Professional Documents
Culture Documents
Operating Manual
MD.492.EN.03
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Table of contents
Table of contents
1 About This Document........................................................................................ 6
1.1 What You Need to Know............................................................................................... 6
1.2 Target Group................................................................................................................. 6
1.3 Storage and Distribution ............................................................................................... 6
1.4 Meanings of the Safety Instructions and Symbols ........................................................ 6
1.4.1 Safety Instructions ........................................................................................................ 6
1.4.2 Symbols......................................................................................................................... 7
1.4.3 Operation Using Keys.................................................................................................... 7
1.5 More Detailed Information ........................................................................................... 7
7 Troubleshooting............................................................................................. 135
8 Customer Services.......................................................................................... 141
9 Shutting Down and Disposal........................................................................... 142
Index.............................................................................................................. 143
DANGER
Danger that will lead to death or severe injuries!
► Here you can find how to avoid the danger.
WARNING
Danger that may lead to death or severe injuries!
► Here you can find how to avoid the danger.
CAUTION
Danger that may lead to medium or minor injuries!
► Here you can find how to avoid the danger.
NOTICE
Danger that may lead to damage to assets!
There is no risk of injury.
► Here you can find how to avoid the danger.
1.4.2 Symbols
► Press key ①.
2 About Safety
The system has been designed according to the state of the art
and fulfils the latest safety standards.
When using the system, risks may occur that could threaten your
life or health or lead to material damage. In order to avoid these
risks, all instructions in this manual concerning safety and all
relevant documentation of the entire system must be observed.
The system and all of its components are only intended for use in
industrial environments.
The system may only be put into operation if the following
guidelines are also complied with:
■ The product must only be installed or operated in a non-
explosive atmosphere.
■ The product and all components must only be used in a perfect
technical condition.
■ All technical safety equipment must be in a perfect technical
condition.
■ The product must only be operated using the components that
belong to the system. An exception are such third party com-
ponents that have been supplied by BST eltromat International
or have been explicitly approved for being operated with the
system.
■ Any part found to be working incorrectly must be replaced
using original spare parts immediately.
■ All work on or with the product must only be carried out by in-
structed and qualified personnel, see chapter Qualification of
the Personnel, page 13.
■ These instructions and all safety information must be observed.
■ The operating conditions and performance limits specified in
the technical specifications must be observed.
DANGER
Danger of death when operated in potentially explosive areas!
► The system must not be installed or operated in potentially
explosive areas.
DANGER
Danger to life due to moving machine components!
Crushing, shearing, scraping, pulling in or impact injuries of body
parts may occur.
► Never reach into the area containing moving rollers or machine
components.
► Do not wear necklaces, scarves or similar near moving rollers/
machine components.
► Never stay within the swivel/movement range of moving
machine components or reach into these areas.
► Prior to set-up/operation of the system, ensure that no persons
are in the operating range of moving machine components.
DANGER
Danger to life due to electrocution!
Fatal injuries due to incomplete shut-down or residual currents.
► If insulation defects or defects on live components occur,
immediately shut down the power supply and have the system
repaired by a qualified electrician.
► Completely switch off the system, disconnect it from the power
supply and wait for ten minutes before carrying out any main-
tenance, repair, cleaning or assembly work.
► Secure the system against being switched on again.
WARNING
Danger of cutting on sharp edges of the material web!
Severe cutting injuries caused by the edges of the moving material
web.
► Never touch the edges of moving material webs.
WARNING
Danger to life caused by movements of the setting drive!
If position control is active, the setting drive may execute auto-
matic movements in manual mode . Body parts could be crushed,
sheared or impacted.
► Ensure that no persons remain in the swivel or positioning
range of machine components positioned by the actuator.
WARNING
Danger of falling and damage to assets caused by stepping/climb-
ing onto components!
Stepping/climbing onto components (e.g. traverse bars or camera
housing) can lead to life-threatening falling accidents and to the
destruction of the components.
► Never climb or step onto components.
WARNING
Danger to life due to missing Emergency Stop devices!
Severe injuries may occur, if no Emergency Stop device (Emer-
gency Stop button) is installed on the overall machine line. Only an
Emergency Stop device permits an immediate stop of the machine
line in emergencies. It is not permitted to operate the overall ma-
chine line without an Emergency Stop device.
► If one is not already installed, have an Emergency Stop button
and Emergency Stop systems installed by the owner/user/ma-
chine manufacturer prior to using the machine line.
WARNING
Severe injuries due to unfamiliarity with/non-observance of
Emergency Stop devices and safety information!
► Prior to starting work, familiarize yourself with the Emergency
Stop and rescue devices of the overall machine line, e.g. Emer-
gency Stop button.
► Prior to starting work, ensure that all safety regulations and
instructions are observed.
NOTICE
Damage to electronic components caused by ESD (electrostatic
discharge)!
Destruction/loss of capacity of electronic assembly elements
caused by contact with electro-statically charged persons/objects.
► Only open system components at ESD-compliant workplaces
(according to 61340-5-1).
► If there is no ESD-compliant workplace, take ESD protection
measures (according to DIN EN 61340-5-1) to discharge electro-
static charges in a controlled manner.
► When returning electronic assembly elements, adhere to DIN
EN 100015 (“Protection of protection of electrostatic-sensitive
devices”).
► To transport electronic components, only use suitably marked,
electrically conductive ESD packaging.
NOTICE
Damage to the touchscreen due to faulty operation!
Use of sharp, strong or coarse objects (e.g. pens, gloves) may dam-
age the surface of the touchscreen.
► Touch the touchscreen only using bare fingers or a special input
pen (touchpen).
Preventative Measures
Emergency and rescue equipment must be ready for use in every
company. These include, for example, emergency stop buttons,
fire extinguisher, first aid kit and equipment for reporting acci-
dents.
► Always be prepared for emergencies, accidents and fire.
► Familiarize yourself as to where the emergency and rescue
equipment is located and how to use it.
► Keep emergency and rescue equipment at hand and ready for
use.
► Ensure all access routes for rescue vehicles and escape routes
are kept free.
2.8.1 Disclaimer
BST eltromat International GmbH is not liable for damage or
defects arising from any incorrect or non-intended use of the
product, see Non-intended Use, page 9.
Liability for defects does also not apply if the fault originates from
one or more of the following causes:
■ Catastrophic events and force majeure
■ Natural wear
■ Incorrect operation of the product resulting from the effect of
connected or neighboring third party devices
■ Malfunction of the product due to unsuitable operating
resources, spare parts, chemical, electro-chemical or electrical
factors.
■ Unsuitable or faulty execution of the maintenance work
described by the operating company, see Maintenance and
Cleaning, page 132.
3.1 Design
The ekr 500 digital Unit Touch comprises the controller and the
removable ekr commander control panel.
3.1.1 Controller
The housing of the controller includes the entire control electrics
and connections for all necessary web guiding components
(sensors, actuator, servo center transducer, remote controls, etc.).
3.2 Function
With web edge guiding or web center-line guiding in automatic
mode, one or two edge sensors connected to the controller detect
the current position (ACTUAL position) of the material web and
transmit the respective information to the integrated position
controller.
With line and contrast guiding, the sensor CLS Pro 600 detects the
current position (ACTUAL position) of a line or contrast transition
on the material web and transmits the respective information to
the position controller.
The position controller compares the ACTUAL recorded position
against the predetermined SETPOINT position. The controller will
send a relevant correction signal to the actuator if a deviation is
found to exist between the two values. The actuator will move the
guiding device (rotating frame guide or swivel roll guide) until the
material web returns to its SETPOINT position.
3.4.1 Watchdog
The Watchdog function is used to prevent the web from wander-
ing after the total loss of the printed line or contrast transition
during line or contrast guiding. If the printed line or the contrast
transition disappear from the scanning area of the line and con-
trast sensor (e.g. if the print is not carried out, a poor splice or
similar), the current web position is detected by the edge sensor
(capture sensor) and saved by the controller. Then the controller
will switch over from the line and contrast sensor (Sensor 3) to the
edge sensor (Sensor 1 or Sensor 2) used. Switching back to the line
and contrast sensor is carried out automatically immediately after
re-detecting the printed line or the contrast transition.
For a detailed description of this function, see chapter Watchdog,
page 68.
3.4.3 Oscillation
The oscillation is used, for example, for the rewinding of tubular
films or for materials with an irregular thickness profile in order to
avoid poor winding. The function enables the controlled transverse
displacement of the web of material with an adjustable amplitude
(size of the displacement) and frequency (speed of the displace-
ment). You can choose from a triangular or sinus oscillation curve.
For a detailed description of this function, see chapter Oscillation,
page 77.
3.6.2 Keys
Four different groups of keys are located on the control panel
with the following functions:
Green keys: Select the operating mode
Grey keys: Select the guiding mode
Blue keys: Call up / quit setup mode
Move the guiding device manually,
Set the guiding setpoint,
White keys:
Adjust the controller gain,
Edit the parameter values
CAN address = 21
Left
edge
CAN address = 21
Left Right
edge edge
Fig. 8: Web edge or web center-line guiding with one CCD camera
Dual-camera system
Left Right
edge edge
3.8 Nameplates
The nameplates are located on the top of the controller and on
the rear of the control panel.
The nameplate displayed is only an example. Please obtain the
current data from the nameplate attached to the product.
4 Technical Specifications
For the technical specifications of the ekr 500 digital Unit Touch
controller and the connectable web guiding components please
refer to the installation and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.
5 Operation
NOTICE
Damage to the touchscreen due to faulty operation!
Use of sharp, strong or coarse objects (e.g. pens, gloves) may dam-
age the surface of the touchscreen.
► Touch the touchscreen only using bare fingers or a special input
pen (touchpen).
On the control panel you will find all control and display elements
that you need for the operation of the web guiding system.
You can find the function of the individual keys in the following
table.
Center
Center positioning of the guiding device
positioning
Watchdog
Watchdog with sensor 1
Sensor 1
Watchdog
Watchdog with sensor 2
Sensor 2
Manual positioning
Arrow keys In manual operating mode:
of the guiding
left / right Position the guiding device to the left / right
device
Shifting the guiding Arrow keys In automatic operating mode:
setpoint left / right Shift the guiding setpoint to the left / right
In manual operating mode:
Call up the setup menu
SETUP
In automatic operating mode:
Activate the gain setting
Setup mode
ENTER Accept the set value (gain setting)
5.4.1 Overview
The operation display in the display of the control panel shows the
different operating states and all relevant control parameters as
graphical symbols and numeric values. You will find the meanings
for the individual symbols in the following illustration.
Symbol meanings
The white triangle marks the set position of the web edge in
①
the sensor scanning area.
The numeric value indicates the current web edge position.
Connection via CAN bus:
②
Position of the web edge in the sensor scanning area
(unit [mm] or [inch])
Symbol meanings
① The triangle marks the guiding setpoint set.
Line guiding:
The white bar marks the current position of the line.
② Contrast guiding:
The black bar marks the current position of the contrast
transition.
The value specifies the relative position of the line or
③
contrast transition in relation to the sensor scanning area.
The line is located in the center The line is located at 25% of the
of the sensor scanning area. sensor scanning area.
One-camera system
Dual-camera system
Symbol meanings
CAN address of the assigned CCD camera
One-camera system: 21
①
Dual-camera system: camera 1 = 21, camera 2 = 31
(see CCD Cameras (Sensor 1/2), page 27)
② The triangle marks the guiding setpoint.
The value specifies the web edge position as a percentage or
③ absolute value (see Display of the Web Edge Position, page
43).
The contrast transition (white / black) marks the actual posi-
④
tion of the web edge.
OFF OFF ON
The web edge is located in the The distance from the web edge
center of the camera measuring to the center of the camera
range. measuring range is 148.3 mm.
Symbol meanings
The tachometer symbol indicates that the speed-dependent
①
guiding is activated.
② The black line marks the zero position of the actuator.
The symbol indicates that the position control for the
③
actuator is switched on.
The value specifies the relative position of the actuator in
④
relation to the end positions.
⑤ The grey bar marks the current position of the actuator.
You can select the pages that are displayed using the swiping
function. This means that the display is configurable. The selection
of the displays and setting menus that are displayed using the
swiping function is done in a special setup menu (see Switching
the Configurable Displays and Setting Menus On/Off, page 109).
Fig. 23: Setup menu for selecting the displays and setting menus
5.6.1 Overview
WARNING
Danger of cutting on sharp edges of the material web!
Severe cutting injuries caused by the edges of the moving material
web.
► Never touch the edges of moving material webs.
► Carry out the material setup only when the production machine
is stationary.
During the material setup the controller is automatically adjusted
to the properties of the material to be scanned.
Bright value
► Completely clear the sensor's scanning area (no material in the
scanning area).
Dark value
► Completely cover the sensor’s scanning area with the material
to be scanned.
Fig. 24: Screen display with the connection of the sensor via CAN bus
Each screen display for the connection of the sensor via CAN bus
is shown in the following chapters.
The screen display shows the operating step necessary for gen-
erating the bright value for the selected sensor (Sensor 1 here).
The screen display shows the operating step necessary for gen-
erating the dark value for the selected sensor (Sensor 1 here).
WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
Position control
WARNING
Danger to life caused by movements of the setting drive!
If position control is active, the setting drive may execute auto-
matic movements in manual mode . Body parts could be crushed,
sheared or impacted.
► Ensure that no persons remain in the swivel or positioning
range of machine components positioned by the actuator.
5.8.2 Automatic
In this operating mode, automatic web guiding is carried out
depending on the guiding mode selected (guiding to the left or
right web edge, web center-line guiding, line or contrast guiding).
WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
Symbol meanings
① The triangle marks the set guiding setpoint during operation.
② Numeric display of the set guiding setpoint
③ The black line marks the set guiding setpoint
You can select the following two methods to adjust the guiding
setpoint:
■ Adjusting the guiding setpoint using the arrow keys of the
control panel
■ Adjusting the guiding setpoint using a special setting menu
The two methods are described in the following chapters.
›› The setting menu for the guiding setpoint has been activated in
the setup menu for the configurable displays and setting
menus (see Switching the Configurable Displays and Setting
Menus On/Off, page 109).
›› The display shows the operation display.
1. Select the desired guiding mode (see Selecting the Guiding
Mode, page 53).
2. Call up the setting menu for the guiding setpoint using the
swiping function (see Configurable Displays and Setting Menus,
page 46).
The set guiding setpoint is shown in the display as a numeric
value and using a ruler display with slider.
3. Set the desired guiding setpoint by entering the corresponding
numeric value (see Entering the numerical values via the input
keyboard, page 32) or using the slide bar (see Editing the
numerical values via the slide bar, page 33).
The new setting will have an immediate effect on the guiding.
5.9.3.1 Function
In Manual or Center Positioning mode, you can move the material
web into the desired position for guiding (e.g. by moving the
guiding device manually using the arrow keys or by moving the
edge sensor acrossy to the web running direction). Then accept
the current position of the web edge as the guiding setpoint for
web guiding. Depending on the acceptance mode, the acceptance
is triggered by pressing a key or by a remote control signal (see
Acceptance Modes, page 60).
The controller accepts the current position of the web edge as the
new guiding setpoint for the web guiding.
Fig. 28: Display of the parameter set loaded for the guiding setpoint
Center
camera measuring range
CCD camera
Machine frame
Offset
Material web
Machine center
Problem If the value "0" is set on the controller for the guiding setpoint,
the material web will be guided to the center of the camera
measuring range. Due to the off-center assembly of the CCD
camera, a difference (offset) results between the center of the
camera measuring range and the machine center. This difference
results in that with the set guiding setpoint "0", the material web
does not run in the middle of the machine.
Objective If the guiding setpoint on the controller is set to the value "0", the
material web should run exactly in the middle of the machine.
Procedure
›› The material web is pulled into the machine.
1. Activate the Web center-line guiding mode.
Application example
Offset
You have to set the gain for each guiding mode separately.
You can set the controller gain either using the arrow keys or by
entering a specific value using the touchscreen function.
5. Keep reducing the gain using the left arrow key until the
oscillation ceases (stable guiding operation).
If you desire a slower reaction of the guiding, you can reduce
the gain even further.
Pressing both arrow keys at the same time will reset the gain to
a value of 5.0.
6. Press the ENTER key.
ð The gain setting is complete.
5.11.1 Watchdog
5.11.1.1 Function
The Watchdog function is used to prevent the web from wander-
ing after the total loss of the printed line or contrast transition
during line or contrast guiding. If the printed line or the contrast
transition disappear from the scanning area of the line and con-
trast sensor (e.g. if the print is not carried out, a poor splice or
similar), the current web position is detected by the edge sensor
(capture sensor) and saved by the controller. Then the controller
will switch over from the line and contrast sensor (Sensor 3) to the
edge sensor (Sensor 1 or Sensor 2) used. Switching back to the line
and contrast sensor is carried out automatically immediately after
re-detecting the printed line or the contrast transition. When the
Watchdog function is activated, the scanning area of the capture
sensor is limited to 80%.
5.11.1.2 Requirements
The following requirements must be fulfilled for operating the
Watchdog function:
■ A CLS Pro 600 line and contrast sensor is connected to the
controller.
■ At least one edge sensor is connected to the controller.
■ The edge sensor (capture sensor) is arranged at the same
height or behind the line and contrast sensor in the web
running direction (see Figure).
Fig. 32: Correct arrangement of the capture sensor and the line / contrast sensor
① Capture sensor
② Line and contrast sensor (CLS Pro 600)
③ Capture sensor scanning area
④ Line and contrast sensor scanning area
► Set the guiding setpoint of the CLS Pro 600 line and contrast
sensor to the value 0 (see Switching on the Watchdog, page
69, Step 4).
WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
8. Press the key for the capture sensor used (Sensor 1 or Sensor 2).
9. First release the Sensor 3 key and then the key for the capture
sensor used (Sensor 1 or Sensor 2).
Caution! Observe the order in all cases!
The LED of the capture sensor key illuminates.
ð The Watchdog function is switched on.
If the capture sensor takes over the guiding in event of losing the
printed line or the contrast transition then the LED of the respective
key (Sensor 1 or Sensor 2) flashes.
20
5.11.3.1 Function
The Master-Slave guiding is used when two material webs have to
be guided together precisely to the edge (laminating control).
In doing so, the positions of both material webs are detected by
two edge sensors or two CCD cameras.
Slave web
Guiding
device
Sensor 2
Master web
Distance
web edges
Sensor 1
5.11.3.2 Requirements
The following requirements must be fulfilled for operating the
Master-Slave guiding:
■ Two edge sensors or CCD cameras are connected to the controller.
■ Sensor 1 detects the position of the Master web.
■ Sensor 2 detects the position of the Slave web.
■ A guiding device (e.g. rotating frame guide) guides the Slave web.
① Text MASTER
② Operation display Sensor 2 (mirrored)
③ Text SLAVE
① Text MASTER
② Text SLAVE
5.11.4.1 Use
The Tear-Off Detection is used for the web edge guiding with CCD
camera if, during operation of the web guiding system, material
defects (tear-off) are to be expected on the web edges to be
scanned. The function detects both tears into the material web
(inward tear) as well as projecting material (outward tear).
Inward
tear
CCD camera
Outward
tear
5.11.4.2 Function
With tear-off detection activated, in automatic mode the sensor
value of the CCD camera is read-in at a pre-set time interval
(scanning cycle). If a tear on the web edge occurs in the measuring
range of the CCD camera, the sensor value read in jumps
suddenly. If the change of the sensor value exceeds from one
scanning cycle to the next by a determined minimum value, the
change is detected as tear-off and the web guiding system is
blocked automatically for the pre-selected blocking time. It is
possible to deactivate the tear-off detection after the detection of
a tear-off for a pre-selected period (blocking hold time).
Sensor signal
Minimum
change of the
sensor value
Tear-off detection
Actuator
correction signal
5.11.5 Oscillation
5.11.5.1 Function
The oscillation enables the controlled transverse displacement of
the web of material with an adjustable amplitude (size of the dis-
placement) and frequency (speed of the displacement). It is used
for rewinding of tubular films or for materials with an irregular
thickness profile in order to avoid poor winding. You can choose
from a triangular ( ) or sinus ( ) oscillation curve.
Triangular curve
Oscillation form
Sinus curve
Range of values
Range of values 0.1 … 50.0 [1/min]
for the oscillation
frequency Range of values
1 … 500 [1/min]
Adjustment range
The adjustment range for the oscillation amplitude depends on
the guiding mode selected and on the sensor used.
Guiding mode Sensor Adjustment range
0 … 19.2 mm *
IR 2011
(± 9.6 mm)
Web edge guiding/ 0 … 12 mm *
IR 2012
web center-line guiding (± 6 mm)
0 … 9.6 mm *
US 2010
(± 4.8 mm)
0 … 12.5 mm
Line/contrast guiding CLS Pro 600
(± 6.25 mm)
Oscillation
(triangular
wave)
Material web
Material web
Sensor
scanning
area
Center Center
sensor scanning area sensor scanning area
WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
Adjustment range
1 … 500 [1/min] *
* The maximum possible oscillation frequency is restricted by
■ the maximum actuating speed of the actuator used
■ the actuating path of the actuator used
■ the set amplitude of the oscillation
WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
Oscillation amplitude
Guiding setpoint
5.11.6.1 Function
In this special type of oscillation the oscillation frequency is auto-
matically adjusted to the web speed. This means that the oscilla-
tion frequency rises with the increasing web speed. This ensures
that the ratio between oscillation frequency and web feed rate
remains constant.
5.11.6.2 Requirements
The following requirements must be fulfilled for operating the
speed-dependent oscillation:
■ A tacho generator that supplies a speed-dependent analogue
signal (0 … 10 V) is connected to the terminals 56 and 57 of the
controller.
WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.
5.11.7.1 Function
The web width measurement with edge sensors or CCD camera(s)
enables a continuous monitoring of the web width during the pro-
duction process.
The function calculates the width of the web of material from the
positions of the two material edges detected by the edge sensors
or CCD cameras of the web guiding system. The material width
calculated is shown in the display of the control panel. If the web
width measured is less or more than the warning or error limit
preset by the operator, it is displayed. The controller provides
digital message outputs for the warning and error limits.
For the web width measurement with edge sensors, two sensors
are used for detecting both material edges regardless of the
material width. For the web width measurement with CCD
camera(s), one or two CCD cameras are used depending on the
maximum material width.
► Call up the display of the web width using the swiping function
(see Configurable Displays and Setting Menus, page 46).
The width of the material web determined by the web width
measurement is shown in the display (500.5 mm in the example).
The material width has fallen below the specified error limit
or has exceeded the specified error limit.
An red signal field appears in the lower left corner of the
display. The signal field shows the deviation of the material
width measured with regard to the specified target width
(+3.2 mm in the example).
Web of material
Web of material
Material width
Web of material
Material width
Web of material
Material width
Fig. 47: Example for the specification of the warning and error limits
The following table shows the values for the target width and the
warning and error limits set in the example.
Lower error limit Lower warning limit Target width Upper warning limit Upper error limit
The following tolerance, warning and error limits result from the
values specified in the example:
Lower error range Lower warning range Tolerance Upper warning range Upper error range
(red) (orange) range (orange) (red)
(grey)
< 486 mm 486 … 496 mm 496 … 504 mm 504 … 512 mm > 512 mm
1. Call up the setting menu for the warning and error limits of the
width measurement in the setup menu (see Calling up the
Setup Menu, page 106).
The setting menu is displayed.
2. For specifying the warning and error limits tap on the editing
field behind the corresponding Minus or Plus button.
A numeric keypad is displayed.
3. Enter the desired value for the warning or error limit.
4. Confirm your entry with the button.
The keypad is closed.
1. Tap on the adjacent button in the lower right corner of the web
width display.
5.11.8.1 Function
The line width measurement enables a continuous monitoring of
the width of a printed line during the production process. In doing
so, the line is scanned by a BST eltromat CLS Pro 600 line and con-
trast sensor.
5.12.1 Utilization
The ekr 500 digital Unit Touch controller has a connection for a
motorized FVG POS 100 sensor positioner. The sensor positioner
enables the motorized positioning of the edge sensors connected
(Sensor 1, Sensor 2).
Fig. 51: ekr 500 digital Unit Touch controller with FVG POS 100 sensor positioner
The white triangle marks the set position of the web edge in
①
the sensor scanning area.
The numeric value indicates the current position of the web
②
edge in the sensor scanning area (unit [mm] or [inch])
5.12.3 Operation
Web center-line guiding Both sensor slides carry out the edge detection.
5.12.3.4 Pre-Positioning
This function is used to carry out material web pre-positioning to a
position determined by the operator.
WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.
5.13.1 Utilization
The ekr 500 digital Unit Touch controller has connections for two
positioning units. The positioning units enable the motorized
positioning of sensors or tools. The main field of application of the
positioning unit is the motorized positioning of a BST eltromat
CLS Pro 600 line and contrast sensor (Sensor 3) across the web
running direction in slitter-winders.
Control panel
ekr commander
Control panel
CLS Pro 600
Controller
ekr 500 digital Unit Touch
Positio
ning un
it
Fig. 53: Motorized positioning of a CLS Pro 600 line and contrast sensor (example)
5.13.2 Requirements
The following requirements must be fulfilled for operating the
positioning unit for Sensor 3 with the ekr 500 digital Unit Touch
controller:
■ A positioning unit with a BST eltromat CLS Pro 600 line and con-
trast sensor is connected to the socket X101 (Sensor 3) of the
controller.
5.13.3 Operation
WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.
4. Activate the slow speed level for the fine positioning of the
sensor slide.
If activated, the turtle symbol is displayed with a blue back-
ground.
5. Carry out fine positioning of the sensor slide using the arrow
keys of the control panel.
WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.
Before using this method for the first time, three dashes are dis-
played in the editing field for the target position. They indicate
that the sensor slide is in an undefined position.
›› The operation menu for the positioning unit is displayed. For
calling up the menu see Calling Up the Operating Menu, page
102.
3. To call up the next page of the setup menu, keep pressing the
right arrow button until the desired menu page is shown in the
display.
4. Tap the symbol of the desired setting function or service dis-
play on the touchscreen.
The setting menu or service display selected appears in the dis-
play.
Fig. 56: Setup menu for the configurable displays and setting menus
Operating the
See Positioning Unit, page 101
positioning unit
Pos. Meaning
① Symbol of the system component
② Type designation of the system component
For system components, whose type designation is placed in a black frame, you can call up the
③ Switch Position service display by tapping the frame on the touchscreen (see Displaying Switch
Positions, page 114).
④ The internal terminating resistor of the system component is activated.
The above illustration shows the system components of a standard
web guiding system. The following table lists possible other system
components.
Symbol System component Designation Type
Controller ekr500d ekr 500 digital Unit Touch controller
comndr1 ekr commander control panel of the controller
Control panel Additional ekr commander control panel
comndr2
(remote control)
IR2011 Optical sensor IR 2011
IR2012 Optical sensor IR 2012
US2010 Ultrasonic sensor US 2010
Edge sensor 1/2
Infrared wide array edge sensor IR SEN …,
WideAr
Ultrasonic wide array edge sensor US SEN …
FvgPos FVG POS 100 sensor positioner
CCD camera 1/2 ccd 1, ccd 2 CCDPro or CCD CAM 100 CCD camera
3. Press the button at the end of the list to quit the service
display.
The setup menu is displayed.
Fig. 59: Display of the switch positions (here for the ekr 500 digital Unit Touch controller)
You can read the content of the QR code using your Smartphone or
Tablet PC with camera and a QR code scanner software. You can
find free Apps with QR code scanners on the internet.
With active keyboard interlock all keys of the control panel are
blocked. The keyboard interlock is activated by a 24 V⎓ signal at
terminal 9 (see truth table, installation and commissioning manual
ekr 500 digital Unit Touch, document number MD.497).
With active setup lock, the SETUP button of the control panel is
blocked. The setup lock is activated by a 24 V⎓ signal at terminal
22 (see truth table, installation and commissioning manual
ekr 500 digital Unit Touch, document number MD.497).
Fig. 70: Screen display with the loss of the line / contrast transition to be scanned
Fig. 72: Screen display with an active fault in the external motor output stage for
the EMS 23 actuator
5.18.1 EFE 1
With the electronic remote precision adjustment EFE 1, you set
the guiding setpoint of the web in the automatic operating mode.
2. Using the arrow keys of the EFE 1000, move the guiding device
to the desired position.
NOTICE
Damage to the components from working on live parts.
► Before opening the controller, switch off the power supply.
Claims on the warranty and claims for damage are invalid if main-
tenance and cleaning work have not been carried out or not been
carried out correctly.
DANGER
Danger of death from electric shock!
Life threatening injuries caused by incomplete switching off or
residual current.
► Electrically isolate the controller.
► Secure the power supply against being switched back on.
► Check that the unit is voltage-free.
► Earth the controller.
► Cover or fence off any adjacent parts that are still live.
WARNING
Risk of injury and material damage caused by incorrect mainten-
ance / cleaning!
► Have the maintenance and cleaning carried out only by
qualified personnel that have been instructed by BST eltromat
service personnel or authorized personnel.
► Carry out the maintenance and cleaning as described in the
following chapters.
► With particularly intensive stress / soiling, reduce the specified
maintenance intervals.
NOTICE
Damage to the components caused by solvents!
Cleaning agents containing solvents damage the surfaces of the
system components.
► Never use cleaning agents containing solvents, not even with
intensive soiling, unless the respective cleaning agent is
explicitly listed in the instructions.
► Follow the cleaning instructions.
6.3.4 Cleaning the Housing of the CLS Pro 600 Line and Contrast Sensor
See separate operating instructions Line and contrast sensor
CLS Pro 600, document number MD.323.
7 Troubleshooting
WARNING
Danger to life and assets caused by incorrect rectification of mal-
functions!
► Only allow qualified personnel instructed by BST eltromat
service staff or authorized personnel to rectify malfunctions.
► Only rectify malfunctions using the following measures or
follow the instructions of BST eltromat customer service.
Fault
Possible causes Measures for eliminating the fault
The actuator / the guiding device reacts too slowly or the guiding operates incorrectly.
► Optimize the controller gain. See Optimizing the
Controller Gain, page 66.
The controller gain has been set too low.
► Perform material setup. See Performing the
Material Setup, page 47.
The actuator / the guiding device does not carry out any guiding movement.
► Check the setting of the DIL switch S4 in the
An incorrect actuator has been selected during controller. See installation and commissioning
commissioning. manual ekr 500 digital Unit Touch, document
number MD.497.
► Optimize the controller gain. See Optimizing the
The controller gain has been set too low.
Controller Gain, page 66.
In operating mode Automatic the actuator / the guiding device moves to an end position and remains
stationary there (with material web threaded in).
A material setup was not run after the material ► Perform material setup. See Performing the
was changed. Material Setup, page 47.
► Reverse the guiding direction of the actuator.
See installation and commissioning manual
The actuator guiding direction is incorrectly set.
ekr 500 digital Unit Touch, document number
MD.497.
In operating mode Center positioning the actuator / the guiding device moves to an end position and
remains stationary there.
► Reverse the guiding direction of the actuator.
See installation and commissioning manual
The actuator guiding direction is incorrectly set.
ekr 500 digital Unit Touch, document number
MD.497.
The servo center transducer used (OMG 4, OMG 8, ► Check the installation position of the servo
CK 37) has been installed incorrectly. center transducer.
The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Motor overcurrent is shown in the display.
An actuator with position feedback does not carry out any guiding movement.
The symbol Limit switch active is shown in the display.
The actuator has reached a software limit switch.
► Activate the actuator in the opposite direction.
Driving the actuator in the corresponding direction
The symbol is deleted automatically.
is prevented.
The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Controller interlock is shown in the display.
The controller interlock is active. ► Deactivate the controller interlock for the auto-
matic operating mode. See truth table, installa-
tion and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.
The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Motor control timeout is shown in the display.
The actuator has been activated uninterrupted in ► Activate the actuator in the opposite direction.
the same direction for more than 50 seconds. ► Check the actuator for damage (e.g. broken spindle)
No material web has been threaded in. ► Thread up the material web.
There is no web tension present. ► Check the web tension.
The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Faulty bus connection on the actuator is shown in the display.
Fault in the bus connection between the controller ► Check the cable connection between the
and actuator. controller and actuator (Drive Module 160).
The EMS 23 actuator does not carry out any guiding movement.
The warning symbol External motor output stage fault is shown in the display.
The actuator / the guiding device has moved to an end position and the motor switch off does not
function. The LEDs of keys or on the control panel and the screen display flash.
As a result of the increased power consumption of
the actuator, the supply voltage (24 V⎓) falls below ► Check the power pack.
the permissible voltage range.
All the settings for actuator, sensors, servo center transducer, etc. are correct, but the unit does not
control.
The controller gain was inadvertently reduced to
► Set the controller gain. See Optimizing the
the minimum value (0.2). No guiding takes place in
Controller Gain, page 66.
Automatic operating mode.
An exclamation mark is shown in the sensor symbol of a digital edge sensor in the display.
The supply voltage of the controller is outside the ► Check the power pack.
permissible range. ► Check the mains wiring.
If the SETUP button is pressed, the SETUP key symbol with a padlock is displayed.
A shifting of the guiding setpoint of the web using the arrow keys on the control panel is not possible.
► Shift the guiding setpoint using the poten-
The optional electronic remote precision adjust-
tiometer of the electronic remote precision ad-
ment EFE 1 is connected to the controller.
justment EFE 1. See EFE 1, page 123.
During line and contrast scanning using the CLS Pro 600 line and contrast sensor an
exclamation mark is displayed in front of the symbol for Sensor 3.
With the web edge or the web center-line guiding with CCD camera, an exclamation
mark is shown in the display in front of the symbol of the CCD camera.
8 Customer Services
Do you have any questions about this product? Or for any of the
other products or services of BST eltromat International?
Then please contact the following address.
In order to be able to reply to your request as soon as possible,
please provide us with the following data (where available):
■ Product name
■ Job number
■ EDP number and software version
■ Serial number and date of manufacture (see name plate)
Index
A D
Actuator Dark value
Maintenance................................................ 134 Display............................................................ 49
Automatic mode ............................................. 55 Generating ..................................................... 48
Design ............................................................. 18
B Display elements............................................. 24
Disposing of the system................................ 142
Bootloader version
Display.......................................................... 111
Bright value E
Display............................................................ 49 Edge sensor
Generating ..................................................... 48 Malfunction.................................................. 120
BST eltromat homepage Edge sensors
Displaying link .............................................. 115 Installation position ....................................... 25
Bus connection fault ..................................... 120 Maintenance................................................ 134
EFE 1000 ....................................................... 123
C EFE 1 ............................................................. 123
ekr commander ........................................ 24, 30
CCD camera
Electricians
Installation position ....................................... 27
Qualification................................................... 13
Loss of the web edge ................................... 121
Maintenance................................................ 134 Electronic remote precision adjustment ...... 123
Center positioning .......................................... 55 Emergency ...................................................... 15
Components Entering a numerical value
Intended use .................................................... 8 via the input keyboard ................................... 32
Configurable displays...................................... 46 via the slide bar.............................................. 33
Switching on/off........................................... 109 Equipment
Configurable setting menus............................ 46 Protective....................................................... 16
Switching on/off........................................... 109 Error limits
Contacting BST International ........................ 141 Activating ....................................................... 90
Definition ....................................................... 88
Contrast guiding.............................................. 20 Specifying....................................................... 90
Loss of the contrast transition to be scanned 121
Extended device settings .............................. 124
Control elements ............................................ 24
External motor output stage fault ................ 122
Control panel ............................................ 24, 30
Key functions ........................................... 24, 31
Maintenance................................................ 133 F
Touchscreen display....................................... 24 Factory default settings
Controller........................................................ 18 Restoring...................................................... 131
Maintenance................................................ 133 Fault
with additional control panel......................... 19
Display.......................................................... 116
with control panel detached.......................... 18
with control panel fitted ................................ 18 Fehlerbehebung............................................ 135
Controller gain Firewalls.......................................................... 10
Adjustment via touchscreen .......................... 67 Firmware version
Adjustment with arrow keys.......................... 66 Display.......................................................... 111
Display.......................................... 34, 35, 36, 66 Function .......................................................... 19
Optimizing...................................................... 66 FVG POS 100 ................................................... 23
Controller interlock....................................... 118
Customer services......................................... 141 G
Guiding functions............................................ 20
Guiding mode ................................................. 20
Contrast guiding............................................. 20
W
Warning limits
Activating ....................................................... 90
Definition ....................................................... 88
Specifying....................................................... 90
Warranty terms .............................................. 16
Watchdog ....................................................... 20
Function ................................................... 20, 68
Preparation measures.................................... 69
Requirements................................................. 68
Switching on................................................... 69
Web center-line guiding ........................... 20, 53
Web edge guiding ..................................... 20, 53
Web width
Display............................................................ 86
Web width measurement............................... 22
Activating the error limits .............................. 90
Activating the warning limits ......................... 90
Calibration...................................................... 93
Digital message outputs................................. 91
Error limits ..................................................... 88
Function ......................................................... 86
Specifying the error limits.............................. 90
Specifying the warning limits ......................... 90
Warning limits................................................ 88