BST Ekr 500 Leitfaden

Web Guiding System

Installation and

Commissioning Manual

ekr 500 digital Unit Touch

MD.497.EN.08

Translation of the Original Manual

BST GmbH

Remusweg 1

D-33729 Bielefeld

Tel.: +49 (0) 521 400 70 0

Fax: +49 (0) 5206 999 999

E-Mail: [email protected]

Internet: www.bst.group

This documentation is protected by copyright. The translation as well as reproduction and distribution in any form is forbidden without the approval

of the rights holder and will be pursued under civil and criminal law. Technical modifications reserved.

Table of contents

ekr 500 digital Unit Touch – Installation and Commissioning Manual iii

Table of contents

1 About This Document........................................................................................ 7

1.1 What You Need to Know............................................................................................... 7

1.2 Target Group................................................................................................................. 7

1.3 Storage and Distribution............................................................................................... 7

1.4 Meanings of the Safety Instructions and Symbols........................................................ 7

1.4.1 Safety Instructions ........................................................................................................ 7

1.4.2 Symbols......................................................................................................................... 8

1.4.3 Operation Using Keys.................................................................................................... 8

1.5 More Detailed Information........................................................................................... 9

2 About Safety ....................................................................................................10

2.1 Intended Use............................................................................................................... 10

2.2 Non-intended Use....................................................................................................... 11

2.2.1 Non-intended Infringement of Guidelines.................................................................. 11

2.2.2 Non-intended Operation............................................................................................. 11

2.2.3 Non-intended Modification of Electronic Data........................................................... 12

2.3 Safety Instructions ...................................................................................................... 13

2.3.1 General Safety Instructions......................................................................................... 13

2.4 Qualification of the Personnel .................................................................................... 15

2.5 Duties of the Operating Company and Personnel ...................................................... 16

2.5.1 Duties of the Operating Company .............................................................................. 16

2.5.2 Duties of the Personnel............................................................................................... 17

2.6 Conduct in the Event of Danger and Accidents .......................................................... 17

2.7 Personal Protective Equipment .................................................................................. 18

2.8 Guarantee and Liability............................................................................................... 18

2.8.1 Disclaimer ................................................................................................................... 18

2.8.2 Exceptions to the Disclaimer....................................................................................... 19

2.8.3 License and Liability for Software Supplied ................................................................ 19

3 Design and Function.........................................................................................20

3.1 Design ......................................................................................................................... 20

3.1.1 Controller.................................................................................................................... 20

3.1.2 Control Panel .............................................................................................................. 20

3.2 Function ...................................................................................................................... 21

3.3 Message Output “System OK“ .................................................................................... 22

3.4 Connectable Components........................................................................................... 23

3.5 Designation of the Sensors ......................................................................................... 24

3.5.1 Edge Sensors (Sensor1/2) .......................................................................................... 24

3.5.2 Line, Contrast and Object Sensor (Sensor3)............................................................... 25

3.5.3 CCD Cameras (Sensor 1/2) .......................................................................................... 26

3.6 Accessories.................................................................................................................. 27

3.7 Nameplates................................................................................................................. 27

4 Technical Specifications ...................................................................................28

4.1 Controller.................................................................................................................... 28

4.1.1 Ambient Conditions .................................................................................................... 28

4.1.2 Protection Category.................................................................................................... 28

4.1.3 Power Supply .............................................................................................................. 28

4.1.4 Analogue Inputs.......................................................................................................... 29

4.1.5 Digital Inputs / Outputs............................................................................................... 30

4.1.6 Output Motor Output Stage ....................................................................................... 30

4.1.7 Message Output "System OK" .................................................................................... 31

4.1.8 Bus Interface............................................................................................................... 31

4.1.9 Weight and Dimensions.............................................................................................. 32

4.2 ekr commander Control Panel.................................................................................... 33

4.2.1 Ambient Conditions .................................................................................................... 33

4.2.2 Protection Category.................................................................................................... 33

Table of contents

iv ekr 500 digital Unit Touch – Installation and Commissioning Manual

4.2.3 Power Supply .............................................................................................................. 33

4.2.4 Touchscreen Display ................................................................................................... 33

4.2.5 Weight and Dimensions.............................................................................................. 33

4.3 Power Pack.................................................................................................................. 34

4.4 Sensors........................................................................................................................ 35

4.4.1 Edge Sensors............................................................................................................... 35

4.4.2 Line and Contrast Sensor CLS Pro 600 ........................................................................ 37

4.4.3 Object Sensor CLS CAM 100........................................................................................ 38

4.4.4 CCD Cameras............................................................................................................... 38

4.5 Sensor Positioner ........................................................................................................ 38

4.6 Electric Motor Powered Actuators.............................................................................. 39

4.7 RoHS Conformity......................................................................................................... 41

5 Transport, Delivery and Storage .......................................................................42

5.1 Transport..................................................................................................................... 42

5.2 Scope of Delivery ........................................................................................................ 43

5.3 Unpacking the Delivery............................................................................................... 43

5.4 Storage........................................................................................................................ 43

6 Installation.......................................................................................................44

6.1 Safety Instructions ...................................................................................................... 44

6.2 Selecting the Installation Location.............................................................................. 45

6.3 Installing the Controller .............................................................................................. 46

6.3.1 Installation Positions................................................................................................... 46

6.3.2 Securing Hole Template.............................................................................................. 47

6.3.3 Space Needed to Open the Housing Cover................................................................. 47

6.3.4 Installing the Controller .............................................................................................. 48

6.3.5 Turning the Control Panel........................................................................................... 49

6.4 Installing the Control Panel......................................................................................... 50

6.4.1 Attachment Alternatives............................................................................................. 50

6.4.2 Cable Extension........................................................................................................... 50

6.4.3 Wall Mounting ............................................................................................................ 51

6.4.4 Console Installation..................................................................................................... 53

6.4.5 Magnet Attachment.................................................................................................... 56

7 Electrical Connection........................................................................................58

7.1 Safety Instructions ...................................................................................................... 58

7.2 Cable Routing.............................................................................................................. 59

7.3 Connecting the Cables ................................................................................................ 60

7.4 EMC Suitable Wiring ................................................................................................... 61

7.5 Ensuring Equipotential Bonding.................................................................................. 62

7.6 Connections on the Controller.................................................................................... 63

7.7 Terminal Strips............................................................................................................ 64

7.8 Terminal Assignment .................................................................................................. 65

7.8.1 Overview..................................................................................................................... 65

7.8.2 Terminal Strip X1 - Sensor 1/2 (Analogue Connection) .............................................. 66

7.8.3 Terminal Strip X6 - Power Supply................................................................................ 66

7.8.4 Terminal Strip X7 - Actuator, OMG 4 .......................................................................... 67

7.8.5 Terminal Strip X8 - Sensor 1/2 (CAN Bus) ................................................................... 68

7.8.6 Terminal Strip X9 - ekr commander Control Panel, Sensor 3, Drive Module 160....... 68

7.8.7 Terminal Strip X10 - Controller Interlock, OMG 4, OMG 8, CK 37, EFE1 .................... 69

7.8.8 Terminal Strip X11 - Message Output "System OK".................................................... 69

7.8.9 Terminal Strip X12 - CAN Bus 4 ................................................................................... 69

7.8.10 Terminal Strip X14 - Digital Inputs 1...6, EFE 1000...................................................... 70

7.8.11 Terminal Strip X15 - Digital Inputs 7...12, EFE 1000.................................................... 70

7.8.12 Terminal Strip X16 - Digital Outputs 1 ... 4.................................................................. 70

7.9 Plug Connection.......................................................................................................... 71

7.9.1 X60 - Actuator Connection EMS 17/18/21/22 ............................................................ 71

7.9.2 X70 - Power Supply ..................................................................................................... 72

Table of contents

ekr 500 digital Unit Touch – Installation and Commissioning Manual v

7.9.3 X100 ... 103 - Connection of CAN Bus Participants ..................................................... 73

8 Commissioning.................................................................................................74

8.1 Safety Instructions ...................................................................................................... 74

8.2 Requirements.............................................................................................................. 75

8.3 Setting the DIL Switches of the Controller.................................................................. 76

8.3.1 DIL Switch Overview ................................................................................................... 76

8.3.2 Using the DIL Switch ................................................................................................... 77

8.3.3 Setting DIL Switch S4................................................................................................... 78

8.3.4 Setting DIL Switch S5................................................................................................... 79

8.3.5 Setting DIL Switch S6................................................................................................... 80

8.3.6 Setting DIL Switch S7................................................................................................... 80

8.4 Setting the DIL Switches of the Control Panel ............................................................ 81

8.5 Setting the Jumper...................................................................................................... 82

8.6 Checking the Device Addresses .................................................................................. 83

8.6.1 Controller Device Address........................................................................................... 83

8.6.2 Control Panel Device Address..................................................................................... 84

8.7 Setting the Terminating Resistors............................................................................... 85

8.7.1 Terminating Resistor of the Controller ....................................................................... 85

8.7.2 Terminating Resistor of the Control Panel.................................................................. 87

8.8 Calling up the Setup Menu.......................................................................................... 89

8.9 Setting the Dimension Unit......................................................................................... 92

8.10 Setting the Motor Rotation Direction ......................................................................... 93

8.11 Commissioning the Actuator Without Position Feedback .......................................... 94

8.11.1 Setting the Guiding Direction for Center Positioning.................................................. 94

8.11.2 Setting the Gain of the Servo Center Transducer ....................................................... 95

8.12 Commissioning the Actuator With Position Feedback................................................ 97

8.12.1 Setting the Guiding Direction for Center Positioning.................................................. 97

8.12.2 Setting Stroke Limitation and Servo-Center Position.................................................. 98

8.12.3 Activating the Normalized Display of the Actuator Position..................................... 101

8.12.4 Activating Position Control ....................................................................................... 104

8.13 Setting the Guiding Direction.................................................................................... 105

8.13.1 Guiding Direction for Web Edge Guiding and Web Center-Line Guiding (Sensor 1/2) .105

8.13.2 Guiding Direction for Line / Contrast / Feature Guiding (Sensor 3).......................... 106

8.14 Performing the Material Setup ................................................................................. 106

8.15 Adjusting the Controller Gain ................................................................................... 107

8.16 Commissioning the CCD Camera............................................................................... 109

8.16.1 CCD Camera Calibration............................................................................................ 109

8.16.2 Material Thickness Compensation............................................................................ 113

8.16.3 Setting the Material Thickness (After Changing the Material).................................. 116

8.16.4 Entering the Position Offsets .................................................................................... 117

8.17 Commissioning the Sensor Positioner ...................................................................... 119

8.17.1 Calling Up the Setting Menu ..................................................................................... 119

8.17.2 Overview Setting Menu ............................................................................................ 120

8.17.3 Activating Retract Mode ........................................................................................... 121

8.17.4 Activating Automatic Setpoint Acceptance .............................................................. 122

8.17.5 Setting Automatic Sensor Tracking........................................................................... 123

8.17.6 Activating Automatic Edge Sensor Standardization.................................................. 124

8.17.7 Entering the Position Offset for the Sensor Slides.................................................... 125

8.18 Commissioning the Positioning Unit......................................................................... 127

8.18.1 Utilization.................................................................................................................. 127

8.18.2 Calling Up the Setting Menu ..................................................................................... 128

8.18.3 Overview Setting Menu ............................................................................................ 128

8.18.4 Reversing the Operating Direction of the Arrow Keys.............................................. 129

8.18.5 Entering the Position Offset for the Sensor Slides.................................................... 131

8.19 Commissioning the Electronic Remote Precision Adjustment (Optional)................. 133

8.19.1 EFE 1.......................................................................................................................... 133

8.19.2 EFE 1000.................................................................................................................... 134

Table of contents

vi ekr 500 digital Unit Touch – Installation and Commissioning Manual

9 Remote Control (Digital Inputs / Outputs)......................................................135

9.1 Safety Information .................................................................................................... 135

9.2 Digital Inputs / Outputs............................................................................................. 135

9.2.1 Digital Inputs............................................................................................................. 135

9.2.2 Digital Outputs.......................................................................................................... 135

9.2.3 Truth Tables .............................................................................................................. 136

9.2.4 Digital Inputs / Outputs Configuration...................................................................... 137

9.3 Remote Control With External Control Keyboard ekr commander .......................... 150

10 Service LEDs ...................................................................................................151

10.1 Status Display of Remote Control Inputs .................................................................. 152

10.2 Status Display of Digital Outputs .............................................................................. 152

10.3 Display of CAN Bus Status......................................................................................... 153

10.4 Display of Device Status............................................................................................ 153

10.5 Status Display of Message Output "System OK"....................................................... 153

10.6 Status Display of Power Supply................................................................................. 153

10.7 Status Display of Controller Interlock ....................................................................... 153

11 Accessories and Spare Parts ...........................................................................154

11.1 Order Address........................................................................................................... 154

11.2 Accessories................................................................................................................ 154

12 Customer Services..........................................................................................155

13 Connection Diagram.......................................................................................156

13.1 Application with Edge Sensors.................................................................................. 156

13.2 Application with CCD Cameras.................................................................................. 157

13.2.1 Application with CCD CAM 100................................................................................. 157

13.2.2 Application with CCDPro 30000/5000 ...................................................................... 158

13.3 Application with Sensor Positioner FVG POS 100 ..................................................... 158

Index..............................................................................................................159

About This Document 1

ekr 500 digital Unit Touch – Installation and Commissioning Manual 7/162

1 About This Document

1.1 What You Need to Know

These instructions help you to install and start up the system in a

safe manner. The following instructions must be observed in order

to avoid hazards and incorrect operation:

■Every user that has been assigned with the installation and the

start-up of the system must have read these instructions in full

before working with or on the system.

■Every user must follow the safety information in these instruc-

tions.

■The basic operation and the system functions are described in

the operating manual. Every user must be familiar with the

operating manual and observe the safety instructions contained

therein.

1.2 Target Group

These instructions are directed to all persons that have been

assigned with the installation and the start-up of the system. The

operating company of the entire system and supervising

personnel must also be familiar with these instructions.

1.3 Storage and Distribution

These instructions must be stored at the workplace in such a

manner that the user has access to them at all times.

These instructions and all other applicable documents are a com-

ponent of the product and must be handed over to the operating

company of the system.

1.4 Meanings of the Safety Instructions and Symbols

1.4.1 Safety Instructions

DANGER

Danger that will lead to death or severe injuries!

►Here you can find how to avoid the danger.

WARNING

Danger that may lead to death or severe injuries!

►Here you can find how to avoid the danger.

CAUTION

Danger that may lead to medium or minor injuries!

►Here you can find how to avoid the danger.

NOTICE

Danger that may lead to damage to assets!

There is no risk of injury.

►Here you can find how to avoid the danger.

1About This Document

8/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual

1.4.2 Symbols

Information that is essential for successful operation.

Information that makes operation easier.

Action requirements may include the following symbols:

›› Requirements that must be fulfilled for the action steps.

1. Prompt for you to act. Namely ...

2. ... in the listed sequence.

►Requirement for you to take actions - without any certain

sequence.

1.4.3 Operation Using Keys

Operations using the keys are indicated by the following symbols:

►Press key ①.

►Press key ① or key ②.

►Press key ① and key ② at the same time.

About This Document 1

ekr 500 digital Unit Touch – Installation and Commissioning Manual 9/162

1.5 More Detailed Information

►Observe the accompanying documents (e.g. order confirmation)

for this system and the operating instructions of the entire sys-

tem.

The latest version of these instructions in all available languages

as well as further documents on this system can be found in the

Internet on our help portal BST.Help. Simply click on the docu-

ment number in the table. The link will lead you directly to the se-

lected document on BST.Help.

Document Document

Number

Operating manual

ekr500digitalUnitTouch MD.492

Installation and operating manual

ekr500digitalUnitTouch –

Application with wide array edge sensors

MD.503

Operating manual

ekr500digitalUnitTouch –

Master-slave guiding with sensor positioner

MD.535

Interface description

ekr500digitalUnitTouch –

CANopen user gateway

MD.520

2About Safety

10/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual

2 About Safety

The system has been designed according to the state of the art

and fulfils the latest safety standards.

When using the system, risks may occur that could threaten your

life or health or lead to material damage. In order to avoid these

risks, all instructions in this manual concerning safety and all

relevant documentation of the entire system must be observed.

2.1 Intended Use

The system is only determined for web guiding. It permits guiding

according to the web edges, web center-line, printed lines,

contrast edges or print features.

The system is integrated in a machine or connected with another

machine to form a machine as defined by machinery directive

2006/42/EC. All machines and the overall machine line must meet

the requirements of the machinery directive after integration of

the system.

The system and all of its components are exclusively intended for

commercial use in an industrial environment.

Moreover, the system may only be started up, if the following

regulations are adhered to:

■The product must only be installed or operated in a non-

explosive atmosphere.

■The product and all components may only be used while in

perfect condition.

■All safety devices must be in perfect condition.

■The product may only be operated with the components

belonging to the system. The only third-party components

exempt from the above are those supplied by BST or explicitly

approved for use with the system.

■Parts that are not in perfect condition must immediately be

replaced with original spare parts.

■All work on or with the product may only be performed by

instructed and qualified personnel, see chapter Qualification of

the Personnel, page 15.

■Always adhere to this operating manual and all safety instruc-

tions.

■The operating conditions and performance limits indicated in

the technical data must be observed.

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