BST ekr1000 en

Web Guiding Systems
Web Viewing Systems
BST - web guiding system
EKR 1000 H
with analogue sensors
Operating manual
BST International GmbH
Heidsieker Heide 53
33739 Bielefeld
Germany
Telefon: ++49(0)5206/ 999 - 0
Fax:
++49(0)5206/ 999 - 999
E-Mail: [email protected]
Issue:
07.04.1997
EDV Nr.:
V3D.002.01.02
Definition of the symbols in this manual
Attention
Comments of this type have to be taken into consideration to protect the operator
against mechanical risks
Caution
Comments of this type have to be absolutely considered to protect the
operator against electrical risks
press key
key combination;
between the keys means that these keys
have to be actuated simultaneously
LED ‘OFF’
LED constantly lighted = activated phase
LED blinking
0.0
Table of contents
Table of contents
Chapter 1
Description
1.1 General
1.2 General plan
1.3 Operating elements
1.4 Signification of the keys on the front panel
1.5 Signification of the LED’s on the front panel
1.6 Safety instructions
1.7 Emissions
Chapter 2
Technical Data
2.1 EKR 1000
2.2 Optical edge sensor IR 2001
2.3 Optical edge sensor IR 2002
2.4 Ultrasonic sensor US 2003
2.5 pneumoelectric transducer ZT 6008
Chapter 3
Transportation/Storage
Chapter 4
Installation
4.1 Requirements to location
4.2 Installation
4.3 Mounting plan
4.4 Installation of EMC-wiring
4.5 Installation of pneumatic sensors KF ...
Chapter 5
Start-up
5.1 Requirements for Start-up
5.2 Adjustment of sensors
5.3 Start-up
5.4 Basic SET UP
5.5 Determine desired sense of rotation for manual operation
5.6 Automatic operation with sensor 1 (and possibly sensor 2)
5.7 Preparation for actuator ‘electric’
5.8 Preparation for actuator ‘hydraulic’
5.9 Preparation for ZT 6008
Chapter 6
Operation
6.1 Amplifier
Chapter 7
Remote control
Chapter 8
Trouble shooting
Chapter 9
Maintenance
Chapter 10 De-commissioning
Enclosure:
* general plan
* connecting plan
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 0.0
page: 1/1
1.0
Please follow the instruction of
start-up, maintenance and installation
as described in the operating instruction!
1. Description
1.1 General
The EKR 1000 system is a microprocessor-controlled amplifier. This amplifier could be used for
- web edge guiding (right or left)
- center guiding
Please contact the producer for any different application.
The amplifier has PLC-compatible inputs and also an ‘OK-relay’ with NO and NC contact.
Full integration into the machine control system via:
- I-O Module
- Intercon-Module
- Interbus-S Module
- PDP-Module
potential-free in- and outputs for extended PLC messages and
commands
direct, serial connection for integration of system results,
messages and commands into the machine control system.
direct connection to Interbus-S Module as remote bus station
for instantaneous communication with locally peripheral
equipment
Notice: Please find the connection plans of the nominated modules at the corresponding
operating instructions.
1.2 Components available for connection
The general plan (annex 2) indicates the connectable edge sensors and components to the
amplifier.
1.3 Operating elements
* The amplifier includes all necessary operating elements.
Option:
- Remote control by external signals, sensors or keys
Attention! External keys will interlock the reverse function keys at the amplifier.
- If system locking is desired (e. g., in case of machine stop), this can be
achieved by means of external contacts or signals from the PLC.
* Connection of components via separated terminal compartment.
Advantage: quick and easy accessibility to the terminal parts.
* Indication of web edge position by two LED arrays
Advantage: - simple control of the web edge within the measuring range of sensors
- simple adjustment of the desired position of the web or edge sensors
- variations of web width exceeding via the admissible value
Web guiding system
EKR 1000H with analogue sensors
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 1.0
page: 1/4
1.0
1.4 Signification of the keys on the front panel
15 16 17 18 19
10 11 12 13 14
4
5
1
6
2
7
3
8
key and/or combination of keys
9
function
AUTO (1)
= automatic guiding
MAN
(2)
= manual positioning
S-C
(3)
= servo-center of the servo component
← / + (4) + MAN
+ AUTO
= manual shifting
= shifting of guiding point to the left
*
+ SET UP + AUTO = increase of gain
→ / - (5) + MAN
+ AUTO
= manual shifting
= shifting of guiding point to the right *
+ SET UP + AUTO = decrease of gain
SET UP (6)
AUTO = release of gain with the keys (4) and (5).
+ MAN and/or S-C = SET UP when changing the material
ENTER (7)
= storing of the adjustment and end of SET UP
functions
„SENSOR LEFT“ (8)
= guiding to the left web edge
„SENSOR RIGHT“ (9)
= guiding to the right web edge
* The shifting of set point via the arrows keys can be locked by a DIL-switch (see also chapter 5,
point 5.1).
Web guiding system
EKR 1000H with analogue sensors
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 1.0
page: 2/4
1.0
1.5 Signification of the LED´s on the front panel
* The LED’s on the keys indicate the switched-on function.
* The blinking of LED’s AUTO (1) , MAN (2) , S-C (3) , SET UP (6) or LED- arrays 10 - 14
and/or 15 - 19 indicate a fault message. Simultaneously, the OK-relay is switched-off. (see
also chapter 8)
* LED-No. 10, 14,15 and 19 (red) signalise the limits of the measuring band of the sensors.
* LED-No. 12 and 17 (green) signalise the center of the measuring band of the sensors.
10 11 12
Web guiding system
EKR 1000H with analogue sensors
13 14
15 16 17
18 19
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 1.0
page: 3/4
1.0
2. Safety instructions
* Installation of the BST equipment into the production machine according to the relevant rules
( EN 294, EN 349) and the specific branch-oriented regulations for prevention of accidents,
such as:
- Safety distance between BST equipment and customer´s specification, e. g. machine walls,
construction etc.
- Installation of connecting cables between amplifier and controller and/or edge sensor
stumble-free, nontension and well anchored.
- Take care of free headroom. If the free passage is limited, respective building components
have to be stuffed and painted in yellow/black.
Assembly, installation and commissioning must be carried out by qualified personnel !
Please do not open the unit until the line voltage is switched off!
When operation at open unit is necessary, only protection class IP20 is present. There
will be an increased risk of danger by line voltage !
- Please do not use the guiding frame as a tread or a step ladder.
- Don’t remove any safety devices.
During functional testing outside of production machine and/or during the start-up
procedure the actuator will carry-out positioning movements!
Make relevant safety arrangements during performance check !
During start-up procedure, the total safety concept of the production machine will have to
be considered.
* Before commissioning remove transport safety devices (if present).
3. Emissions
The A-rated equivalent continuous sound level of the equipment is lower than 70 dB(A).
Web guiding system
EKR 1000H with analogue sensors
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 1.0
page: 4/4
2.0
2. Technical Data
2.1EKR 1000
* Line voltage:
115V/230V
+10% / -20%
50-60Hz
* Power consumption: approx. 80VA
* Fuses:
115V
230V
1 AT
0,5 AT
* Outputs:
amplifier (adjustable, see also ‘Lay jumper according to
application’, chapter 5.0, point 5.1)
+/- 24V; max. 1A or
+/- 24V; max 0,33A or
+/- 300mA current source of electric power short circuit proof,
Dither amplitude adjustable
Supply to accessories
+/- 12V (min. +/- 11,4V)
+ 24V non regulated supply
at max. 50mA
max. 0,4A
Status signal (“system OK“)
potential-free change-over switch, max. 230V, 1A
* Inputs:
remote inputs (signification see “Truth table“ chapter 7)
lock-out (controller interlock): possible by means of external
switch or PLC
limit switch inputs: (without cutout)
Ri
active (1)
not active (0)
= 4,7 kOhm
> 8V
< 4V
tlow
Uin Max
> 30ms
acc. to IEC 1,2kV / 50µs
analogue inputs (see also chapter 5, point 5.1 and connecting
plan)
2x
0...+ 5V or 0...+ 10V, individual adjustable
2x
± 9,75V or 0... + 9,75V, individual adjustable
2x
± 11,75V
1x
NAMUR adaptation with output ± 11,75V
tacho input for motor powered actuator
* Interface:
serial interface RS485 for BST module bus
* Protection class:
IP 54
* Ambience conditions: temperature: 0 - max. 45 deg.C
atmospheric humidity: 0 - 90%, non-condensed
* Dimensions:
W = 263mm, D = 214mm without screwed connections,
H = 115mm
* Weight:
approx. 3kgs
Web guiding system
EKR 1000H with analogue sensors
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 2.0
page: 1/3
2.0
2.2
Edge sensor IR 2001
Power supply:
by amplifier
Measuring band:
Maximum sensing range:
12mm, typical
15mm, typical
Output:
analogue
Protection class:
IP54
Ambience conditions:
temperature: 0 - 45 deg.C
atmospheric humidity: 5 - 90%, non-condensed
Dimensions (standard application):
2.3
Edge sensor IR 2002
Power supply:
by amplifier
Measuring band:
Maximum sensing range:
8mm, typical
13mm, typical
Output:
analogue
Protection class:
IP54
Ambience conditions:
temperature: 0 - 45 deg.C
atmospheric humidity: 5 - 90%, non-condensed
Dimensions (standard application):
2.4
W = 40mm
H = 95mm
L = 107mm
W = 25mm
H = 57mm
L = 85,5mm
Ultrasonic sensor US 2003
Power supply:
by amplifier
Measuring band:
Maximum sensing range:
15mm, typical
15mm, typical
Output:
analogue
Protection class:
IP54
Ambience conditions:
temperature: 0 - 45 deg.C
atmospheric humidity: 5 - 90%, non-condensed
Dimensions (standard application):
Web guiding system
EKR 1000H with analogue sensors
W = 25mm
H = 76mm
L = 113mm
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 2.0
page: 2/3
2.0
2.5
Pneumoelectric transducer ZT 6.008
Power supply:
by amplifier
Signal inputs:
0 - 10 mbar
Output:
± 10V
Protection class:
IP54
Ambience conditions:
temperature: 0 - 45 deg.C
atmospheric humidity: 5 - 90%, non-condensed
Dimensions (standard application):
Web guiding system
EKR 1000H with analogue sensors
W = 200mm
H = 70mm
L = 120mm (without air connections)
EDV-No.:V3D.002.01.02
Date:
07.04.97
chapter: 2.0
page: 3/3
3.0
3. Transport/Storage
The unit will be delivered in working order. For transport purposes, the unit will be packed in
standard cardboard boxes with cellular lining material. If the unit is not incorporated immediately,
please storage it in a non-moistured room until mounting.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 3.0
Page: 1/1
4.0
4. Mounting / Installation
4.1 Requirements to location
The amplifier has to be installed at non-moistured, vibration-free area.
Ambient temperature:
0 - max. 45 deg.C
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04 97
chapter: 4.0
page: 1/5
4.0
4.2 Installation
19
Mounting plan see page 7
1 - Open terminal
compartment
Pull the two rear
mounting rails upward
and screw into the
mounting wall
SET UP
SENSORLEFT
ENTER
SENSOR RIGHT
214
MAN
150
AUTO
25
S-C
6
264
115
10
276
AUTO
SET UP
MAN
SENSOR LEFT
ENTER
SENSOR RIGHT
2 - Push the housing upward so that the mounting rails stay flush
again in respect of the
upper edge of the
housing
S-C
AUTO
SET UP
MAN
SENSOR LEFT
ENTER
3 - Apply the third fixing in
the terminal compartment. Complete wiring
and close terminal
compartment.
SENSOR RIGHT
S-C
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04 97
chapter: 4.0
page: 2/5
4.0
4.3 Mounting plan
262
180
M4 or Ø 5
housing EKR 1000
212
191
131
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04 97
chapter: 4.0
page: 3/5
4.0
4.4 Installation of EMC-wiring
disk of the cable
fitting
shield
remove 90mm of
external insulation
black rubber
sealingparts
conical sealing
(metal/rubber)
nut
unscrew nut and
sealing parts and pin
them up to the end
of the cable
figure 1
figure 2
insulated cable leads
remove 60mm of shield, so
that 30mm remain visible
galvanised washer
10 x 16 x 0,5 DIN 988
30mm
vanished shield
Fan the protective shield, so
that the individual wires of the
shield protrude evenly from
the cable, approx. at right angle.
Tread the individual insulated
leads through the galvanised
washer, included in delivery
and press the washer onto the
shield braiding.
figure 3
figure 4
only for connecting cable CCD 5000
up to hardware version G
and Interbus-S
ferrite core
Refold and twist the shield
braiding over the washer.
Tighten the cable in the cable
gland. Strip the lead ends
(eventually, use protective lugs)
and wire according to connection
diagram.
housing
cable gland
Screw down the cable gland and
then pin up the ferrite core to the
end of the cable, according
to the drawing.
figure 5
Web guiding system
EKR 1000H with analogue sensors
figure 6
EDV-No.: V3D.002.01.02
Date:
07.04 97
chapter: 4.0
page: 4/5
4.0
4.4 Installation of pneumatic sensing system
1. Pneumatic edge sensors have to be mounted in such a way that with horizontal web path the
connection S1, carrying the higher pressure, is placed below (air escape S1 turned towards
above).
2. Slip the hose ends onto the corresponding connection pieces S1 and S2.1at the pneumoelectronic transducer ZT 6.008.
3. Connect the second edge sensor with the second connection piece S1 and the connection
piece marked S2.2. If only one sensor is present, seal the second connection S1 at the
ZT 6.008. S2.2 remains open and blows off.
4. The hose pipes towards the sensors should not exceed a length of 3m each and should have a
few ‘bends’ if possible.
5. Connect the air outlet at the BS 100 unit by means of single air hose with the connection piece
in the middle (not varnished) at the ZT 6.008 transducer.
When the ZT 6.008 is not directly mounted to the BS 100 unit, the length of the air hose may
be up to 6m (please contact the manufacturer for longer hoses).
Attention: Do not connect BS 100 with the connections S1, S2.1 or S2.2 at the ZT 6.008
transducer; such action will destroy the ZT 6.008!
Blowing in compressed air is inadmissible and will also destroy the unit!
The lateral channel compressor unit BS 100 has to be installed on even and plane surface either
vertically or horizontally.
In case of separate mounting, the pneumo-electronic transducer ZT 6.008 has to be attached to
a vibration-free surface. Make sure that free access to the interior of the box is possible after
having removed the cover.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04 97
chapter: 4.0
page: 5/5
5.0
5. Start-up
5.1 Requirements for Start-up
1. Set DIL-switches according to application.
Lageplan EKR 1000 H
EPROM
Prozessor
RAM
TRAFO
S T U
V W X
JX12
JX13
H J K
L M N
JX8
JX14
I
Z
Y
JX9
H11
115V: F1= 1AT
230V: F1= 0,5AT
F1
L N
OK
444546474950515253545556575859606162636465666768697071727374
O
P 404142
0 6 7 8 9 1011 0 13141516171820212224252628293132333435363738
R Relais
S1.1
S1.2
S1.3
S1.4
S1.5
S1.6
S1.7
S1.8
S2.1
S2.2
S2.3
S2.4
S2.5
S2.6
S2.7
S2.8
H1
H2
H3
H4
A
B JX11
C
H5
H6
H7
Darstellung nicht maßstäblich!
H8
H10 H9
D
E
F
JX10
LED +5V
S1.1
=
Inverse function Automatic
S1.2
=
OFF
ON
S1.3
=
Inverse function S-C
S1.4
=
OFF
ON
=
=
normal operation
guiding to sensor 3 and 4 with scaling = 1:1 (e. g. Slave)
S1.5
=
OFF
ON
=
=
EMS1/plunger coil regulator
EMS5 or EMS 1000 power module
S1.6
=
ON
=
chase and follow system with camera CCD 5000
S1.7
=
=
inverse function CCD camera 3
S1.8
=
OFF
ON
=
=
EKR 1000, EKR 1500
CCD Line Guider
S2.1
=
OFF
=
reserved
S2.2
=
OFF
=
reserved
S2.3
=
OFF
=
reserved
S2.4
=
OFF
ON
=
=
„Shifting of guiding point“ via arrow keys is permitted
„Shifting of guiding point“ via arrow keys is locked
S2.5
=
=
from software version E0030401 see schedule 1
S2.6
=
=
exposure time adjustment of ‘CCD 2004 from H’ is locked
=
see schedule 2
S2.7 and S2.8
ON
=
=
Web guiding system
EKR 1000H with analogue sensors
electric motor powered actuator
lifting of zero level and Dither for hydraulic units
(from software version E0030401 see schedule 1)
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:1/14
5.0
Schedule 1
Special functions of the DIL switches S1 and S2
from software version E0030401
S1.2
S2.5
function
OFF
OFF
electric motor powered actuator
• lifting of zero level OFF
• Dither OFF
OFF
ON
electric motor powered actuator
• lifting of zero level ON
• Dither OFF
ON
OFF
hydraulic actuator
• lifting of zero level ON
• Dither ON
ON
ON
hydraulic actuator
• lifting of zero level OFF
• Dither ON
Schedule 2
Signification of LED´s in the terminal box for service indication
The type of indication can be selected by means of S2.7 and S2.8.
LED
H1
S2.7 OFF
S2.8 OFF
CCD1
H2
CCD2
H3
CCD3
H4
INTERCON (1/2)
H5
INTERBUS-S module
H6
I-O module (1/2)
H7
FVG 1000 module
H8
blinker
S2.7 ON
S2.8 OFF
locking from
remote control
locking from
CCD1
locking from
CCD2
locking from
CCD3
locking from external
command module
INTERBUS,
INTERCON,
I-O Modul
locking from
FVG 1000 module
internal locking of the
EKR
blinker
S2.7 OFF
S2.8 ON
actuator fully
stabilized
external release of
keyboard and remote
control interlock
S2.7 ON
S2.8 ON
blinker
blinker
The blinker indicates a perfect program flow.
LED H11 indicates the correct function of the relay ‘system ok’ (LED is lighting)
LED extinguishes if a failure occurs (see also chapter 8 ‘Trouble shooting’)
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:2/14
5.0
2. Lay jumper according to the application
The amplifier (standard version with electric motor powered actuator) is preset by manufacturer as
follows:
jumper O-P
jumper J-K
jumper M-N
jumper D-E
jumper A
jumper S-T
jumper V-W
equipotential bonding carried out
signal input 0...10V
signal input 0...10V
tacho ‘OFF’
motor ± 24V
signal input ± 9,75V
signal input ± 9,75V
Modification/adjustment is only necessary by a different application.
Socket
Jumper
JX1
O-P
P-R
equipotential bonding
PE / 0V
carry out equipotential bonding
non equipotential bonding
JX8
H-J
J-K
signal sensor 3
(terminal 56)
signal input 0...5V
signal input 0...10V
JX9
L-M
M-N
signal sensor 4
(terminal 60)
signal input 0...5V
signal input 0...10V
JX10
D-E
E-F
motor tacho +
motor tacho -
tacho ‘OFF’
tacho ‘ON’
JX11
A
B
C
servo component A
servo component B (0V)
motor ± 24 V
plunger coil ± 300mA
servo valve ± 1A
JX 12
S-T
T-U
signal sensor 1
(terminal 11)
signal input ± 9,75V
signal input 0...9,75V
JX13
V-W
W-X
signal sensor 2
(terminal 18)
signal input ± 9,75V
signal input 0...9,75V
JX14
I-Z
Z-Y
Web guiding system
EKR 1000H with analogue sensors
Function
Comment
reserved
reserved
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:3/14
5.0
3. Set line voltage
Make sure that the voltage on the name plate of the amplifier corresponds to the actual supply
voltage!
Correct in case of deviation.
230V
Lageplan EKR 1000 H
EPROM
F1 = 0,5AT
Prozessor
RAM
TRAFO
S T U
V W X
JX12
JX13
H J K
L M N
JX8
JX9
JX14
I
Z
Y
H11
115V
115V: F1= 1AT
230V: F1= 0,5AT
F1
L N
OK
444546474950515253545556575859606162636465666768697071727374
O
P 404142
0 6 7 8 9 1011 0 13141516171820212224252628293132333435363738
R Relais
Darstellung nicht maßstäblich!
S1.1
S1.2
S1.3
S1.4
S1.5
S1.6
S1.7
S1.8
S2.1
S2.2
S2.3
S2.4
S2.5
S2.6
S2.7
S2.8
H1
H2
H3
H4
A
B JX11
C
H5
H6
H7
H8
H10 H9
D
E
F
JX10
LED +5V
F1 = 1AT
4. Connection of components according connection plan
Installation of EMC-wiring see point 4.4
5. Connection of remote control according connection plan (if present)
6. Switch-on line voltage.
5.2 Sensor adjustment
Using sensors of the type PLE ... or GL 240, adjustment of the sensors have to be carried before
start-up.
Sensor PLE ...
1) Switch on light source and amplifier
2) After 15 minutes warm up time the output signal of the PLE units should be adjusted (when
BME sensor frames are supplied the adjustment is made by manufacturer).
• Remove the cover plate with the cable gland and pull out the PCB
• Connect an AVO meter to the terminals 2 and 3
• Ensure that there is no obstruction between the light source and the PLE, then rotate
the PLE around its longitudinal axis until the meter gives maximum reading. With the
AVO still connected turn potentiometer on the PCB to give a reading of -5V
• Reposition the PCB and attach the cover plate
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:4/14
5.0
Sensor GL 240
1) Switch on sensor
2) After 15 minutes warm up time carry out the compensation:
• Remove the upper housing cover. Both the fluorescent lamp and the electronics
are accessible.
• A measuring instrument with an internal resistance greater than 10 kOhm/V should be
connected between the connections 3 and 6.
• Cover receiver side with opaque material completely and check if the measuring
instrument shows ‘zero’. If this should not be the case, a correction of the zero point
should be made with the potentiometer 2.
• With free fork-shaped opening, a room temperature of 15...25°C and a lamp voltage of
220V, the measuring instrument must indicate 5V. Corrections can be carried out by
means of potentiometer 1.
5.3 Start-up
The system only admits operation with components actually present.
Regarding actions to be carried out, also see ‘components connected’.
5.4 Basic SET UP
Only necessary after installation or
change of components connected!
5.4.1 Conditions:- non material in viewing range of edge sensors
- clean the lenses of the edge sensors
- set remote precision adjusting device to center position (if present)
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:5/14
5.0
5.4.2 Basic initialisation
The basic initialisation has to be carry out once at first start-up. The amplifier recognised
hereby the connected components.
1. Actuate simultaneously keys ‘PLUS’ and ‘SET UP’
SET UP
2. Press key ‘ENTER’
ENTER
3. Clean existing edge sensors. Remove material out of the viewing range of the edge sensors
(if present)
Press key ‘ENTER’
ENTER
4. Cover the edge sensors completely, e. g. with card board
Press key ‘ENTER’
ENTER
5. Release present edge sensors
Press key ‘ENTER’
ENTER
6. Cover edge sensors completely again.
Press key ‘ENTER’
ENTER
The basic initialisation is completed and will only repeated when additional components
are connected.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:6/14
5.0
5.5 Determine desired sense of rotation for manual operation
1. Press key ‘MAN’
2. Press key ‘PLUS’ or
‘MINUS’
or
Observe guiding device !
If opposed positioning movement is
desired interchange actuator polarity a
at terminals 28 and 29.
Attention: When actuator EMS 6 will be
employed, interchange the terminals 65 and 66 in addition.
5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2)
5.6.1 Carry out material SETUP with sensor 1/sensor 2
The material SET UP is to carry out only in the presence of
- pneumatic sensor or
- transparent web material with optical sensing system or
- sound transmitting web material with ultrasonic sensing system
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:7/14
5.0
5.6.1.1 Procedure for web edge guiding
1. Adjust guiding to ‘MAN’ or ‘S-C’
or
2. Select sensors
or
3. Press key ‘SET UP’
SET UP
4. Remove material from the sensor and clean the lenses!
Press key ‘ENTER’
ENTER
5. Cover the sensor with the material to be guided!
Press key ‘ENTER’
ENTER
The SET UP is now completed, and the guiding system may be put into operation.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:8/14
5.0
5.6.1.2 Procedure for guiding to web center-line
1.Adjust guiding to ‘MAN’ or ‘S-C’
or
2. Preselect both sensors
3. Press key ‘SET UP’
SET UP
4. Remove all material from the sensors and clean the lenses!
Press key ‘ENTER’
ENTER
5. Cover the sensors with the material to be guided!
Press key ‘ENTER’
ENTER
6. Remove material from both sensors and clean the lenses!
Press key ‘ENTER’
ENTER
7. Cover completely the sensors with the material to be guided!
Press key ‘ENTER’
ENTER
The SET UP is now completed, and the guiding system may be put into operation.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:9/14
5.0
5.6.2 Check and/or determine guiding direction
1) Press key ‘edge left’ (8)
2) Press key ‘AUTO’
If the actuator guides the material out of the viewing range, DIL switch S 1.1 has to be
switched over.
Setting is required only for the first start-up.
If the type of the web material requires reversion of the guiding direction, this happens automatically during the material-SET UP.
5.6.3 Adjustment of gain for sensor 1 and sensor 2
condition:
- material web is pulled in
- actuator is not in a stop position
1) Press key ‘AUTO’
2) Press key ‘SET UP’
3)
4)
SET UP
The LED´s at the amplifier (LED 10 - 19)
reverse automatically and indicates the value of
gain..
Increase gain with key ‘PLUS’, until the guiding device starts
oscillating. The ‘light spot’ of LED indication at the amplifier
moves from LED 10 to LED 19.
(LED 19 = maximum of gain, we encouraged to leave the
maximum of gain, if there is non oscillating)
Decrease adjustment of gain with key ‘MINUS’, until the guiding
operates ‘stable’. If slow guiding reaction is desired, the gain
may still be reduced further.
ENTER
5) Press key ‘ENTER’
Gain has been stored.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:10/14
5.0
5.6.4 Start-up of servo-center operation
Press key ‘S-C’
The servo component must move towards the center a
and stop there. If the servo component is moving into t
the final position, DIL switch S1.3 has to be switched
over.
Attention: If using an analogue servo-center transducer (CK 37, BI 5 G....) preselect
the adjustment of gain.
Procedure:
1) Press simultaneously key ‘S-C’ and ‘SET UP’
SET UP
LED indication at EKR 1000 switch over
and indicate the value of gain.
2)
Increase adjustment of gain with key ‘PLUS’, until the guiding
device starts oscillating. ‘Light spot’ moves from LED 10 to
LED 19 (LED 19 = maximum of gain).
3)
Decrease adjustment of gain with key ‘MINUS’, until the
oscillating stops. If slow guiding reaction is desired, the gain
may still be reduced further.
4) Press key ‘ENTER’
ENTER
The adjustment is finished.
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:11/14
5.0
5.7 Electric powered actuators
Attention!
During the start-up the actuator will carry out positioning movements !
The machine must be protected against danger of injury according to the
relevant rules and regulations!
5.7.1 Use of limit switches
Limit switches for limitation of the regulating distance (stroke) can be used only with electric
motor powered actuators.
The motor is switched off when reaching the end of stroke by means of an alarm contact of the
limit switch. The output will be switched off by a software program.
The motor will be switched off without cutout.
When reaching the end of stroke, the LED on the controller corresponding to the mode of
operation selected (AUTO, S-C or MAN) will start blinking.
When activating the opposite direction the alarm message will reset automatically.
When using a Power Module the alarm message “thermal protection active“ will be generated by
the alarm signal “both limit switches activated“. The output will then be switched off.
The alarm message will keep up also after ‘power off’.
The alarm message can only be reset by pressing the key “ENTER“ at the commander.
function
terminal 71
terminal 73
limit switch 1
1
0
limit switch 2
0
1
thermal protection (output OFF)
1
1
5.7.2 Positions of the DIL switches and jumpers
Actuator EMS 1 and EMS 10
S1.2 = OFF
S1.5 = OFF
Set jumper ‘A’
Set jumper ‘D-E’
Actuator EMS 6
S1.2 = OFF
S1.5 = OFF
Set jumper ‘A’
Set jumper ‘E-F’
Web guiding system
EKR 1000H with analogue sensors
Actuator EMS 5
S1.2 = OFF
S1.5 = ON
Set jumper ‘A’
Set jumper ‘D-E’
Power module (EMS 3 and EMS 4)
S1.2 = OFF
S1.5 = OFF
Set jumper ‘A’
Set jumper ‘D-E’
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:12/14
5.0
5.8 Hydraulic powered actuators
5.8.1 Zero point adjustment
Also by adjustment of DIL switches, carry out a zero point adjustment when using an
electrical-hydraulic guiding unit with plunger coil regulator
Procedure:
1) switch on electrical-hydraulic guiding unit and EKR 1000
2) Press key ‘MAN’ at EKR 1000
3) Press key ‘SET UP’ at EKR 1000
4) Bring actuating cylinder by means of arrows keys (4) and/or (5) into center position.
5) Remove metal cover of the plunger coil regulator and unlock the knurled wheel
arranged in the upper area.
6) Turn knurled wheel into one direction - at maximum 5 rotations - until the actuating
cylinder starts moving. Record position.
7) Turn knurled wheel into the opposite direction - at maximum 10 rotations - until the
actuating cylinder starts moving into the opposite direction. Record position.
8) Turn knurled wheel into the center of the a/m two positions and lock it. Close again the
cover of the plunger coil regulator.
From software version E00304-01 Dither amplitude
and zero point adjustment can be varied
5.8.2 Adjustment of Dither amplitude
Attention:
mode of operation
EKR...
MAN
without Set up
MAN
with Set up
AUTO or
S-C
Dither amplitudes are significant for output setting = ± 300mA only.
Software
version up to
E00303-01
terminal 71=X
terminal 73=X
41 Hz
5mA
41Hz
25mA
41Hz
25mA
Software version from E00304-01
S1.2 has to be set to ON
terminal 71=0
terminal 73=0
50Hz
5mA
50Hz
5mA
50Hz
25mA
terminal 71=1
terminal 73=0
50Hz
10mA
50Hz
10mA
50Hz
10mA
terminal 71=0
terminal 73=1
50Hz
25mA
50Hz
25mA
50Hz
25mA
terminal 71=1
terminal 73=1
50Hz
50mA
50Hz
50mA
50Hz
50mA
5.8.3 Lifting of zero level
Special application of the DIL switches S1.2 and S2.5.
Only significant from software version E00304-01.
S1.2
S2.5
ON
OFF
ON
ON
Web guiding system
EKR 1000H with analogue sensors
lifting of zero level
Dither
lifting of zero level
Dither
ON
ON
OFF
ON
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:13/14
5.0
5.8.4 Adjustment of DIL switches and jumper
S1.2 = “ON“
S1.5 = “OFF“
Set jumper “B“
Set jumper “D-E“
5.9 Preparation for BS 100 and ZT 6.008
1) Switch on lateral channel compressor unit BS 100 and check sense of rotation (see arrow
marking on compressor housing) if necessary, correct sense of rotation.
Note:
The LED diodes Pmin, Pmax and OK as well as the adjusting screw for regulating the air
flow are located in the ZT 6.008 box. For adjustment, remove cover of the ZT 6.008.
2) The pressure of the air flow can be adapted to the respective application by means of the
adjusting screw in the ZT 6.008 while the sensors are free from material.
• The air pressure is within the admissible tolerance when only the green LED ‘OK’ is
lighted.
• Should the red LED Pmin be lighted, screw in the adjusting screw until Pmin gets
extinguished and the green LED OK lighted.
• If the red LED Pmax is lighted, screw out the adjusting screw until Pmax gets
extinguished and the green LED OK lighted.
Attention:
Never clean the edge sensor with compressed air!
It will destroy the pressure pick up!
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 5.0
page:14/14
6.0
6. Operation
The system only admits operation with
the components actually present!
Function key and control symbols on the front panel
Operating functions
=
green coloured area
Preset functions
=
red coloured area
Setting and control functions
=
blue coloured area
6.1 Operating functions
Select the desired operating functions as follows:
Automatic
- Press key ’ AUTO’
Manual positioning
- Press key ‘MAN’
Manual positioning of the actuator
1) Press key ‘MAN’
2)
Web guiding system
EKR 1000H with analogue sensors
or
adjust positioning with key ‘PLUS’ or
‘MINUS’
EDV-no.: V3D.002.01.02
Date:
07.04.97
chapter:6.0
page: 1/4
6.0
Servo-Center S-C
- Press key ‘S-C’
6.1.2 Preset functions
Web edge guiding, left web edge*
Web edge guiding, right web edge*
* in running direction of the material
Web center-line guiding
6.1.3 Setting and control functions
Adjustment of gain
* basic adjustment: automatically after material SET UP
* optimisation: during operation see point 5.6.3
Web guiding system
EKR 1000H with analogue sensors
EDV-no.: V3D.002.01.02
Date:
07.04.97
chapter:6.0
page: 2/4
6.0
shifting of guiding point
1) Press key ‘AUTO’
2)
or
shifting of guiding point with key ‘PLUS’ or
‘MINUS’. The indication of shifting occurred
via EKR display.
The possible shifting of guiding point is max. 80% and/or. +/- 40% from the
max. viewing range of the sensors.
Note: If the ‘remote precision adjustment EFE 1’ is connected, the shifting of guiding point will
be occurred only via EFE 1.
Key ‘PLUS’ and ‘MINUS’ are then out of function!
Web guiding system
EKR 1000H with analogue sensors
EDV-no.: V3D.002.01.02
Date:
07.04.97
chapter:6.0
page: 3/4
6.0
6.1.4 Test of material contrast and scanning with optical sensors
Press simultanously key ‘SET UP’ and ‘PLUS’
SET UP
The LED arrays indicates the absolute
senor signals. Clean lenses of the sensors
and determine the contrast according to the
graph below.
indication
left sensor
indication
right sensor
contrast
smaller or the same
4,3%
5,1%
6,3%
15%
30%
50%
60%
70%
90%
= LED ‘ON’
= LED ‘OFF’
Web guiding system
EKR 1000H with analogue sensors
EDV-no.: V3D.002.01.02
Date:
07.04.97
chapter:6.0
page: 4/4
7.0
7. Remote control
Truth table for the remote control inputs EKR1000 (e.g. activation by PLC):
Terminal 31 = +24V non regulated supply
Terminal 38 = GND (0V)
Terminal
32
33 34 35 36 37 72 70 71 73
Automatic
X
1
0
X
X
0
X
X
X
X
Manual
X
0
0
X
X
1
X
X
X
X
Servo-Center (S-C)
X
0
1
X
X
0
X
X
X
X
Edge left
X
X
X
1
0
X
0
X
X
X
Edge right
X
X
X
0
1
X
0
X
X
X
Center-line guiding
X
X
X
1
1
X
0
X
X
X
X
1
0
X
X
1
X
X
X
X
X
X
1
X
X
1
X
X
X
X
Controller lock-out
1
X
X
X
X
X
X
X
X
X
External SET UP
X
1
1
X
X
0
X
X
X
X
Electrical coupling FVG 1000
X
X
X
X
X
X
X
1
X
X
function
Interface conditions:
1 = „high“
0 = „low“
X= not relevant
t low, t high
U in Max.
Attention:
U in high: Min. +8V, Max. +35V
U in low: Min. -30V, Max. +4V
: min. 30ms
: acc. IEC 1.2kV/50µs
Please ensure, that terminals 33 / 34 are locked-out against each other when
switching from AUTO to Servo-Center
Web guiding system
EKR 1000H with analogue sensors
EDV-No: V3D.002.01.02
Date:
07.04.97
Chapter:7.0
page: 1/1
8.0
8. Trouble shooting
When an error is detected, the relay „System OK“ falls off. When pressing
ENTER
Note
:
key
, the error message is switched off, and the relay „System OK“
is re-energised, provided that no further error is present.
Error
Responsible
actuator / guiding device
‘trembles’
*
guiding system overdrive
actuator too slow
and/or guiding operates
not correctly
gain was decreased
MAN
or
Remedy
* optimise gain
* carry out ‘material SET UP’
* possibly new ‘basic SET UP’
+ material SET UP
+ optimise gain
* optimise gain
* ‘carry out ‘material SET UP’
* possibly new ‘basic SET UP’
+ material SET UP
+ optimisation of the gain
* actuating device has moved
activate into the opposite
into a final position and blocked direction. Error message will be
cleared automatically.
* limit switch was activated (if
present)
or
* actuating device has been
activated into one direction for
a longer period of time
* with connected
or
Attention:
after basic SET UP
all LED`s are blinking
Web guiding system
EKR 1000H with analog sensors
power module
Working temperature of the
actuating motor is too high.
Motor was switched off.
Check the actuating motor. Error
message can be cleared by
pressing the key ‘ENTER’
lenses of the sensors are
strongly contaminated
* clean sensors
* carry out ‘material SET UP’
Message of contaminiation only at material SET UP
faulty ‘Basic SET UP’ was carry
out
repeat ‘Basic SET UP’ according
to point 5.4
EDV-No.: V3D.002.01.02
Date:
07.04.97
Chapter: 8.0
Page: 1/2
8.0
Error
Responsible
Remedy
LEDs at the commander
are blinking as follows:
With connected FVG 1000
During shifting of guiding point
via arrow keys a limit stop was
reached. Displacement of the web
will be stopped.
LEDs at the commander
are blinking as follows:
With connected FVG 1000
During edge seeking or after
web tear, the inner limit switch was
reached. Commander switched in
operation mode ‘Retraction’.
actuate shifting into opposite
direction
restart the seeking operation
with present web or confirm
action temporarily by pressing
the key ‘ENTER’
= LED blinking
= LED off
Web guiding system
EKR 1000H with analog sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
Chapter: 8.0
Page: 2/2
9.0
9. Maintenance
The amplifier is maintenance-free.
The cleaning of the keyboard should be carry out with a dry, clean and smooth cloth.
By high contamination, use for cleaning a usual liquid cleaner, benzene or spirit.
amplifier has to be switched off!
Web guiding system
EKR 1000H with analogue sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter: 9.0
page: 1/1
10.0
10. De-commissioning
De-commissioning (scrapping) of the guiding system must carry out only together with the complete unit.
The procedure used has to be defined by the OEM.
Regarding the guiding equipment, please bear in mind that mainly electric/electronic components are
involved. The disposal of which is subject to the relevant legal rules and regulations.
A taking back of the equipment by BST Servo Technik GmbH is possible. Please reach the necessary
agreements.
Web guiding system
EKR 1000H with analog sensors
EDV-No.: V3D.002.01.02
Date:
07.04.97
chapter:10.0
page: 1/1
Connecting Plan EKR 1000H with analog sensors
Power supply
Actuators
Components
Remote electronic precision adjusting
EMS1
EMS5
EMS 10
EMS 16
EKR 3000
Operation with connecting box
EFE 1
1
5
9
4
Limit switch 2
Remote control (PLC inputs) acc. to chap. 7
EFE 1000
Stationary operation
EMS6
X1
Limit switch 1
Remote
control
The signal direction of the tachometer generator has to be adapted
to the direction of rotation of the motor. Therefore switch over the
commander to mode “MAN“. Press one of the arrow keys.
If the actuator is moving to the end of the guiding device, interchange
the terminals 65 and 66.
If the functional direction of the EFE 1 remote control
(right/left) shall be reversed, the connections at the
terminals 20 and 21 have to be interchanged.
External keyboard
EKR 3000
X2
Servo-center components
Sensors
US 2003
US 2007
US 2008
IR 2001
IR 2002
IR 2005
74
73
KIB-M12Pö/002-KL2
71
67
KIB-M12Pö/002-KL2
31
29
28
US 2003
US 2007
US 2008
IR 2001
IR 2002
IR 2005
EMS 16P
The allocation of the limit switches
can be adapted to the sense of
rotation of the motor by interchanging the terminals 71 and 73
if necessary.
OMG 4
OMG 6
OMG 7
OMG 8
CK 37
Bi5G
Wiring colors:
rt = red
rs = pink
br = brown
gr = grey
gn = green
bl = blue
ws = white
ge = yellow
sw = black
Oscillation
Metal plate
Attention: Both limit switches must be
covered by the metal plate
during normal operation.
(limit switches are carried out
as break contacts).
Additional module
bus subscriber’s
station
OZ 3
- Not required components will fall away! The corresponding
terminals stay free!
- Shields are pinched in the screwing.
(see installation of EMC-wiring).
Limit switches
R = 10 kΩ
Connection of BST module bus with cable
Twisted Pair Unitronic-Bus LD 3x2x0,22.
Modules
R2 = 2,7 kΩ / 0,3 W
FVG 1000 module
IO-module
Interbus-S module
Intercon module
PDP-module
CAN-module
R1 = 680 Ω / 0,3 W
Plunger
coil
regulator
Servo valve SV 1-10
Pneumo
electronic
transducer
ZT 6008
Please contact the manufacturer for setting of
cross-bonding boxes.
Setting of DIL switches and position of the jumpers see
chapter „Start-up“.
R = 10 kΩ
If only one edge sensor connected, the not used connection
piece S1 in ZT will be locked with a plug. The not used
connection piece S2 will be always unlocked.
V3D.002.01.A09 / 15.12.2000
Annex 2
EKR 1000 with analogue sensors
remote control
commander EKR 1000
set point shifting
EFE 1
servo-center component
OMG 4
EFE 1000
CK 37
oscillation
edge sensors
OZ 3
BI5G
sensor 1
IR 2001
IR 2002
US 2003
GL 240
sensor 2
PLE
PLE
actuators
EMS 1 / EMS 10
PLE 500
PLE 800
EMS 6
BS 100
EMS 5
ZT 6.008
plunger coil regulator
EH-St 9/3
KF 2, KF 3, KF 12
EMS 1000 power module
~3
V3D.002.01.02
Web Guiding Systems
Web Viewing Systems
BST - Web Guiding System
EKR 1000 H
with CCD 30000 or
CCD 5000 from hardware version M
-STANDARD-
Operating manual
BST International GmbH
Heidsieker Heide 53
33739 Bielefeld
Germany
Telefon: ++49 (5206) 999-0
Fax:
++49 (5206) 999-999
E-Mail: [email protected]
Issue:
04.02.00
EDV no.:
V3D.043.01.03
Definition of the symbols in this manual
Attention
Comments of this type have to be taken into consideration to protect the operator
against mechanical risks
Caution
Comments of this type have to be absolutely considered to protect the
operator against electrical risks
press key
key combination;
between the keys means that these keys
have to be actuated simultaneously
LED ‘OFF’
LED constantly lighted = activated phase
LED blinking
0.0
Table of contents
Table of contents
Chapter 1
Despription
1.1 General
1.2 General plan
1.3 Operating elements
1.4 Signification of the keys on the front panel
1.5 Signification of the LED’s on the front panel
1.6 Safety instructions
1.7 Emissions
Chapter 2
Technical Data
2.1 EKR 1000
2.2 CCD 30000 / CCD 5000M
2.3 Viewing ranges / viewing distances CCD camera
Chapter 3
Transport/Storage
Chapter 4
Mounting/Installation
4.1 Location requirements
4.2 Installation
4.3 Mounting plan
4.4 Installation CCD 30000 / CCD 5000M
4.5 Installation of EMC-wiring
Chapter 5
Start-up
5.1 Start-up requirements
5.2 Start-up
5.3 Basic SET UP
5.4 Determine desired sense of rotation for manual operation
5.5 Adjustment of cameras
5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2)
5.7 Electric powered actuators
5.8 Hydraulic powered actuators
5.9 Special indications Mastersetup
5.10 Reset to manufacturers settings
Chapter 6
Operation
6.1 Amplifier
6.2 Set point scaling when change over the web edge
6.3 Status indications
6.4 Operation with BST interface
Chapter 7
Remote control
Chapter 8
Trouble shooting
8.1 Indications on the EKR 1500
8.2 Indications on the CCD 30000 / CCD 5000M
Chapter 9
Maintenance
9.1 Amplifier EKR 1000
9.2 Camera CCD 30000 / CCD 5000M
9.3 Hydraulic powered actuator with plunger coil regulator
9.4 Electric motor powered actuator
Chapter 10 De-commissioning
Enclosure: Annex 1 Connecting plan EKR 1000 with cameras CCD 30000 / CCD 5000M
Annex 2 General plan EKR 1000 with 1x CCD 30000 / CCD 5000M
Annex 3 General plan EKR 1000 with 2x CCD 30000 / CCD 5000M
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 0.0
Page:
1/1
1.0
Please follow the instruction of
start-up, maintenance and installation
as descripted in the operating instruction
1. Description
1.1 General
The EKR 1000 system is a microprocessor-controlled amplifier.
With the CCD-cameras 30000 and 5000M this amplifier could be used for:
- web edge guiding (right or left)
- center line guiding
Please contact the producer for any different application.
The amplifier has PLC-compatible inputs and also an ‘OK-relay’ with NO and NC contact.
Full integration into the machine control system via:
- I-O Module
- Intercon-Module
- Interbus-S Module
- Profibus-DP module
potential-free in- and outputs for extended PLC messages and
commands
direct, serial connection for integration of system results,
messages and commands into the machine control system.
direct connection to Interbus-S Module as remote bus station
for instantaneous communication with locally peripheral
equipment
Notice: Please find the connection plans of the nominated modules at the corresponding
operating instructions.
1.2 General plan
The general plan (annex 2 and 3) indicates the connectable edge sensors and components to the
amplifier.
1.3 Operating elements
• The amplifier includes all necessary operating elements.
Option:
- Remote control by external signals, sensors or keys.
Attention! External keys will interlock the reverse funktion keys at the amplifier.
- If system locking is desired (e. g., in case of machine stop), this can be achieved
by means of external contacts or signals from the PLC.
• Anschluß der Komponenten über separaten Klemmenraum.
Vorteil: - schnelle und leichte Zugänglichkeit zu den Klemmstellen.
• Indication of web edge position by two LED arrays
Advantage: - simple control of the web edge within the measuring range of sensors
- simple adjustment of the desired position of the web or edge sensors
- variations of web width exceeding via the admissible value
Web Guiding System
EKR 1000 H with CCD 30000 / 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 1.0
Page:
1/4
1.0
1.4 Signification of the keys on the front panel
15 16 17 18 19
10 11 12 13 14
4
5
1
6
2
7
3
8
key and/or combination of keys
9
function
AUTO (1)
= automatic guiding
MAN
(2)
= manual positioning
S-C
(3)
= servo-center of the servo component
MAN (2) + ← / + (4)
= manual shifting
AUTO (1) + ← / + (4)
= shifting of guiding point to the left *
AUTO (1) + SET UP + ← / + = increase of gain
MAN (2) + → / - (5)
= manual shifting
AUTO (1) + → / - (5)
= shifting of guiding point to the right *
AUTO (1) + SET UP + → / -
= decrease of gain
S-C
(3) + SET UP + ← / + = increase of S-C transducer gain
S-C
(3) + SET UP + → / -
= decrease of S-C transducer gain
AUTO (1) + SET UP (6)
= release of gain with the keys (4) and (5)
MAN bzw. S-C + SET UP
= SET UP when changing the material
ENTER (7)
= storing of the adjustment and end of SET UP
functions
„SENSOR LEFT“ (8)
= guiding to the left web edge
„SENSOR RIGHT“ (9)
= guiding to the right web edge
= center-line guiding = „Sensor left“ + „Sensor right“
* The shifting of set point via the arrows keys can be locked by a DIL-switch
(see also chapter 5, point 5.1).
Web Guiding System
EKR 1000 H with CCD 30000 / 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 1.0
Page:
2/4
1.0
1.5 Signification of the LED´s on the front panel
• The LED’s on the keys indicate the switched-on function.
• The blinking of LED’s AUTO (1) , MAN (2) , S-C (3) , SET UP (6) or LED- arrays 10 – 14
and/or 15 - 19 indicate a fault message.
Simultaneously, the OK-relay is switched-off. (see also chapt. 8)
• LED-No. 10, 14,15 and 19 (red) signalize the limits of the measuring band of the sensors.
• LED-No. 11, 13, 16 and 18 (green) signalize the admissible measuring band of the sensors.
• LED-No. 12 and 17 (green) signalize the center of the measuring band of the sensors.
• additional indications of the LED's for gain and shifting of the guiding point see point 6.1.3 and
point 6.3.
10 11 12
13 14
Web Guiding System
EKR 1000 H with CCD 30000 / 5000M
15 16 17 18 19
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 1.0
Page:
3/4
1.0
1.6 Safety instructions
• Installation of the BST equipment into the production machine according to the relevant rules
( EN 294, EN 349) and the specific branch-oriented regulations for prevention of accidents,
such as:
-
Safety distance between BST equipment and customer´s specification, e. g. machine walls,
construction etc.
-
Installation of connecting cables between amplifier and controller and/or edge sensor
stumple-free, nontension and well anchored.
-
Take care of free headroom. If the free passage is limited, respective building components
have to be stuffed and painted in yellow/black.
Assembly, installation and commissioning must be carried out by qualified personnel !
Please do not open the unit until the line voltage is switched off!
When operation at open unit is necessary, only protection class IP20 is present.
There will be an increased risk of danger by line voltage !
-
Please do not use the guiding frame as a tread or a step ladder.
Don’t remove any safety devices.
During functional testing outside of production machine and/or during the start-up
procedure the actuator will carry-out positioning movements!
Make relevant safety arrangements during performance check !
During start-up procedure, the total safety concept of the production machine will have
to be considered.
• Before commissioning remove transport safety devices (if present).
1.7 Emissions
The A-rated equivalent continuous sound level of the equipment is lower than 70 dB(A).
Web Guiding System
EKR 1000 H with CCD 30000 / 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 1.0
Page:
4/4
2.0
2. Technical Data
2.1 EKR 1000
Line voltage:
115V/230V +10% / -20%
50-60Hz
Power consumption:
80VA
Fuses:
115V
230V
Outputs:
amplifier (adjustable, see also ‘Lay jumper according to application’,
chapter 5.0, point 5.1)
± 24V, max. 1A
or
± 24V, max. 0,33A or
± 300mA short circuit proof, dither amplitude adjustable
1A T
0,5A T
Supply to accessories
± 12V (min.± 11,4V),
+ 24V non regulated supply,
at max. 50mA
max. 0,4A
Status signal (“system OK“)
potential-free change-over switch, max. 230V, 1A
Inputs:
remote inputs (signification see “Truth table“ chapter 7)
lock-out (controller interlock): possible by means of external switch
or PLC
limit switch inputs: (without cutout!)
Ri
active (1)
not active (0)
= 4,7 kOhm
> 8V
< 4V
tlow
Uin Max
> 30ms
acc. to IEC 1,2kV / 50µs
analogue inputs (see also chapter 5, point 5.1 and connecting plan
2x 0...+ 5V or 0...+ 10V, individual adjustable
2x ± 9,75V or 0...+ 9,75V, individual adjustable
2x ± 11,75V
1x NAMUR adaption with output ± 11,75V
tacho input for motor powered actuator
Interface:
serial interface RS485 for BST module bus
Protection class:
IP 54
Ambience conditions:
temperature:
0 - max. 45 deg. C
atmospheric humidity: 0 - 90%, nicht kondensierend
Dimensions:
W = 263mm, D = 214mm without screwed connections, H= 115mm
Weight:
approx. 3kgs
Web Guiding System
EKR 1000 H with CCD 30000/ CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 2.0
Page:
1/3
2.0
2.2 CCD 30000 / CCD 5000M
Line voltage:
15 to 24V (from EKR 1000)
Power consumption:
3W
Measuring range:
depending on the lenses (see point 2.3)
Sensor resolution:
SUB pixel resolution:
5000 pixels
max. factor 6 for CCD 30000,
CCD 5000 from hardware version M factor 1 in general
Exposure time:
min. 0,6ms
max. 30ms (with interface up to 60ms)
Interface:
serial internal BST module bus interface R485
Protection class:
IP54
Ambience conditions:
temperature:
0 – 45 deg. C
atmospheric humidity: 5 - 90%, non-condensed
Weight:
0,845 kgs
Web Guiding System
EKR 1000 H with CCD 30000/ CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 2.0
Page:
2/3
2.0
2.3 Viewing ranges/ viewing distances CCD camera
Scanning of entire web width
with one camera
Scanning of web width
with one camera per edge
Minimum necessary camera measuring range M:
M=( ABmax + 2 x J ) x 1,1
M=
ABmax - ABmin + 2 x J
2
x 1,1
ABmax = maximum web width
ABmin = minimum web width
J
= incoming error of web to one side
The definition of measuring distance D occurs in dependence on
the necessary measuring range M and the type of camera.
CCD 5000M/ 50, CCD 30000/ 50:
α = 35°
CCD 5000M/ 28, CCD 30000/ 28:
α = 60°
M
D
distance
setting
M
D
distance
setting
330
515
0,60 m
220
200
0,20 m
470
715
0,80 m
480
400
0,50 m
600
915
1,00 m
720
600
0,60 m
940
1415
1,50 m
960
800
0,80 m
1960
2915
3,00 m
1190
1000
1,00 m
1800
1500
1,50 m
Important:
Layout / positioning of the HF fluorescent lamp:
Keep in reserve additional 50 mm luminous range on
both sides of the camera measuring range!
Web Guiding System
EKR 1000 H with CCD 30000/ CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 2.0
Page:
3/3
3.0
3. Transport/storage
Depending upon the order, delivery will be carried out:
•
•
completely built-in and connected with the actuator
as component parts in standard cardboard boxes with cellular lining material
If the unit is not incorporated immediately, it should be stored in a dry room.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 3.0
Page:
1/1
4.0
4. Mounting / Installation
4.1 Location requirements
The amplifier has to be installed at dry, vibration-free area.
Ambience conditions:
temperature:
0 - max. 45 deg. C
atmospheric humidity: 5 - 90%, non condensed
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 4.0
Page:
1/4
4.0
4.2 Installation
19
Mounting plan see point 4.3
1 - Open terminal
compartment
U
T
S
A
-
E
N
S
S
E
O
R
N
S
L
EO
T
R
F
U N
E
R
T
I
G
P T
H
E
R
T
C
25
S
NS
E
214
M
Pull the two rear
mounting rails upward
and screw into the
mounting wall
O
150
A
6
264
115
10
276
A
U
T
O
S
M
A
S
N
S
-
A
E
N
S
S
E
O
N
R
SL
E
EO
S
UN
E
R
T
I
G
PT
H
E
R
T
C
U
T
O
S
M
T
R
F
2 - Push the housing upward so that the mounting rails stay flush
again in respect of the
upper edge of the
housing
A
NS
-
E
N
S
S
O
E
R
N
SL
E
EO
F
T
R
T
E
R
U N
I
G
P T
H
E
R
3 - Apply the third fixing in
the terminal compartment. Complete wiring
and close terminal
compartment.
T
C
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 4.0
Page:
2/4
4.0
4.3 Mounting plan
262
180
M4 or Ø 5
housing EKR 1000
212
191
131
4.4 Installation CCD 30000 / CCD 5000M
4.4.1 Connectable components
Up to a maximum of three cameras CCD 30000 / CCD 5000M can be connected to one amplifier.
A combination with a CCD 2004 camera and/or an Analog Interface module is possible.
Attention! The use of a CCD 30000 camera and a CCD 5000 camera within the same
system is forbidden.
4.4.2 Installation
Attention! Includes a guiding system more than one CCD 30000 / CCD 5000M, the connecting
plugs of the cameras must be mounted in the same direction.
Connecting plug of camera 1 must point to the outside.
Switch off line voltage before pin up or pull off the connecting plug.
CCD
camera 1
CCD
camera 2
Web
scanning direction
transition
bright/dark
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
dark/bright
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 4.0
Page:
3/4
4.0
4.5 Installation of EMC-wiring
disk of the cable
fitting
-
shield
remove 90mm of
external insulation
black rubber
sealingparts
conical sealing
(metal/rubber)
nut
unsrew nut and
sealing parts and pin
them up to the end
of the cable
figure 1
figure 2
insulated cable leads
remove 60mm of shield,
so that 30mm remain visible
galvanised washer
10 x 16 x 0,5 DIN 988
30mm
vanished shield
Fan the protective shield, so
that the individual wires of the
shield protrude evenly from
the cable, approx. at right angle.
Tread the individual insulated
leads through the galvanised
washer, included in delivery
and press the washer onto the
shield braiding.
figure 3
figure 4
only for connecting cable CCD 5000
up to hardware version G
and Interbus-S
ferrite core
Refold and twist the shield
braiding over the washer.
Tighten the cable in the cable
gland. Strip the lead ends
(eventually, use protective lugs)
and wire according to connection
diagram.
Housing
cable gland
Screw down the cable gland and
then pin up the ferrite core to the
end of the cable, according
to the drawing.
figure 5
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
figure 6
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 4.0
Page:
4/4
5.0
5. Start-up
5.1 Start-up requirements
1) Set DIL-switches according to application.
Lageplan EKR 1000 H
EPROM
Prozessor
RAM
TRAFO
S T U
V W X
JX12
JX13
H J K
L M N
JX8
JX9
JX14
I
Z
Y
H11
115V: F1= 1AT
230V: F1= 0,5AT
F1
L N
OK
44454647495051525354555657585960616263646566676869707172737475
O
P 404142
0 6 7 8 9 1011 0 1314151617182021222425262829313233343536373839
R Relais
S1.1
S1.2
S1.3
S1.4
S1.5
S1.6
S1.7
S1.8
S2.1
S2.2
S2.3
S2.4
S2.5
S2.6
S2.7
S2.8
H1
H2
H3
H4
A
B JX11
C
H5
H6
H7
H8
H10 H9
Darstellung nicht maßstäblich!
D
E
F
JX10
LED +5V
S1.1
=
Inverse function Automatic'
S1.2
=
OFF
ON
S1.3
=
Inverse function S-C
S1.4
=
OFF
ON
=
=
normal operation
guiding to sensor 3 and 4 with scaling = 1:1 (e. g. Slave)
S1.5
=
OFF
ON
=
=
EMS1/plunger coil regulator , EMS 1000/1001 power module
EMS5
S1.6
=
ON
=
chase and follow system with CCD 5000 / CCD 30000
S1.7
=
OFF
=
inverse function CCD camera 3
S1.8
=
OFF
=
EKR 1500
S2.1
=
see schedule 2
S2.2
=
see schedule 2
S2.3
=
OFF
=
reserved
S2.4
=
OFF
ON
=
=
“Shifting of guiding point“ via arrow keys is permitted
“Shifting of guiding point“ via arrow keys is locked
S2.5
=
S2.6
=
S2.7 and S2.8
=
=
electric motor powered actuator
lifting of zero level and Dither for hydraulic units
(from software version E0030401 see schedule 1)
from software version E0030401 see schedule 1
ON
=
exposure time adjustment of 'CCD 2004 from H' is locked
=
see schedule 3
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
1/24
5.0
Schedule 1
Special functions of the DIL switches S1 and S2
from software version E0030401
S1.2
S2.5
function
OFF
OFF
electric motor powered actuator
• lifting of zero level OFF
• Dither OFF
OFF
ON
electric motor powered actuator
• lifting of zero level ON
• Dither OFF
ON
OFF
hydraulic actuator
• lifting of zero level ON
• Dither ON
ON
ON
hydraulic actuator
• lifting of zero level OFF
• Dither ON
Schedule 2
Special functions of the DIL switches S2.1 and S2.2
from software version E0030501
The DIL switches S2.1 and S2.2 are used to adjust the fundamental gain of the amplifier according
to the application.
S2.1
S2.2
fundamental gain
OFF
OFF
0,125 (manufacturer setting CCD 30000, CCD 5000A)
OFF
ON
0,25
ON
OFF
0,5
ON
ON
1
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
(manufacturer setting CCD 5000M)
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
2/24
5.0
Schedule 3
Signification of LED´s in the terminal box for service indication
The type of indication can be selected by means of S2.7 and S2.8.
LED
H1
S2.7 OFF
S2.8 OFF
CCD1
H2
CCD2
H3
H4
CCD3 / Analog-Interface
(recognized)
INTERCON (1/2)
H5
INTERBUS-S Module
H6
I-O Module (1/2)
H7
FVG 1000 Module
H8
blinker
S2.7 ON
S2.8 OFF
locking from
remote control
locking from
CCD 1
locking from
CCD2
locking from
CCD3
locking from external
command module
INTERBUS,
INTERCON,
I-O Module
locking from
FVG 1000 module
internal locking within
the EKR
blinker
S2.7 OFF
S2.8 ON
guiding device
centered
external release
of keyboard and
remote control
interlock
S2.7 ON
S2.8 ON
blinker
blinker
The blinker indicates a perfect program flow.
LED H11 indicates the correct function of the relay 'system ok' (LED is lighting).
LED extinguishes if a failure occurs (see also chapter 8 'Trouble shooting').
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
3/24
5.0
2) Lay jumper according application
The amplifier (standard version with electric motor powered actuator) is preset by manufacturer
as follows:
- jumper
- jumper
- jumper
- jumper
- jumper
- jumper
- jumper
O-P
J-K
M-N
D-E
A
S-T
V-W
equipotential bonding carried out
signal input 0 ... 10V
signal input 0 ... 10V
tacho 'OFF'
motor ±24V
signal input ± 9,75V
signal input ± 9,75V
Modification / adjustment is only necessary by a different application.
Socket
Jumper
Function
Comment
JX1
O-P
P-R
equipotential bonding
PE / 0V
carry out equipotential bonding
non equipotential bonding
JX8
H-J
J-K
signal sensor 3
(terminal 56)
signal input
signal input
0...5V
0...10V
JX9
L-M
M-N
signal sensor 4
(terminal 60)
signal input
signal input
0...5V
0...10V
JX10
D-E
E-F
motor tacho +
motor tacho -
tacho ‘OFF’
tacho ‘ON’
JX11
A
B
C
servo component A
servo component B (0V)
motor ± 24V
plunger coil ± 300mA
servo valve ± 1A
JX12
S-T
T-U
signal sensor 1
(terminal 11)
signal input
signal input
± 9,75V
0...9,75
JX13
V-W
W-X
signal sensor 2
(terminal 18)
signal input
signal input
± 9,75V
0 ... 9,75V
JX14
I-Z
Z-Y
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
reserved
reserved
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
4/24
5.0
3) Set line voltage
Make sure that the voltage on the name plate of the amplifier corresponds to the actual supply
voltage! Correct in case of deviation.
Lageplan EKR 1000 H
230V
F1 = 0,5AT
EPROM
Prozessor
RAM
TRAFO
S T U
V W X
JX12
JX13
H J K
L M N
JX8
JX9
JX14
I
Z
Y
H11
115V: F1= 1AT
230V: F1= 0,5AT
F1
L N
115V
F1 = 1AT
OK
44454647495051525354555657585960616263646566676869707172737475
O
P 404142
0 6 7 8 9 1011 0 1314151617182021222425262829313233343536373839
R Relais
Darstellung nicht maßstäblich!
S2.2
S1.1
S1.2
S1.3
S1.4
S1.5
S1.6
S1.7 H1
S1.8
H2
S2.1 H3
H4
A
S2.3 H5
S2.4
H6
S2.5 H7
S2.6
H8
S2.7
H10 H9
S2.8
B
C
D
E
F
JX11
JX10
LED +5V
4) Connection of components according connection plan
Installation of EMC-wiring see point 4.4
5) Connection of remote control according connection plan (if present)
6) Switch-on line voltage
7) Check of the camera address
After switching on line voltage (usually “power on“ on the amplifier) the LED array of the CCD
camera is displayed as a running array.
About one second after all LEDs are lit, the camera address given by the connection appears for
a short time.
LED 10
LED 1
SET UP
LED
10
9
8
●
●
●
7
6
5
4
3
2
1
running LED array after switching
on the amplifier
About one second after all LEDs are lit, one of the following combinations of indication appears.
O
O
O
O
O
O
O
O
O
●
O
O
O
O
O
O
O
O
●
O
O
O
O
O
O
O
O
O
●
●
O
O
O
O
O
O
O
●
O
O
● = LED on
camera 1 with camera 2
existing in the guiding system
camera 2
camera 1 without camera 2
existing in the guiding system
camera 3
O = LED off
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
5/24
5.0
5.2 Start-up
Attention: During the start-up the actuator will carry-out
positioning movements!
The machine must be protected against danger of
injury according to the relevant rules and regulations!
Start-up must be carried out by qualified personnel!
The system only admits operation with components actually present.
5.3 Basic SET UP
Only necessary after installation or
change of components connected!
1) Clean the lenses
2) Press simultaneously keys ‘PLUS’ and ‘SET UP’
SET UP
The basic initialization is switched on.
If the guiding device with connected servo-center switch is in center position or if no servo-center
switch is connected, the guiding device will be displaced automatically for a short moment in
order to check whether a servo-center switch is connected.
3) Press key ‘ENTER’
ENTER
The basic initialization is finished.
The CCD 30000 / CCD 5000M cameras are preset on edge scanning by nontransparent material in
processing of transmitted light with a HF fluorescent lamp.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
6/24
5.0
5.4 Determine desired sense of rotation for manual operation
1) Press key ‘MAN’
2) Press key ‘PLUS’ or
‘MINUS’
Observe guiding device!
If opposed positioning movement is
desired interchange actuator polarity a
at terminals 28 and 29.
or
Attention: When actuator EMS 6 will be
employed, interchange the
terminals 65 and 66 in
addition.
5.5 Adjustment of cameras (to be carried out only once at the first start-up)
5.5.1 Basic adjustment of camera 1
Alignment of the camera can be carried out in two different ways:
• Aligning the camera by means of the standard indicators on the display of the camera
• Aligning the camera by means of an oscilloscope connected through the BST measuring
adapter
5.5.1.1 Alignment by means of the standard displays of the camera
1) Remove the guard ring and clean the lenses
2) at the amplifier:
SET UP
Basic initialization is switched on.
The LED array of the CCD 30000 / CCD 5000M is switched to the indication 'Special
indications Mastersetup' and the first parameter selection 'Indication exposure time' is
activated.
LED 10
LED 1
SET UP
Set the diaphragm of the CCD 30000 / CCD 5000M to the value 11.
The indication of the exposure time occurs by means of the LEDs.
The allocation is shown in the schedule on the next page.
For adjustment of additional parameters, if necessary, see chapter 5.9 'Special indications
Mastersetup'.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
7/24
5.0
LED 10
LED 1
SET U P
LED
10
9
8
7
6
5
4
3
2
1
exposure time in ms
✹
o
o
o
o
o
o
o
o
●
≤ 0,6 (possibly overexposed)
✹
o
o
o
o
o
o
o
●
●
≤1
✹
o
o
o
o
o
o
o
●
o
≤2
✹
o
o
o
o
o
o
●
●
o
≤3
✹
o
o
o
o
o
o
●
o
o
≤4
✹
o
o
o
o
o
●
●
o
o
≤5
✹
o
o
o
o
o
●
o
o
o
≤6
✹
o
o
o
o
●
●
o
o
o
≤7
✹
o
o
o
o
●
o
o
o
o
≤8
✹
o
o
o
●
●
o
o
o
o
≤9
✹
o
o
o
●
o
o
o
o
o
≤ 10
✹
o
o
●
●
o
o
o
o
o
≤ 15
✹
o
o
●
o
o
o
o
o
o
≤ 20
✹
o
●
●
o
o
o
o
o
o
≤ 30
✹
o
●
o
o
o
o
o
o
o
≤ 40
✹
●
●
o
o
o
o
o
o
o
≤ 50
✹
●
o
o
o
o
o
o
o
o
≤ 60
o = LED off
● = LED on
✹ = LED blinker
standard value
values can only be reached if the camera is parameterized via interface
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
8/24
5.0
3) Adjustment of diaphragm
a) The camera has to adjusted on the HF fluorescent lamp and/or on the lightened band, that if
possible a minimum of LEDs will be lighten
b) If the LEDs indicates no reaction, this procedure has to be repeat again with a larger
diaphragm opening.
c) Does only one LED or no LED lighten, lower diaphragm and repeat adjustment of the camera
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page:
9/24
5.0
4) Adjust camera parallel to the HF fluorescent lamp (fixing of the viewing range)
a) Push in the cover until the exposure
time increases (position at which the
number of LEDs lighted will increase).
Mark this position.
fluorescent lamp
b) Push in the cover until the exposure
time increases (position at which the
number of LEDs lighted will increase).
Mark this position.
fluorescent lamp
fixed
viewing range
c) Is the viewing range found approx. equal
to the physical viewing range M
according to table, point 2.3 ?
yes
no
alignment of the
camera has to be
camera ok
aligned
→ continue with point e) → continue with point d)
d) Alignment of the camera
Screw in or screw out
adjusting screw Y
fluorescent lamp
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 10/24
5.0
e) Centering of the scanning position to the longitudinal axis
of the luminous band / fluorescent lamp
Screw in (-) or
screw out (+) the
adjusting screw X
Test of the scanning position compared
to the luminous band / fluorescent lamp
position of the
dark/bright transition
alignment
correction
correct
Push in the cover to such extent
that the bright/dark transition
will be displayed
to adjust
to adjust
luminous field and/or
fluorescent lamp
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 11/24
5.0
5.5.1.2 Aligning the camera by means of an oscilloscope
1) Connect the BST measuring adapter to the camera.
Attention:
Only connect and remove connecting cables to the CCD camera that are not live.
2) Connect the standard camera cable to the measuring adapter.
3) Connect the oscilloscope to the measuring adapter.
4) Switch on the voltage again.
5) Remove the guard ring and clean the lens.
SETUP
6) On the amplifier
press the 'SETUP' and 'PLUS' keys.
+
The basic set-up is switched on.
The LED array of the CCD 30000 / CCD 5000M is switched to the display ‘special display
master set-up’’ and the first parameter selection of ‘display exposure period‘ is activated.
LED 10
LED 1
SET UP
Adjust the diaphragm of the CCD 30000 / CCD 5000M to the value 11.
The LED’s show the exposure time. You can see the relationship between exposure time and
the appropriate LED display from the table on page 7
7) Align the camera parallel to the fluorescent lamp / to the luminous field (Y-direction).
Adjustment screw (Y-direction)
a) screw it in
or
b) screw it out
fluorescent lamp /
luminous field
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 12/24
5.0
a) If the camera is properly aligned to the fluorescent
lamp/luminous field, i.e. parallel, the following
brightness profile appears on the oscilloscope.
b) If the camera is not aligned parallel to the fluorescent
lamp / luminous field, there is a limited visual field
with the following brightness profile.
Align the camera to produce a brightness profile as per (a) by screwing in or screwing out the
adjustment screw (Y-direction).
8) Align the camera to the longitudinal axis (X-direction)
screw the adjustment screw
(X-direction) in (+) or out (-)
a tooth appears on the oscilloscope
at the point where the camera
records the object
insert a long small object
such as a screwdriver
luminous field or
fluorescent lamp
It is necessary to correct it depending upon the position of the transition point.
Position of the transition point
Alignment
Correction
correct
no
should be corrected
yes (+)
should be corrected
yes (-)
9) Adjusting the exposure time
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 13/24
5.0
The exposure time should be adjusted to 2 – 3 ms. Open or close the diaphragm of the camera
lens accordingly. The oscilloscope shows the following image:
exposure time
5.5.1.3 Alignment of the camera to the scanning plane (web) (Z-direction)
+
1) Press ‘PLUS’ and ‘MINUS’ key simultaneously
LED 1 to 10 at the camera
are blinking.
2) Cover the optics completely and press the key on the camera.
The blinking of the LED’s will be interrupted for some seconds.
Comment:
You may have to press the key on the camera a second time before the LED’s start blinking
again.
SETUP
3) When the LEDs are blinking again
press key ‘SET UP’ at the EKR.
4) Push in nontransparent material (e.g. paper) into the viewing range of the camera.
The web edge will be displayed at the LED array of the camera.
Attention:
Only one edge of material may be within the viewing range of the camera,
In the following manner:
• with camera 1 bright/dark transition
• with camera 2 dark/bright transition
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
seen from the connector plug of the camera
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 14/24
5.0
Example:CCD camera connected as camera 1
(if camera 2 should be aligned, please press key ‘SENSOR RIGHT’ first)
prepositioning by displacement
of the camera on the guide bar
AUTO
6) Adjust the camera (screw in or
screw out the adjusting screw Z)
so that the positioning device
don't move into a limit position
Reference edge e.g. machine frame
5) Press key ‘AUTO’
(the positioning device
moves into a limit
position)
a
material
b
fluorescent lamp
distance a = distance b
7) The sensitivity of adjustment can be determined by means of the adjustment of gain
(see point 5.6.2). Select a high gain to reach a high accuracy of adjustment
8) Check adjustment of the camera parallel to the fluorescent lamp (Y-direction).
See point 5.5.1.1 respectively 5.5.1.2.
Press keys “Setup“ (6) and “+“(4) at the amplifier simultaneously.
The basic setup is switched on.
9) If an adjustment is necessary, repeat the operation according to point 5.5.1.3 alternately.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 15/24
5.0
5.5.1.4 Adjustment of focus (the system stays in basic initialization)
Press key 'SET UP' on the camera until the parameter 'Indication focus value' will be shown
(LED 2 is blinking in addition to LED 10).
Push in a well defined contrast into the measuring range of the camera and adjust the focus to a
minimum
LED 10
LED 1
SET UP
LED
10
9
8
7
6
5
4
3
2
1
Number of pixels necessary for
contrast threshold
✹
O
O
O
O
O
O
O
O
O
No contrast within the viewing range!
✹
O
O
O
O
O
O
O
O
●
≤1
✹
O
O
O
O
O
O
O
●
●
≤2
✹
O
O
O
O
O
O
O
●
O
≤3
✹
O
O
O
O
O
O
●
●
O
≤4
✹
O
O
O
O
O
O
●
O
O
≤5
✹
O
O
O
O
O
●
●
O
O
≤6
✹
O
O
O
O
O
●
O
O
O
≤7
✹
O
O
O
O
●
●
O
O
O
≤8
✹
O
O
O
O
●
O
O
O
O
≤9
✹
O
O
O
●
●
O
O
O
O
≤ 10
✹
O
O
O
●
O
O
O
O
O
≤ 11
✹
O
O
●
●
O
O
O
O
O
≤ 12
✹
O
O
●
O
O
O
O
O
O
≤ 13
✹
O
●
●
O
O
O
O
O
O
≤ 14
✹
O
●
O
O
O
O
O
O
O
≤ 15
✹
●
●
O
O
O
O
O
O
O
≤ 16
✹
●
O
O
O
O
O
O
O
O
≤ 17
✹ = LED blinking
O = LED off
● = LED on
Place the guard ring again!
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 16/24
5.0
5.5.1.5 Carry out white balance
Attention!
- Clean lenses and lamps
- Old modes will be overruled
- If selected by error this compensation, use key
SET UP
for leaving the compensation without change
1) Remove the material out of the viewing range , that the camera only recognize the HF
fluorescent lamp. If working in the vertical illumination, the visible surface has to be covered by
an even white dull material (e.g. poster board).
2) Press the keys ‘SET UP’ and ‘PLUS’
simultaneously.
SET UP
3) Press the keys ‘PLUS’ and ‘MINUS’
simultaneously.
+
+
At the camera LED 1 to 10 are blinking.
4) Press key ‘SET UP´ on the camera
for a short moment.
L E D
1 0
L E D
1
Three LED blocks appear in the display of the camera at short intervals after one another with
three switched on LED´s. The automatic white balance is following!
Afterwards the LED 1 to 10 are blinking again.
5) Press key ‘ENTER’.
ENTER
Basic initialization with camera 1 is finished
5.5.2 Basic inizialisation of camera 2
See point 5.5.1 for the adjustment of camera 2.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 17/24
5.0
5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2)
5.6.1 Check and/or determine guiding direction
1) Press key ‘edge left’ (8).
2) Press key ‘AUTO’.
If the actuator guides the material out of the viewing range, DIL switch S 1.1 has to be switched
over.
Setting is required only for the first start-up.
If the type of the web material requires reversion of the guiding direction, this happens
automatically during the material-SET UP.
5.6.2 Adjustment of gain for sensor 1 and sensor 2
Condition:
- material web is pulled in
- actuator is not in a stop position
1) Press key ‘AUTO’.
2) Press key ‘SET UP’.
SET UP
The LED´s at the amplifier (LED 10 - 19)
reverse automatically and indicates the value of
gain.
3)
Increase gain with key ‘PLUS’, until the guiding device starts
oscillating. The ‘light spot’ of LED indication at the amplifier
moves from LED 10 to LED 19.
( LED 19 = maximum of gain, we encouraged to leave the
maximum of gain, if there is non oscillating)
4)
Decrease adjustment of gain with key 'MINUS', until the guiding
operates 'stable'. If slow reaction is desired, the gain may still
be reduced further.
ENTER
5) Press key ‘ENTER’.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
Gain has been stored.
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 18/24
5.0
5.6.3 Start-up of servo-center operation
Press key ‘S-C’.
The servo component must move towards the center
and stop there. If the servo component is moving into
the final position, exchange the connections 25 and 26.
Attention: If using an analog servo-center transducer (CK 37, BI 5 G....) preselect their
adjustment of gain.
Procedure:
1) Press simultaneously key ‘S-C’ and ‘SET UP’.
SET U P
LED indication at EKR 1500 switch over
and indicate the value of gain.
2)
Increase adjustment of gain with key ‘PLUS’, until the guiding
device starts oscillating. ‘Light spot’ moves from LED 10 to
LED 19 (LED 19 = maximum of gain).
3)
Decrease adjustment of gain with key ‘MINUS’, until the
oscillating stops. If slow guiding reaction is desired, the gain
may still be reduced further.
4) Press key ‘ENTER’.
ENTER
The adjustment is finished.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 19/24
5.0
5.7 Electric powered actuators
Attention! During the start-up the actuator will carry out positioning movements!
The machine must be protected against danger of injury according to the
relevant rules and regulations!
5.7.1 Use of limit switches
Limit switches for limitation of the regulating distance (stroke) can be used only with electric
motor powered actuators.
The motor is switched off when reaching the end of stroke by means of an alarm contact of the limit
switch. The output will be switched off by a software program.
The motor will be switched off without cutout.
When reaching the end of stroke, the LED on the controller corresponding to the mode of operation
selected (AUTO, S-C or MAN) will start blinking.
When activating the opposite direction the alarm message will reset automatically.
When using a Power Module the alarm message “thermal protection active“ will be generated by
the alarm signal “both limit switches activated“. The output will then be switched off.
The alarm message will keep up also after ‘power off’.
The alarm message can only be reset by pressing the key “ENTER“ at the commander.
function
terminal 71
terminal 73
limit switch 1
1
0
limit switch 2
0
1
1
1
thermal protection (output OFF)
5.7.2 Positions of the DIL switches and jumpers
Actuator EMS 1 and EMS 10
Actuator EMS 5
S1.2 = OFF
S1.5 = OFF
Set jumper “A“
Set jumper “D-E“
S1.2 = OFF
S1.5 = ON
Set jumper “A“
Set jumper “D-E“
Actuator EMS 6
POWER-MODUL(EMS 3 und EMS 4)
S1.2 = OFF
S1.5 = OFF
Set jumper “A“
Set jumper “E-F“
S1.2 = OFF
S1.5 = OFF
Set jumper “A“
Set jumper “D-E“
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 20/24
5.0
5.8 Hydraulic powered actuators
5.8.1 Zero point adjustment
Also by adjustment of DIL switches, carry out a zero point adjustment when using an electricalhydraulic guiding unit with plunger coil regulator.
Procedure:
1) Switch on electrical-hydraulic guiding unit and EKR 1000.
2) Press key ‘MAN’ at EKR 1000.
3) Press key ‘SET UP’ at EKR 1000.
4) Bring actuating cylinder by means of arrows keys (4) and/or (5) into center position.
5) Remove metal cover of the plunger coil regulator and unlock the knurled wheel arranged in the
upper area.
6) Turn knurled wheel into one direction - at maximum 5 rotations - until the actuating cylinder
starts moving. Record position.
7) Turn knurled wheel into the opposite direction - at maximum 10 rotations - until the actuating
cylinder starts moving into the opposite direction. Record position.
8) Turn knurled wheel into the center of the a/m two positions and lock it.
Close again the cover of the plunger coil regulator.
From software version E00304-01 dither amplitude
and zero point adjustment can be varied.
5.8.2 Adjustment of Dither amplitude
Attention: Dither amplitudes are significant for output setting ± 300mA only.
Software
version up to
E00303-01
Software version from E00304-01
S1.2 has to be set to ON
operation mode terminal 71=X terminal 71=0
EKR ...
terminal 73=X terminal 73=0
terminal 71=1
terminal 73=0
terminal 71=0
terminal 73=1
terminal 71=1
terminal 73=1
MAN
41Hz
without Set up 5mA
50Hz
5mA
50Hz
10mA
50Hz
25mA
50Hz
50mA
MAN
with Set up
41Hz
25mA
50Hz
25mA
50Hz
10mA
50Hz
25mA
50Hz
50mA
AUTO or
S-C
41Hz
25mA
50Hz
25mA
50Hz
10mA
50Hz
25mA
50Hz
50mA
EH-St 9/3
SV 1-10
HR 024
Aggregate, e.g.:
X = not relevant
0 = „low“
1 = „high“
Uinlow: min. -30V, max. +4V
Uinhigh: min. +8V, max. +35V
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 21/24
5.0
5.8.3 Lifting of zero level
Special application of the DIL switches S1.2 and S2.5.
Only significant from software version E00304-01.
S1.2
S2.5
ON
OFF
ON
ON
lifting of zero level
Dither
lifting of zero level
Dither
ON
ON
OFF
ON
5.8.4 Adjustment of DIL switches and jumper
S1.2 = “ON“
S1.5 = “OFF“
Set jumper “B“
Set jumper “D-E“
5.9 Special indications Mastersetup
Press SET UP key on the camera for several seconds.
The 'Actual parameter' selection will be indicated by blinking of the
corresponding LED (in addition to the LED 10).
LED 10
LED 1
SET UP
LED
10
9
8
7
6
5
4
3
2
1
✹
?
?
?
?
?
?
?
?
?
signification
Signalizes Special indication
Mastersetup activated
✹
O
O
O
O
O
O
O
O
✹
Selection of parameters
Indication exposure time
(basic adjustment)
✹
O
O
O
O
O
O
O
✹
O
Indication focus value
✹
O
O
O
O
O
O
✹
O
O
Indication actual trigger threshold
O = LED off
✹ = LED blinking
? = depends on the actual parameter value
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 22/24
5.0
Indication of the actual trigger threshold
The trigger threshold of the first contrast transition will be indicated in general
(gray scale value 0-255).
LED 10
LED 1
SET UP
LED
10
9
8
7
6
5
4
3
2
1
Trigger threshold A
✹
O
O
O
O
O
O
O
O
●
≤ 25
✹
O
O
O
O
O
O
O
●
●
≤ 30
✹
O
O
O
O
O
O
O
●
O
≤ 35
✹
O
O
O
O
O
O
●
●
O
≤ 40
✹
O
O
O
O
O
O
●
O
O
≤ 45
✹
O
O
O
O
O
●
●
O
O
≤ 50
✹
O
O
O
O
O
●
O
O
O
≤ 60
✹
O
O
O
O
●
●
O
O
O
≤ 70
✹
O
O
O
O
●
O
O
O
O
≤ 80
✹
O
O
O
●
●
O
O
O
O
≤ 90
✹
O
O
O
●
O
O
O
O
O
≤ 100
✹
O
O
●
●
O
O
O
O
O
≤ 125
✹
O
O
●
O
O
O
O
O
O
≤ 150
✹
O
●
●
O
O
O
O
O
O
≤ 175
✹
O
●
O
O
O
O
O
O
O
≤ 200
✹
●
●
O
O
O
O
O
O
O
≤ 255
✹ = LED blinking
O = LED off
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
● = LED on
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 23/24
5.0
5.10 Reset to manufacturers settings
Attention:
The reset to manufacturers settings may be carried out after start-up and correct
addressing of the cameras (camera 1/2/3).
Any preceding adjustments will be overruled!
configuration
camera 1 and 2
(two-camera system)
one-camera system
camera 3
edge 1
last bright/dark
transition
first bright/dark
transition
edge 2
first dark/bright
transition
last dark/bright
transition
insignificant for
camera 3
insignificant for
camera 3
Parameters
Interpolation
Exposure time MIN limit
Exposure time MAX limit
Automatic exposure timer
middle between
edge 1 and 2
edge 1 and 2
first bright/dark
transition and last
dark/bright transition
Trigger thresholds
Minimum edge width after trigger threshold
Minimum edge width before trigger threshold
Imaginary center-line guiding
Preset by manufacturer
factor 6 with CCD 30000; factor 1 with CCD 5000M
0,6ms
30ms
activated
Adjustment also when no contrast is within the
viewing range
127
69 pixels
0 pixel
activated
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 5.0
Page: 24/24
6.0
6. Operation
The system only admits operation with
the components actually present!
6.1 Amplifier
Function key and control symbols on the front panel
Operating functions
=
green coloured area
Preset functions
=
red coloured area
Setting and control functions
=
blue coloured area
6.1.1 Operating functions
Select the desired operating functions as follows:
Automatic
- Press key ’AUTO’
Manual positioning
- Press key ‘MAN’
Manual positioning of the actuator
1) Press key ‘MAN’
2)
or
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
adjust positioning with key ‘PLUS’ or
‘MINUS’
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
1/6
6.0
Servo Center S-C
- Press key ‘S-C’
6.1.2 Preset functions
Web edge guiding, left web edge*
Web edge guiding, right web edge*
* in running direction of the material
Web center-line guiding
6.1.3 Setting and control functions
Adjustment of gain
* optimization: during operation see point 5.6.2
* with analog servo-center device see point 5.6.3
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
2/6
6.0
shifting of guiding point
In operation mode 'AUTO' with switched off SET UP a shifting of the guiding point for the
activated sensing mode is possible via arrow keys (4) and (5).
Attention:
SET UP muß ausgeschaltet sein. Nach einem SET UP wird der Sollwert
automatisch gelöscht.
1) Press key ‘AUTO’
2)
or
shifting of guiding point with key ‘PLUS’ or
‘MINUS’. The indication of shifting occured
via EKR display.
The actual position of the et point will be
displayed.
set point
center range
set point
limit 1
set point
limit 2
LED ON
LED OFF
The possible shifting of guiding point is max. 80% and/or. +/- 40% from the
max. viewing range of the sensors.
Note:
If the ‘remote precision adjustment EFE 1’ is connected, the shifting of guiding point will
be occurred only via EFE 1.
Key ‘PLUS’ and ‘MINUS’ are then out of function!
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
3/6
6.0
6.2 Set point scaling when change over the web edge
The actual position of web edge or web center-line can be taken over as set point for guiding by
means of scaling the set point before switch on the guiding to edge 1, edge 2 or center-line guiding.
That means, the web will be guided accurate at this position.
So it is possible to switch over from center-line guiding to web edge guiding without displacement of
the web.
Condition:
This function is only available with one or two cameras CCD 5000 guiding to edge 1,
edge2 or center-line guiding.
This function can't be activated when camera CCD 5000 is sensor 3. It is only possible
to take over a position within the range F.
Is the position outside of range F, the nearest position possible is taken over.
sensor m easuring range
center
40%
40%
F = 80%
sensor m easuring range
Attention: This function can not be used with connected EFE 1!
Procedure:
The set point scaling can be carried out for 'guiding to edge 1', 'guiding to edge 2' and 'center line
guiding'. A separate adjustment has to be done for the different guiding modes.
You can continue to change the set point by hand after set point scaling.
1) Press key “MAN“ or “S-C“
or
2) Bring web in the desired position
3) Select the desired sensing mode
or
or
SET UP
4) Press key ‘SET UP’
LED of the key lightens
ENTER
5) Press key ‘ENTER’
Set point scaling will be finished automatically.
LED of the key 'SET UP' extinguishes.
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
4/6
6.0
6.3 Status indications
The following typical indications can appear during normal operation.
Please pay attention that the bright / dark transition indicates the position of the contrast referred to
the measuring range.
LED 10
LED 1
SET U P
scanning direction
LED
10
9
8
7
6
5
4
3
2
1
signification
O
O
O
O
O
O
●
●
●
●
bright / dark transition
●
●
●
●
O
O
O
O
O
O
dark / bright transition
●
●
●
●
O
O
O
O
●
●
dark line (web center)
O
O
O
●
●
●
●
O
O
O
bright line
(e.g. web center with incident light)
●
●
●
●
O
●
●
●
●
●
narrow dark line
(narrow web center)
O
O
●
●
●
●
●
●
O
O
wide bright line
(wide web center)
●
●
●
●
●
●
●
●
●
●
no contrast; guiding stopped
(interlocked)
O
O
O
O
O
✹
✹
✹
✹
✹
No function for the time being
O = LED off
● = LED on
✹ = LED blinking
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
5/6
6.0
6.4 Operation with BST interface
Parameters of the camera can set and/or changed via a corresponding BST interface.
Programming and procedure see manual of the used interface.
Web guiding system
EKR 1000H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 6.0
Page:
6/6
7.0
7. Remote control
Truth table for the remote control inputs EKR 1000 (e.g. activation by PLC):
Terminal 31 = +24V non regulated supply
Terminal 38 = GND (0V)
Terminal:
32 33 34 35 36
37 72 70 71 73
Automatic
X
1
0
X
X
0
X
X
X
X
Manual
X
0
0
X
X
1
X
X
X
X
Servo Center (S-C)
X
0
1
X
X
0
X
X
X
X
Edge left (watchdog ‘OFF’)
X
X
X
1
0
X
0
X
X
X
Edge right (watchdog ‘OFF’)
X
X
X
0
1
X
0
X
X
X
Servo-center guiding (watchdog‘OFF’) X
X
X
1
1
X
0
X
X
X
Guiding to a printed line / edge
without watchdog
X
X
X
0
0
X
1
X
X
X
Guiding to a printed line / edge *
watchdog edge left
X
X
X
1
0
X
1
X
X
X
Guiding to a printed line / edge *
watchdog edge right
X
X
X
0
1
X
1
X
X
X
X
X
X
1
1
X
1
X
X
X
X
1
0
X
X
1
X
X
X
X
X
X
1
X
X
1
X
X
X
X
Controller lock-out
1
X
X
X
X
X
X
X
X
X
External SET UP
X
1
1
X
X
0
X
X
X
X
Electrical coupling FVG 1000
X
X
X
X
X
X
X
1
X
X
Function
Guiding to a printed line / edge
watchdog web center line
(still out of operation)
* only for use with EKR 1500
Interface conditions:
1 = „high“
0 = „low“
X= not relevant
tlow, thigh
U in Max.:
U in high: Min. +8V, Max. +35V
U in low: Min. -30V, Max. +4V
:
min. 30ms
acc. IEC 1.2kV/50µs
Attention: Please ensure, that terminals 33 / 34 are locked-out against each other
when switching from AUTO to Servo-Center.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 7.0
Page:
1/1
8.0
8. Trouble shooting
8.1 Indications on the EKR 1000
When an error is detected, the relay „System OK“ falls off. When pressing
ENTER
the error message is switched off, and the relay “System OK“
key
is re-energized, provided that no further error is present.
Note:
Error
Responsible
Remedy
Actuator / guiding device
‘trembles’
Guiding system overdrive
• Optimize gain
• Possibly new ‘basic SET UP’
Actuator too slow
and/or guiding operates
not correctly
Gain was decreased
• Optimize gain
• Possibly new ‘basic SET UP’
• Guiding device has reached
the end of stroke or is stuck.
• Limit switch was actuated
(if present).
• The guiding device was
activated continuously in one
direction for a long time
(approx. 50 sec).
• Activate into the opposite direction.
Error message is cleared
automatically.
MAN
or
or
• with connected power module
The working temperature of the
servomotor is too high.
Motor was switched off.
• Check servomotor.
Error message can be cleared by
pressing the key 'ENTER'.
After basic SET UP
all LED`s are blinking
Faulty ‘Basic SET UP’ was
carried.
Repeat ‘Basic SET UP’ according
to point 5.3.
SETUP
Message of contamination
The sensor has to be cleaned soon.
The error message will be switched
off automatically then.
The guiding is further working
LEDs at the EKR 1500 are
blinking as follows:
or
or
During set point scaling the web Bring web edge back into the
edge was recognized outside
permissible measuring range.
the valid measuring range (appr. Error message will be cleared
80% of the measuring range).
automatically.
(Actual position of the web edge
is not taken over but the next
valid position).
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 8.0
Page:
1/2
8.0
8.2 Indications on the CCD 30000 / CCD 5000M
Error messages will be indicated by fast blinking of the LEDs.
Error messages can be deleted by pressing the 'SET UP’ key of the CCD camera.
LED 10
LED 1
SET UP
LED
10
9
8
7
6
5
4
3
2
1
O
O
✹
✹
O
O
✹
✹
O
O
O
✹
✹
✹
O
O
✹
✹
✹
O
O
O
O
O
O
O
O
O
✹
O
O = LED off
Error
message
lighting error during white
balance (without contrast)
lighting error during white
balance (overexposed)
EEPROM error
✹ = LED blinking
Responsible
Remedy
Lighting error during white Maximum exposure time is reached.
balance (without contrast) (black balance was carried out).
• Check alignment camera /
fluorescent lamp.
• Check fluorescent lamp.
• Check diaphragm.
• Remove protection cap.
• Repeat start-up of the camera.
Lighting error during white Minimum exposure time is reached.
balance (overexposed)
• Check fluorescent lamp.
• Check diaphragm.
• Repeat start-up of the camera.
EEPROM error
• Carry out white balance and
Setup.
• Carry out parameterization again
if the camera has been
parameterized via interface.
EEPROM values are not correct.
Camera is not ready for operation.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 8.0
Page:
2/2
9.0
9. Maintenance
9.1 Amplifier EKR 1000
The amplifier is maintainance-free.
The cleaning of the keyboard should be carry out with a dry, clean and smooth cloth.
By high contamination, use for cleaning a usual liquid cleaner, benzine or spirit.
The amplifier has to be switched off!
9.2 Camera CCD 30000 / CCD 5000M
For optimum guiding results, the lenses of the CCD cameras have to be kept clean.
Therefore, clean the lenses and the lighting equipment regularly.
9.3 Hydraulic powered actuator with plunger coil regulator
See separate manual.
9.4 Electric motor powered actuator
The electric motor powered actuator is maintenance-free.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: MD.043.01.03
Date:
04.02.00
Chapter: 9.0
Page:
1/1
10.0
10. De-commissioning
De-commissioning (scrapping) of the guiding system must carry out only together with the complete
unit. The procedure used has to be defined by the OEM.
Regarding the guiding equipment, please bear in mind that mainly electric/electronic components
are involved. The disposal of which is subject to the relevant legal rules and regulations.
A taking back of the equipment by BST Servo Technik GmbH is possible.
Please reach the necessary agreements.
Web Guiding System
EKR 1000 H with CCD 30000 / CCD 5000M
EDV no.: V3D.043.01.03
Date:
04.02.00
Chapter: 10
Page:
1/1
Annex A1:
Connecting plan EKR 1000H with CCD 30000/CCD 5000M
Power supply
Actuators
Components
Remote electronic precision adjusting
EMS1
EMS5
EMS 10
EMS 16
External keyboard EKR 3000 Commander
Operation with connecting box
EFE 1
1
5
9
4
Limit switch 2
Remote control (PLC inputs) acc. to chap. 7
EFE 1000
Stationary operation
EMS6
X1
Limit switch 1
If the functional direction of the EFE 1
remote control (right/left) shall be reversed,
the connections at the terminals 20 and 21
have to be interchanged.
remote
control
The signal direction of the tachometer generator has to be adapted
to the direction of rotation of the motor. Therefore switch over the
amplifier to mode “MAN“. Press one of the arrow keys.
If the actuator is moving to the end of the guiding device, interchange
the terminals 65 and 66.
X2
Servo center components
External keyboard
EKR 3000
Commander
isolated
74
73
KIB-M12Pö/002-KL2
71
67
KIB-M12Pö/002-KL2
isolated
CCD
camera
sensor 3
31
29
28
EMS 16P
The allocation of the limit switches
can be adapted to the sense of
rotation of the motor by interchanging
the terminals 71 and 73 if necessary.
OMG 4
Sensors
OMG 6
OMG 7
OMG 8
CK 37
Bi5G
Wiring colours:
rt = red
rs = pink
br = brown
gr = grey
gn = green
bl = blue
ws = white
ge = yellow
sw = black
Oscillation
isolated
CCD
camera
sensor 2
Metal plate
Attention: Both limit switches must be
covered by the metal plate
during normal operation
(limit switches are carried
out as break contacts).
Sensor 2 could be drop off,
sensor 1 could also be
used for web center
guiding.
isolated
limit switches
CCD
camera
sensor 1
Modules
- Not required components will fall away!
The corresponding terminals stay free!
- Shields are pinched in the screwing
(see installation of EMC-wiring).
Please contact the manufacturer for setting of
cross-bonding boxes.
Setting of DIL switches and position of the
jumpers see chapter „Start-up“.
R2 = 2,7 kΩ / 0,3 W
R1 = 680 Ω / 0,3 W
OZ 3
Connection of BST module bus with cable
Twisted Pair Unitronic-Bus LD 3x2x0,22.
Plunger
coil
regulator
FVG 1000 module
IO module
Interbus-S module
Intercon module
CAN module
Additional
module bus
subscriber’s
station
Servo valve SV 1-10
V3D.043.01.03.A01 / 01.02.2001
Annex 2
General plan EKR 1000 with 1x CCD 30000 / CCD 5000M
Interface ( see
separate manual )
remote control
Commander EKR 1000
Set point shifting
EFE 1
Servo-center component
OMG 4
EFE 1000
CK 37
Oscillation
CCD 30000 / CCD 5000M
sensor 1
OZ 3
BI5G
HF fluorescent lamp
Actuators
EMS 1 / EMS 10
EMS 6
EMS 5
plunger coil regulator
EH-St 9/3
EMS 1000 power module
~3
V3D.043.01.02 / 08.06.99
Annex 3
General plan EKR 1000 with 2x CCD 30000 / CCD 5000M
Interface ( see
separate manual )
remote control
Commander EKR 1000
Set point shifting
EFE 1
Servo-center component
OMG 4
EFE 1000
CK 37
Oscillation
CCD 30000 / CCD 5000M
sensor 1
sensor 2
OZ 3
BI5G
HF fluorescent lamp
Actuators
EMS 1 / EMS 10
EMS 6
EMS 5
plunger coil regulator
EH-St 9/3
EMS 1000 power module
~3
V3D.043.01.02 / 08.06.99
Web Guiding Systems
Web Viewing Systems
BST - web guiding system
FVG 1000 Module
Operating manual
BST International GmbH
Heidsieker Heide 53
33739 Bielefeld
Germany
Telefon: ++49(0)5206/ 999 - 0
Fax:
++49(0)5206/ 999-999
E-Mail: [email protected]
Issue:
19.11.97
EDV No.:
V3D.015.01.02
Definition of the symbols in this manual
Attention
Instructions with this symbol safeguard the operator from injury
Caution
Instructions with this symbol must be strictly adhered to failure to do so could result in
electrocution
information sign / step to be carried out
Table of contents
Table of contents
1
1. Description
1.1 Usage
1.2 General plan
2
2. Safety instructions
3
3. Emissions
3
4. Technical Data
4
5. Transport/Storage
4
6. Installation
6.1 Location requirements
6.2 Installation
6.3 Installation of EMC-wiring
6.4 Connection
6.4.1 Terminal plan
5
7. Start-up
8
7.1 Start-up requirements
7.2 Start-up with Sensor positioning device FVG 2 MK
7.3 Start-up with Sensor positioning device FVG 2 MK and/or FVG 1 K
8. Operation
8.1 Functions
8.2 Chase and following guiding mode with FVG 1000
8.3 Positioning accuracy and basis of design
8.4 Web width measurement with FVG 1000 and analogue sensors
8.5 Pre-positioning
11
9. Maintenance
17
10. Error indication
17
11. De-commissioning (scrapping)
17
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 1/17
Please follow the instruction of
start-up, maintenance and installation
as descripted in the operating instruction!
1. Description
1.1 Usage
The FVG 1000 module is a control unit for mechanical sensor positioning device operated by
synchron motor. For operation of this module the EKR commander must have software
E 0030301 or higher.
Therefore, it is suitable for adjustment speed in the range of 30 to 36 mm/sec
and for application with ultra sonic sensors US 2003, pneumatic sensors KF ...and infrared
IR 2001 and/or IR 2002 (usage as fork or reflector control)
The communication is via the BST Modulbus.
Please contact the producer for each different application.
Attention!
Only the edge sensors IR 2001 and US 2003 are approved for pre-positioning and
web width measurement.
Necessary state of software:
commander: E 0030501 or higher
FVG 1000 : K 0010301 or higher
1.2 General plan
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 2/17
2. Safety instructions
- Installation of the BST equipment into production machinery, please pay attention to the relevant
security rules according DIN EN 294, DIN EN 349 and classified UVV.
Assembly, installation and commissioning must be carried out by qualified personnel !
Please do not open the unit until line voltage is switched off!
When operation at open unit is necessary, only protection class IP20 is present. Danger
through line voltage !
During start-up sensor/sensor positioning device will carry out positioning movements.
Danger through squeezing is present. Therefore, make relevant safety arrangements.
3. Emissions The A-rated equivalent continuous sound level of equipment is under 70 dB(A).
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 3/17
4. Technical Data
Line voltage :
115V / 230V
+10% / -20%,
50 - 60Hz
Attention: For application with sensor positioning device FVG 2 ...
only motors with 230V line voltage are allowed at the moment.
If using 115V line voltage there must be added an economical
transformer (non line transformer).
Power consumption:
100 VA (incl. motors)
Fuses:
2 x 0,63AT with 230V or 2 x 1,3 AT with 115V.
The system should be connected so that the power supply is cut when the
message ‘Emergency stop’ is displayed.
Inputs on net potential:
connections for separative limit switches,
max. allowed motor power consumption 180mA per motor
Inputs with isolations from
- if using, which are requisite non-separate limit switches, only use the
net accord. VDE 0551:
nominated message contacts. Lay bridges instead of inputs.
- 4 message contacts for limit switches (make before break)
- RS 485 reserved for BST Modul Bus
Output:
Connections for 2 synchronous motors on net potential. Net voltage
connected at zero crossing via Triac, max. allowed motor power
consumption 180mA per motor
Protection class:
IP54
Ambient temperature:
0 - 45°C
Relative humidity of air:
5 - 90% (not condensed)
Dimensions:
W = 260mm,
Weight:
approx. 3,25 kgs
D = 160mm
H = 90mm
5. Transport/Storage
Depending upon the order, the delivery will be carry out:
- completely built-in and connected at actuator
- as component part in standard cardboard boxes
with cellular lining material.
If the unit is not incorporated immediately, it should be stored in a dry room.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 4/17
6. Mounting
6.1 Installation requirements
The FVG 1000 module has to be installed in a dry, vibration-free area..
Ambient temperature:
0°C bis max. 45°C
Max. relative humidity of air:
5 - 90% (not condensed)
6.2 Installation
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 5/17
6.4
Installation of EMC-wiring
1
disk of the cable fitting
black rubber
sealing parts
conical sealing
(metal/rubber)
nut
unscrew nut and sealing
parts and pin them up to
the end of the cable
3
2
shield
Remove 90mm of
external insulation
30mm
4
Remove 60mm of shield,
so that 30mm remain
visible.
5
insulated cable leads
galvanized washer 8,4mm
DIN 125
vanished shield
Fan the protective shield, so
that the individual wires of the
shield protrude evenly from
the cable, approx. at right angle.
Thread the individual insulated
leads through the galvanised
washer, included in delivery and
press the washer onto the shield
braiding
FVG 1000 module
Refold and twist the shield
braiding over the washer.
Tighten the cable in the
cable gland.
Strip the lead ends
(eventually, use protective
lugs) and wire according
connection diagram.
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 6/17
6.4 Connection
6.4.1 Connection plan
configuration of terminals
terminal
function
X1
net input
X3
Modulbus input
X4
Modulbus output
X5
motor 1 and
separated stop
limits to net
voltage
X6
message of
contacts for
motor 1
X7
motor 2 and
separated stop
limits to net
voltage
X8
message of
contacts for
motor 2
terminal
1
2
3
44
45
46
47
49
50
51
52
1
2
3
4
5
6
7
8
1
2
3
4
L
PE
N
GND (0V)
TXD/RXD
- (TXD/RXD)
external non-guided voltage
GND (0V)
TXD/RXD
- (TXD/RXD)
station 47 of X3
Limit switch motor 1 outside
Limit switch motor 1 outside
Motor 1 terminal 2
Motor 1 terminal 3
Motor 1 terminal 1
Limit switch motor 1 inside
Limit switch motor 1 inside
Motor 1 terminal PE
Non printing
Non printing
Limit switch motor 1 outside (+21V)
Limit switch motor 1 outside;
Indication LED H62
Non signification
Non signification
Non signification
Non signification
Limit switch motor 1 inside (+21V)
Limit switch motor 1 inside; indication LED H67
stop limit motor 2 outside
stop limit motor 2 outside
motor 2 terminal 2
motor 2 terminal 3
motor 2 terminal 1
Limit switch motor 2 inside
Limit switch motor 2 inside
Motor 2 terminal PE
Non printing
Non printing
Limit switch motor 2 outside (+21V)
Limit switch motor 2 outside;
Indication LED H82
Non signification
Non signification
Non signification
Non signification
Limit switch motor 2 inside (+21V)
Limit switch motor 2 inside; indication LED H87
5
6
7
8
9
10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
FVG 1000 module
colour of
wiring
station
green
brown
white
pink
green
brown
white
pink
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 7/17
7. START UP
Assembly and installation must be carried out by qualified personnel !
For connection and adjustments the power must be switched-off !
7.1 Start up requirements
switch off net voltage (external!)
set net voltage
Attention:
Therefore, the motors will not be reversed. Net voltage must correspond with
adjusted system voltage (see type plate!).
connect components according to the connecting plan
Attention:
The connection has to be such, that the FVG 1000 Module will be integrated into
the compound system. When the message ‘Emergency Stop’ the complete system
must stop.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 8/17
adjust DIL-switch according to the application
S 6.1 = reserved
S 6.2 = ON = chase and following guiding
mode ‘ON’
= OFF = chase and following guiding
mode ‘OFF’
S 6.3 to S 6.8 = reserved
S 5.1
S5.1
S 5.2
S5.2
S 5.3
S5.3
S 5.4
S5.4
S 5.5
S5.5
S 5.6
S5.6
S 5.7
S5.7
S 5.8
S5.8
= ON = FVG 2 MK connected
= OFF = FVG 1 MK connected
= ON = Automatic calibration ‘ON’
= OFF = Automatic calibration ‘OFF’
= ON = Sensor moved via reflector bar
= OFF = Other sensors are connected
= OFF = Not used at present
= ON = Retraction with ‘Manual’ mode
= OFF = Retraction with‘S-C’ mode
= ON = Pneumatical sensors (KF..) or ultra sonic sensors (US ..)
= OFF = Other sensors are connected
= ON = FVG2MK with web tear behaviour like FVG1MK ‘ON’
= OFF = FVG2MK with web tear behaviour like FVG1MK ’OFF’
= ON = Automatic calibration time-oriented ‘ON’
= OFF = Automatic calibration time-oriented ‘OFF’
Adjust plug-in according application
terminal JX2
jumper DE - Modulbus without moving load
jumper EF - Modulbus with moving load
(preset by manufactory)
Attention: Jumper EF must be switched,
when FVG 1000 is connected as
last modul at bus.
terminal JX1
jumper AB - connection 0V with protection earth
(PE)
jumper BC - separation 0V from protection earth
(PE) (preset by manufactory)
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 9/17
List 1 Signification through LED’s for service
Service LED
Status
Signification
H1
ON
Amplifier recognised
H2
ON
‘Electric Clutch’ activated
Blinker
Web center position memorised before web tear
H3
ON
Automatic calibration sensor 1/2
H4
ON
Edge seeking sensor 1 / 2
H5
ON
Retraction of the sensors 1 / 2
H6
ON
Adaptation to varying web widths with center-line guiding
H7
ON
Searching for set-point, readjustment or other positioning of the
sensors 1 / 2
H8
Blinker
System ok (perfect program flow)
H9
ON
Internal supply voltage (+5V) ok
H62
ON
Limit switch motor 1 (outside) activated
H67
ON
Limit switch motor 1 (inside) activated
H82
ON
Limit switch motor 2 (outside) activated
H87
ON
Limit switch motor 2 (inside) activated
pull off plug-in terminal X3
switch on net voltage (external!)
7.2 Start-up with Sensor positioning device FVG 2 MK
(sensor position device with 2 motors for separate adjustment of 2 sensors)
Motor 1
- Quickly press key S1, sensor 1 has to move outside.
If sensor moves to web center, the motor connections X5.3 and X5.4 have to reversed.
- Press outside limit switch of positioning device (LED H62 is illuminated).
Subsequently press quickly key S1 and S2. Only by pressing S2 the positioning device moves to
web center. S1 indicates non reaction.
Press inside limit switch of positioning device (LED H67 is illuminated).
Subsequently press quickly key S1 and S2. Only by pressing S1 the positioning device moves to
web center. S2 indicates non reaction.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 10/17
Motor 2
- Carry out the same procedure as for motor 1, using the keys S3 and S4 have. If
pressing S3 and the sensor 2 moves to web center, the motor connections X7.3 and X7.4 have to
reversed. The message from the limit switch will be carried out by LED’s H82 and H87.
- Switch off net voltage and plug-in terminal X3
- Switch on net voltage
- The FVG 1000 module including sensor positioning device are started up and control will be
via the connected amplifier
7.3 Start-up with Sensor positioning device FVG 2 MK and/or FVG 1 K
(sensor position device with 1 motor for general adjustment of 2 sensors, symmetric to web center with
FVG 1 MK and/or only adjustment of 1 sensor with FVG 1 K)
- Press quickly key S1. The mounted sensor has to move outside.
If moving inside, the motor connections X5.3 and X5.4 have to be reversed.
- Press outside limit switch of the positioning device.
Subsequently press quickly key S1 and S2. Only by pressing S2 the positioning device moves to
web center. S1 indicates non reaction.
- Switch off net voltage and plug-in terminal X3
- Switch on net voltage
- The FVG 1000 module including sensor positioning device are started up and control will be
via the connected amplifier
8. Operation
The FVG 1000 module is operated from the connected amplifier.
When the operating mode (edge 1/ edge 2 or web center) is selected on the amplifier, coordination
of performed functions occurs automatically
The change-over from ‘MAN’ or ‘S-C’ to ‘AUTO’ activates the corresponding positioning mode..
Sensors not required stay at the outside limit position or by change-over of operation mode they
moving to that position.
Attention:
FVG 1000 module
The back of sensors and change-over of operation mode is activated,
when the activated sensor has reached its operating position..
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 11/17
8.1 Functions
The following functions are available:
1) Automatic edge seeking for: - sensor 1
- sensor 2
- sensor 1 and sensor 2 (sensors searching for the edge separate)
- sensor 1 or sensor 2 with one sensor positioning device
(the sensor not in use must be out of web range prior the
operation)
- sensor 1 and sensor 2 with one sensor positioning device
by web center guiding with automatic centering of web to
servo center (opposed adjustment of both sensors)
2) Automatically seeking of servo center position corresponding to the last actual position
with two separate positioning devices through:
- electric clutch (terminal 70 in the amplifier): servo center
position will be stored and running each time to edge seeking.
- FVG 1 MK-behaviour with web tear: after web tear the unit
will guide automatically to ‘Retraction’ and the sensors will
move to the outside. A new web can be positioned. There after,
the ‘AUTO’ function has to be activated. The web guiding system
will guide the web automatically to the last actual web position
before the web tear occurred.
At web position non servo center, one sensor will not reach the
outside limit stop. The function can be cancelled by pressing
mode ‘Retraction’ again.(‘MAN’ or ‘S-C’).
Attention! The stored web values will be lost!
3) Automatic adaptation of sensor positions on changing web widths
Automatic re-positioning of one edge sensor or of both edge sensors (parallel) with web
center guiding, when zero point is shifted outside the measuring range of sensor
(through shifting of guiding point via arrow keys)
4) Automatic scaling
During edge seeking an adjustment (SET UP) of sensors
to the present web occurs. A manual adjustment is not
necessary.
5) Time-oriented automatic calibration
condition:
- operation mode ‘AUTO’,
- scanning mode ‘Web center guiding’
- switch S5.2 = ON, S5.8 = ON
Period of automatic calibration of the sensors is approx.
9 min. for compensation of contamination. During
calibration the control system will be locked. After calibration
the sensor will return automatically to last position and
guiding is activated.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 12/17
8.2 Chase and following guiding system with FVG 1000
The adjustment of the function ‘chase and following guiding’ occurs by means of the DIL switch S 6.2.
Motor 1 / sensor 1 is allocated to the master system and motor 2 / sensor 2 is allocated to the slave
system.
Attention! This allocation must be strictly made during installation.
8.3 Positioning accuracy and basis of design
The resolution is 1mm and the accuracy of positioning is ± 0,5mm with positioning by means of sensor
positioning device.
The minimum travelling distance is 1,2mm ± 0,3mm.
Example:
desired position
adjustable position
possible position
57,4mm
57mm
56,5mm < 57mm < 57,5mm
Conversion of the number of steps of the motor z into the length of the travel X [mm]
method of
calculation
given
values
1
z = number of steps
n = output speed [U/min]
U = circumference of the
driving wheel [mm]
f = net frequency
formula
X=
example
n∗ U∗ z
mm
120 ∗ f
active diameter of the
driving wheel = 35.01mm
z=1
f = 50 Hz
n = 15 U/min
X=
15 ∗ π ∗ 35,01 ∗ 1
120 ∗ 50
X = 0,275mm
FVG 1000 module
2
z = number of steps
U = circumference of the
driving wheel [mm]
P = number of pairs of poles
I = transmission ratio of the
motor
X=
3
Z = tooth number of the
driving wheel
i = distance of teeth [mm]
z = number of steps
N = steps per revolution
U∗ z
mm
2∗ P∗ I
X=
Z∗ i∗ z
mm
N
Z = 22
i = 5mm
z=1
N = 400
X=
22 ∗ 5 ∗ 1
400
X = 0,275mm
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 13/17
8.4 Web width measurement with FVG 1000 and analogue sensors
8.4.1 Approved analogue sensors
As analogue sensors are approved:
- ultra sonic sensor US 2003
typical value of the sensor constant for
width measuring = 14mm
- infrared sensor IR 2001
typical value of the sensor constant for
width measuring = 13mm
8.4.2 Restrictions on the application of analogue sensors
The precision of the web width measurement depends above all from the constant transparency of the
material to be measured. A variable transparency will be interpreted as a variable width and falsifies the
result. For example:
- with ultra sonic sensors: by a variable air permeability of the material
- with infrared sensors: by a print on a transparent material or variable transparency within the viewing range of the material
Attention: The application of the IR 2001 for transparent material requires the readjustment of the
virtual measuring range for the material to be scanned.
8.4.3 Basis of the width calculation
Starting point for calculation is the maximum measuring range of the FVG 1000. This value will be
determined by means of a sample of material which width is exactly known.
The maximum measuring range is:
Xmax = Xnorm +
Xmax
Xnorm
nsum
nFsum
Z
i
N
nFmax
Fmax
Z∗ i
XFmax
∗ nsum +
∗ nFsum
N
Fmax
= maximum measuring width [mm]
= known width of material [mm]
= sum signal of the sensor position
= sum signal of the sensor values
= tooth number of the driving wheel of the positioning device
= distance of the teeth of the driving wheel [mm]
= steps of the synchronous motor per revolution
= maximum sensor value
= measuring range of the sensor
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 14/17
n sum = position sensor 1 + position sensor 2
material with known width
position sensor 1
position sensor 2
position = 0
position = 0
xnorm
M1
M2
n Fsum = sensor value 1 + sensor value 2
sensor value 1
sensor value 2
8.4.4 Conversion of the normal sensor value into mm
XF =
XFmax ∗ nF
Fmax
XF
XFmax
nF
Fmax
Example:
IR 2001
XF = 13mm
nF = -200
Fmax = 8192
= sensor value [mm]
= sensor constant [mm]
= sensor value
= measuring range of the sensor
XF = -0,32mm
8.4.5 Definition of the maximum web width
Procedure:
1) Carry out master-setup (see corresponding chapter within the manual of the connected
commander)
2) Carry out material-setup with sample (see corresponding chapter within the manual of the
connected commander)
3) Sample remains in the equipment.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 15/17
4) Press key ‘edge left’
and ‘edge right’
simultaneously
and
Center-line guiding
is switched on.
5) Press key ‘AUTO’
AUTO
Sensors are seeking for the edge of the sample
6) After positioning of the sensors at the web edge the maximum web width can be determined by
means of a Profibus-DP module and the transmitted values sum position sensor 1 and
sensor 2 (nsum) and standardised sensor value (nFsum).
(see also manual ‘Profibus-DP module)
8.4.6 Calculation of the web width
The formula for the actual web width can be derived from the formula for the maximum web width:
X = Xmax −
Z∗ i
XFmax
∗ nsum −
∗ nFsum
N
Fmax
8.5 Sensor pre-positioning
Attention:
Pre-positioning is only possible with the Profibus-DP module for the time being.
(state of software M 0010201 or higher).
The following positioning scope is realised:
1) Absolute positioning: (optional with or without standardisation of the sensors)
- with separate positional parameters for sensor 1 and sensor 2
- with a common positional parameter for sensor 1 and sensor 2
Reference point(s) are the outer limit switches of the FVG 1000.
Example:
Positional parameter +50 effects that the sensors (sensor 1/2 together or separate)
move to a position 50 steps far from the outer limit switch.
2) Relative positioning:
- with separate positional parameters for sensor 1 and sensor 2
Reference point is the actual position of the sensor.
- with a common positional parameter for sensor 1 and sensor 2
The delivered positional parameter will be added to the actual position of sensor 1 and
subtracted from the actual position of the sensor 2.
Example:
The positional parameter +50 effects with the function ‘relative positioning with a
common positional parameter’
- sensor 1: positional displacement of the sensor 50 steps in direction to the web
center
- sensor 2: positional displacement of the sensor 50 steps in direction to the web
edge
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 16/17
3) Load of positional parameters with mode of operation ‘MAN’ and ‘S-C’
Pre-positioning will be activated by switching over to ‘AUTO’.
The following operations can be carried out:
- Taking over of position changes as new
position during control operation
(e.g. through changes of web width or manual
correction by means of the arrow keys)
The new positional parameters are stored.
The sensors move to the new position
at the first switch over to ‘AUTO’.
- No taking over of positional changes as new
position during control operation
The new positional parameters are not
stored. The sensors move to the ‘old’
position at the first switch over to ‘AUTO’.
- Taking over of the actual position as set point
The stored position is equal to the actual
position.
Loaded positional parameters are active (after switch over to ‘AUTO’) until:
- a new value is loaded via Profibus-DP module
- a ‘Master-Setup’ at the commander is carried out (all operation modes of the
FVG 1000 are deleted and the desired positions of the sensors are set to ‘0’).
9. Maintenance
The FVG1000 module is maintenance-free.
10. Error indication
indication at amplifier
signification
During shifting of guiding point via arrow keys a limit
stop was reached.
During edge seeking or after web tear, the inner limit switch
was reached. Amplifier switched in operation mode ‘Retraction’.
= LED off
= LED blinking
11. De-commissioning
De-commissioning (scrapping) of the positioning device has to be made in connection with the whole
machine. The procedure used has to be defined by the OEM.
Please note that the component parts of the guiding system are electrical/electronic. The disposal of
which is subject to the relevant rules and regulations. A recycling process can be carry out by BST ServoTechnik GmbH. Therefore, corresponding declarations have to be occurred.
FVG 1000 module
EDV No.: V3D.015.01.02
Date: 19.11.97 page: 17/17
L PE N
L1 PE N
X5 X6
limit switch
outside (motor 1)
motor 1
ws
rs
module bus
gn br
X3
44 45 46 47
FVG 1000
15 16 23 24
1 2 3 PE
1 2 3 4
X5 X6
br ws
rs
module bus
gn
X4
49 50 51 52
limit switch
inside (motor 1)
15 16 23 24
6 7 9 10
X7 X8
limit switch
outside (motor 2)
X7 X8
limit switch
inside (motor 2)
15 16 23 24
6 7 9 10
EXCEPTION: are no forced separative limit switches connected,
terminals
X5.1 with X5.2,
X5.6 with X5.7,
X7.1 with X7.2,
X7.6 with X7.7
have to be connected by jumpers.
Not used components fall away!
Corresponding terminals stay free.
bl = blue
br = brown
gn = green
rs = pink
ws = white
15 16 23 24
motor 2
1 2 3 4
1 2 3 PE
X7
5 3 4 8
X5
5 3 4 8
C
X1
FVG 1000
B
A
GND (0V)
Connecting plan FVG 1000
V3D.015.01.02