BST Ekr 500 Manuel utilisateur

Web Guiding System

Operating Manual

ekr 500 digital Unit Touch

MD.492.EN.07

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 – Operating Manual iii

Table of contents

1 About This Document........................................................................................ 6

1.1 What You Need to Know............................................................................................... 6

1.2 Target Group................................................................................................................. 6

1.3 Storage and Distribution............................................................................................... 6

1.4 Meanings of the Safety Instructions and Symbols........................................................ 6

1.4.1 Safety Instructions ........................................................................................................ 6

1.4.2 Symbols......................................................................................................................... 7

1.4.3 Operation Using Keys.................................................................................................... 7

1.5 More Detailed Information........................................................................................... 8

2 About Safety ..................................................................................................... 9

2.1 Intended Use................................................................................................................. 9

2.2 Non-intended Use....................................................................................................... 10

2.2.1 Non-intended Infringement of Guidelines.................................................................. 10

2.2.2 Non-intended Operation............................................................................................. 10

2.2.3 Non-intended Modification of Electronic Data........................................................... 11

2.3 Safety Instructions ...................................................................................................... 12

2.3.1 General Safety Instructions......................................................................................... 12

2.4 Qualification of the Personnel .................................................................................... 14

2.5 Duties of the Operating Company and Personnel ...................................................... 15

2.5.1 Duties of the Operating Company .............................................................................. 15

2.5.2 Duties of the Personnel............................................................................................... 16

2.6 Conduct in the Event of Danger and Accidents .......................................................... 16

2.7 Personal Protective Equipment .................................................................................. 17

2.8 Guarantee and Liability............................................................................................... 17

2.8.1 Disclaimer ................................................................................................................... 17

2.8.2 Exceptions to the Disclaimer....................................................................................... 18

2.8.3 License and Liability for Software Supplied ................................................................ 18

3 Design and Function.........................................................................................19

3.1 Design ......................................................................................................................... 19

3.1.1 Controller.................................................................................................................... 19

3.1.2 Control Panel .............................................................................................................. 19

3.2 Function ...................................................................................................................... 20

3.3 Guiding Modes............................................................................................................ 21

3.4 Special Guiding and Monitoring Functions ................................................................. 21

3.4.1 Watchdog.................................................................................................................... 21

3.4.2 Overlaid Web Edge/Web Center-Line Guiding with CLSCAM100 Object Sensor...... 22

3.4.3 Speed Dependent Guiding .......................................................................................... 22

3.4.4 Oscillation ................................................................................................................... 22

3.4.5 Speed-Dependent Oscillation ..................................................................................... 22

3.4.6 Master-Slave Guiding.................................................................................................. 22

3.4.7 Tear-Off Detection ...................................................................................................... 23

3.4.8 Web Width Measurement .......................................................................................... 23

3.4.9 Line Width Measurement ........................................................................................... 23

3.5 Motorized Sensor Positioning..................................................................................... 24

3.5.1 Sensor Positioner ........................................................................................................ 24

3.5.2 Positioning Unit........................................................................................................... 24

3.6 Control and Display Elements..................................................................................... 25

3.6.1 Touchscreen Display ................................................................................................... 25

3.6.2 Keys............................................................................................................................. 25

3.7 Designation of the Sensors ......................................................................................... 26

3.7.1 Edge Sensors (Sensor1/2) .......................................................................................... 26

3.7.2 Line, Contrast and Object Sensor (Sensor3)............................................................... 27

3.7.3 CCD Cameras (Sensor 1/2) .......................................................................................... 28

3.8 Nameplates................................................................................................................. 29

Table of contents

iv ekr 500 digital Unit Touch – Operating Manual

4 Technical Specifications ...................................................................................30

5 Operation ........................................................................................................31

5.1 Safety Instructions ...................................................................................................... 31

5.2 ekr commander Control Panel.................................................................................... 31

5.3 Touchscreen Operation .............................................................................................. 33

5.3.1 Switching Functions On / Off ...................................................................................... 33

5.3.2 Editing Numerical Values ............................................................................................ 33

5.4 Access to the Online Documentation ......................................................................... 35

5.5 Operation Display ....................................................................................................... 35

5.5.1 Overview..................................................................................................................... 35

5.5.2 Edge Sensors Operation Display (Sensor 1/2)............................................................. 42

5.5.3 CLS Pro 600 Line and Contrast Sensor Operation Display (Sensor 3).......................... 43

5.5.4 CLS CAM 100 Object Sensor Operation Display (Sensor 3)......................................... 45

5.5.5 CCD Cameras Operation Display................................................................................. 47

5.5.6 Actuator Operation Display ........................................................................................ 51

5.6 Configurable Displays and Setting Menus................................................................... 52

5.7 Performing the Material Setup ................................................................................... 54

5.7.1 Overview..................................................................................................................... 54

5.7.2 Activating the Material Setup ..................................................................................... 57

5.7.3 Cancelling Material Setup ........................................................................................... 58

5.7.4 Automatic Material Setup........................................................................................... 58

5.7.5 Manual Material Setup ............................................................................................... 59

5.8 Selecting the Operating Mode for the IR 2011/40 Edge Sensor ................................. 60

5.8.1 Function ...................................................................................................................... 60

5.8.2 Requirements.............................................................................................................. 60

5.8.3 IR 2011/40 Operating Modes...................................................................................... 60

5.8.4 Operating Mode Selection.......................................................................................... 62

5.9 Selecting the Guiding Mode........................................................................................ 63

5.10 Selecting the Operating Mode.................................................................................... 64

5.10.1 Manual Mode.............................................................................................................. 64

5.10.2 Automatic ................................................................................................................... 65

5.10.3 Center Positioning....................................................................................................... 65

5.11 Setting the Guiding Setpoint....................................................................................... 66

5.11.1 Adjusting the Guiding Setpoint with the Arrow Keys.................................................. 69

5.11.2 Adjusting the Guiding Setpoint with the Setting Menu .............................................. 70

5.11.3 Accepting Current Position of a Web Edge as Guiding Setpoint................................. 71

5.11.4 Saving and Loading the Guiding Setpoint ................................................................... 73

5.11.5 Entering an Offset Value for the Guiding Setpoint ..................................................... 75

5.12 Optimizing the Controller Gain ................................................................................... 77

5.12.1 Adjusting the Controller Gain with the Arrow Keys.................................................... 78

5.12.2 Adjusting the Controller Gain via the Touchscreen .................................................... 78

5.13 Special Guiding and Monitoring Functions ................................................................. 79

5.13.1 Watchdog.................................................................................................................... 79

5.13.2 Overlaid Web Edge/Web Center-Line Guiding with CLS CAM 100 Object Sensor...... 82

5.13.3 Speed-Dependent Guiding.......................................................................................... 85

5.13.4 Master-Slave Guiding.................................................................................................. 86

5.13.5 Tear-Off Detection ...................................................................................................... 89

5.13.6 Oscillation ................................................................................................................... 91

5.13.7 Speed-Dependent Oscillation ..................................................................................... 97

5.13.8 Web Width Measurement ........................................................................................ 100

5.13.9 Line Width Measurement ......................................................................................... 108

5.14 Sensor Positioner ...................................................................................................... 110

5.14.1 Utilization.................................................................................................................. 110

5.14.2 Operation Display ..................................................................................................... 111

5.14.3 Operation.................................................................................................................. 112

5.15 Positioning Unit......................................................................................................... 115

5.15.1 Utilization.................................................................................................................. 115

5.15.2 Requirements............................................................................................................ 116

Table of contents

ekr 500 digital Unit Touch – Operating Manual v

5.15.3 Operation.................................................................................................................. 116

5.16 Calling up the Setup Menu........................................................................................ 120

5.17 Switching the Configurable Displays and Setting Menus On/Off.............................. 123

5.18 Service Displays......................................................................................................... 124

5.18.1 Displaying System Information ................................................................................. 125

5.18.2 Displaying System Components................................................................................ 126

5.18.3 Displaying Switch Positions....................................................................................... 128

5.18.4 Displaying a Link to the Company Website............................................................... 129

5.18.5 Displaying Service QR Code....................................................................................... 130

5.19 Fault Displays ............................................................................................................ 132

5.19.1 Limit Switch Active.................................................................................................... 132

5.19.2 Actuator Blocked (Motor Overcurrent) .................................................................... 132

5.19.3 Supply Voltage Outside the Permissible Range ........................................................ 133

5.19.4 Motor Control Timeout............................................................................................. 133

5.19.5 Controller Interlock Active........................................................................................ 134

5.19.6 Keyboard Interlock Active......................................................................................... 135

5.19.7 Setup Lock Active...................................................................................................... 135

5.19.8 Bus Connection Fault ................................................................................................ 136

5.19.9 Edge Sensor Malfunction .......................................................................................... 136

5.19.10 Loss of the Line / Contrast Transition (Sensor CLS Pro 600) ..................................... 137

5.19.11 Loss of the Guiding Criterion (Object Sensor CLS CAM 100)..................................... 137

5.19.12 Loss of the Web Edge (CCD Camera) ........................................................................ 138

5.19.13 External Motor Output Stage Fault (Drive Module 160)........................................... 138

5.20 Electronic Remote Precision Adjustment (Option) ................................................... 139

5.20.1 EFE 1.......................................................................................................................... 139

5.20.2 EFE 1000.................................................................................................................... 139

5.21 Extended Device Settings.......................................................................................... 140

5.21.1 Editing the Parameter Value..................................................................................... 140

5.21.2 Public Parameters Lists ............................................................................................. 142

5.22 Restoring Factory Default Settings............................................................................ 147

6 Maintenance and Cleaning.............................................................................148

6.1 Safety Instructions .................................................................................................... 148

6.2 Maintenance Table ................................................................................................... 149

6.3 Maintenance and Cleaning work .............................................................................. 149

6.3.1 Cleaning the Controller Housing ............................................................................... 149

6.3.2 Cleaning the Control Panel Housing.......................................................................... 149

6.3.3 Cleaning the Edge Sensor Housing............................................................................ 150

6.3.4 Cleaning the Housing of the CLS Pro 600 Line and Contrast Sensor......................... 150

6.3.5 Cleaning the Housing of the CLS CAM 100 Object Sensor ........................................ 150

6.3.6 Cleaning the Housing of the CCD Camera................................................................. 150

6.3.7 Cleaning the Electric Motor Powered Actuator Housing .......................................... 150

6.3.8 Cleaning the Sensor Positioner Housing ................................................................... 151

7 Troubleshooting.............................................................................................152

8 Customer Services..........................................................................................158

9 Shutting Down and Disposal...........................................................................159

Index..............................................................................................................160

1About This Document

6/163 ekr 500 digital Unit Touch – Operating Manual

1 About This Document

1.1 What You Need to Know

These instructions help you to work with the system in a safe,

simple and successful manner.

The following instructions must be observed in order to avoid

hazards and incorrect operation:

■Every user 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.

1.2 Target Group

These instructions are directed to all persons that work with or on

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.

About This Document 1

ekr 500 digital Unit Touch – Operating Manual 7/163

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.

1About This Document

8/163 ekr 500 digital Unit Touch – Operating Manual

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

Installation and commissioning manual

ekr500digitalUnitTouch MD.497

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

About Safety 2

ekr 500 digital Unit Touch – Operating Manual 9/163

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 in-

structed and qualified personnel, see chapter Qualification of

the Personnel, page 14.

■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.

2About Safety

10/163 ekr 500 digital Unit Touch – Operating Manual

2.2 Non-intended Use

Every use is non-intended, that is not described in the chapter

Intended Use or does not comply with the guidelines specified

there, see Intended Use, page 9.

2.2.1 Non-intended Infringement of Guidelines

■Infringement of operating, maintaining or installation instructions

■Unsuitable, incorrect or unauthorized use of the product

■Operating the product in an environment not intended for its

use

■Operating the product in breach of the legal safety guidelines

relevant at the location of use

■Neglecting the warning and safety instructions in the relevant

documents for the product

■Operating the product under faulty safety and protective condi-

tions

2.2.2 Non-intended Operation

■Operation by unauthorized or insufficiently qualified personnel

■By-passing, disassembling, switching off or manipulation of

safety equipment

■Incorrect or negligent handling by the customer

■Any intervention, modification or conversions on the product

without the express approval of BST GmbH

■The use of unsuitable operating materials or spare parts

■Operation of the product near to sources of interference, e.g.

electro-magnetic fields (high voltage lines) or sources of heat

■Operation of the product under the influence of chemical,

electro-chemical or electrical factors

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