue to decrease gain if a slower guiding reaction
is desired.

Simultaneously pressing the two arrow keys will


reset the controller gain setting to 0.5.

6. Press key ENTER.


Adjustment of gain is completed.

The gain setting will be terminated automatically


after a pre-set time-out period initiated after the
last key operation has expired.

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