ekr 500
Web guiding controller
with removable control panel
Operating Manual
BST International GmbH
Heidsieker Heide 53
33739 Bielefeld, Germany
Phone: +49 5206/999 – 0
Telefax: +49 5206/999 – 999
E-Mail: info@bst-international.com
The information and drawings contained in this document are the property of BST International GmbH. Any reproduction
of this document as a whole or in part without the written permission of BST International GmbH is prohibited.
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Issue:
29.07.2008
Content
0
Content
ekr 500 web guiding controller
with removable control panel
1
1.1
1.1.1
1.1.2
1.1.3
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.5
1.5.1
1.5.2
1.6
1.6.1
1.6.2
1.7
1.8
1.9
1.10
Description
Symbols used in this manual
Warning signs
Using the keys
LED operating status indications
General
Intended use
System description
System structure
Functional principle
Connectable components
Terms used
Set position
Sensor 1 / Sensor 2
Control panel
Graphical display
Control panel
Safety information
ESD protection
Emissions
RoHS conformity
1
1
1
1
1
2
3
4
4
5
5
6
6
7
8
8
8
10
12
12
12
2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.3
2.3.1
2.3.2
2.4
2.5
Technical Data
Controller
Ambient conditions
Protection class
Power supply (terminal strip X6)
Analogue inputs (terminal strip X1, X2, X3)
Digital inputs (terminal strip X14)
Ouput motor output stage (terminal strip X7)
Output fault relay (terminal strip X10)
Control panel interface (terminal strip X8)
Weight, dimensions
Control panel
Ambient conditions
Protection class
Power supply
Display
Weight, dimensions
Sensors
Infrared sensors
Ultrasonic sensors
Electric-motor-driven actuators
Power pack
13
13
13
13
13
13
14
14
14
15
15
16
16
16
16
16
16
18
18
18
19
20
3
3.1
3.2
Transport
Transport
Storage
21
21
21
4
4.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
Assembly
Installation site requirements
Assembly of the controller
General
Mounting plan
Space needed to open the enclosure cover
Mounting
Turning the control panel
22
22
23
23
23
23
24
25
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Content
4.3
4.3.1
4.3.2
4.3.3
Assembly of the control panel
General
Wall mounting
Control console mounting
26
26
27
29
5
5.1
5.2
5.3
5.4
5.5
5.5.1
5.5.2
5.5.3
5.6
5.6.1
5.6.2
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
Installation
General
Fitting the cable connections
Installation instructions for EMC-wiring
Overview processor board
Terminal assignment
Terminal overview
Terminal assignment
Plug assignments
Set DIL switches
DIL switch S4
DIL switch S5
Service indications
LEDs “Bus status”
LEDs “Device status“
LEDs “Power supply“
LEDs “Controller interlock“/ “OK signal“
LEDs “Remote control“
31
31
31
32
33
34
34
35
38
40
40
41
42
42
42
43
43
43
6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
44
44
44
45
45
6.2
6.3
6.4
Start-up
Start-up actuator
General
Determine sense of motor rotation
Determine guiding direction
Actuator without position feedback
(EMS 5 / 10 / 16)
Actuator with position feedback
(EMS 17, EMS 21, EMS 22)
Carry out material setup
Adjustment of gain
Start-up electronic remote precision adjustment (option)
48
52
53
54
7
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.3
7.3.1
7.3.2
7.3.3
7.4
7.5
7.6
7.7
Operation
Operation display
Basic display
Special displays
Material Setup
General
Activate material setup
Procedure for web edge guiding
Procedure for web center-line guiding
Operating mode selection
Manual positioning
Automatic guiding
Center positioning
Setting the web set point
Optimise gain
Display of system information
Electronic remote precision adjustment (option)
55
55
55
56
60
60
61
62
64
68
68
68
68
69
71
72
73
8
Remote control
74
6.1.5
ekr 500 web guiding controller
with removable control panel
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46
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Content
ekr 500 web guiding controller
with removable control panel
0
9
9.1
9.1.1
9.1.2
9.2
9.2.1
9.2.2
9.3
Default settings
Device addresses
Device address of the controller
Device address of the control panel
Keyboard bus terminating resistors
Controller terminating resistor
Control panel terminating resistor
Generating the default settings
75
75
75
76
77
77
78
79
10
Trouble shooting
80
11
11.1
11.2
11.3
11.4
11.5
Maintenance
General
Controller
Control panel
Sensors
Electric-motor-driven actuator
84
84
84
84
85
85
12
Decommissioning
86
I
Index
A1
Annex 1
Connecting plan
A1
EDV No.: MD.299.01.06
Issue:
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Description
1
12
1 Description
1.1
Symbols used
in this manual
1.1.1 Warning signs
Symbols are used in this operating manual in order to clearly
indicate particularly important places.
!
Attention!
You must obey this type of warning, in order to protect
yourself, as the operator, from bodily injuries arising
from mechanical movements.
Beware!
You must obey by this type of warning without fail, in
order to protect yourself, as the operator, from life
threatening injuries caused by electrical voltages.
Note
This symbol is used to point out additional useful tips,
which will help you to make optimum use of all of the
functions.
1.1.2 Using the keys
Using the keys is represented by the following symbols in this
manual:
Press key.
Key combinations, keys have to be
pressed simultaneously.
1.1.3 LED operating status
indications
Some keys on the control panel have LED’s (light-emitting diodes)
integrated in them. The different LED operating states are
represented as follows:
LED off
LED constantly lit = activated phase
LED flashing
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with removable control panel
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Description
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12
1.2
General
!
The start-up, maintenance and installation
instructions described in this operating manual
must be strictly adhered to!
• The ekr 500 web guiding controller must be mounted and
operated only according to the knowledge of the relevant
operating manual.
This will help avoiding hazards and preventing damages to the
controller caused by improper assembly or operation.
• This operating manual, and particularly the safety instructions
must be observed by all persons working on or with the ekr 500
controller.
• Before operating the system for the first time as well as
before carrying out maintenance work you must read the
safety information provided by chapter 1.7 of this manual!
• Changing or loading firmware on this system must be carried
out exclusively by BST personnel or personnel duely
authorised to do so by BST. Non observance of this may
cause the loss of the warranty rights!
• The values and data shown in this manual (e. g. in the display)
are to be considered as examples, unless otherwise expressly
stated.
• The current version of the operating manual for the web guiding
controller ekr 500 in all available languages can be found on the
Internet at the following address:
http://www.bst-international.com
ekr 500 web guiding controller
with removable control panel
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Description
1
12
1.3
Intended use
The ekr 500 is a microprocessor-controlled web guiding controller
with removable control panel. It may be used for
• web edge guiding
(guiding to the right or left web edge)
• web center-line guiding
The web guiding controller ekr 500 has been designed to be
installed in another machine or to be integrated with other
machines to form a single system in compliance with directive
98/37/EU (Machinery Directive).
It is forbidden to commission the system until the user/operator has
determined that the machine in which the system has been
installed, complies with the specifications given in this directive.
You are only allowed to use BST web guiding systems to correct
the position of web-shaped materials (e.g. those made from paper,
film, cardboard, rubber, etc.).
The controller and the control panel must never be installed in
potentially explosive areas.
Operation is only guaranteed if carried out using the BST web
guiding components listed in chapter 1.4.3 (“Connectable
components“).
BST web guiding systems have been designed and built in
accordance with state-of-the-art standards and the recognized
safety rules.
Nevertheless, its use may constitute a risk to life and limb of the
user or of third parties or damage the BST web guiding systems
and other equipment.
Therefore BST web guiding systems are only to be used if they are
working correctly and in a safe technical condition. Any part found
to be working incorrectly must be replaced immediately.
Only original spare parts are to be used for this. Spare parts
obtained from third parties cannot be guaranteed to comply with
the design and manufacturing conditions and safety regulations.
In this case any guarantee claims made against the BST web
guiding system will be invalidated.
Only qualified personnel who have been trained on the system are
allowed to undertake any work required on the BST web guiding
system (i.e. installation, commissioning, operation, maintenance, etc.).
Intended use also includes adhering to the instructions given in this
operating manual.
Using the machine for purposes other than those mentioned above
is contrary to its intended use. BST International GmbH does not
accept liability for any damage resulting from this type of use.
ekr 500 web guiding controller
with removable control panel
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Description
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12
1.4
System description
1.4.1 System structure
1.4.1.1
General
The ekr 500 consists of the controller and the removable control
panel.
The controller enclosure contains all of the control electronics and
the connections for all of the necessary web guiding components
(sensors, actuator, servo center transducer, remote control).
1.4.1.2
Controller with mounted
control panel
Controller operation is carried out via the control panel that was
attached to the front of the controller in the factory.
Controller with mounted control panel
1.4.1.3
Controller with removed
control panel
If the installation requires a remote mounting of the control panel
due to space or access limits in the machine, it can be removed
und remotely mounted in the machine operator control station.
In this case the connection between the controller and control
panel is made using a cable extension that is available as an
optional extra.
Controller
Control panel
Cable extension
(2 m, 5 m, 10 m)
Controller with removed control panel
The length of the cable used to connect the control
panel to the controller must never exceed 20 m.
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with removable control panel
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Description
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12
1.4.2 Functional principle
In automatic mode one or two edge sensors connected to the
controller scan the actual position of the web of material and
transmit this information to the position controller.
The position controller compares the actual position measured
against the required set position. If there is a difference between
the two values then the controller transmits a correction signal to
the actuator of the guiding device.
The actuator moves the guiding device (rotating frame guide or
swivel roll guide) until the web of material is in its set position again.
1.4.3 Connectable components
The picture shows the components that can be connected to the
controller.
Controller
ekr 500
Controller with
removed control panel
24 V DC
EMS 5, EMS 10, EMS 16
IR 2001
IR 2002
IR 2005
OMG 4,
OMG 8
Actuator without
position feedback
Analogue edge sensors
Servo-center
transducer
US 2003
US 2007
US 2008
US 2009
EMS 17,
EMS 21,
EMS 22
OK signal
Actuator with
position feedback
Remote control, keyboard lock
EFE 1
— optional —
EFE 1000
Electronic remote precision adjustment
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Description
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12
1.5
Terms used
1.5.1 Set position
The set position is the required position for the web of material in
the sensor scanning area. It can be set up in “Automatic“ mode
using the control panel arrow keys (see chapter 7.4).
The set position setting will be marked on the control panel display
by a white triangle being superimposed around the sensor symbol.
Set position = Actual position
Relative coverage of the
sensor scanning area
Deviation between
set and actual position
Center of
sensor scanning area
The relative coverage of the sensor scanning area will be
displayed as a percentage beneath the sensor symbol.
Examples:
Sensor scanning area
Web of material
0% covering
No material within
the sensor scanning area.
50% covering
Only one half of the sensor
scanning area is covered.
100% covering
Sensor scanning area is fully
covered.
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with removable control panel
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1
Description
12
1.5.2 Sensor 1 / Sensor 2
In this operating manual, the sensors that are connected to the
controller are designated with “sensor 1“ and “sensor 2“.
According to the BST definition, the following link applies between
the selection buttons for the guiding mode and the sensors:
= Sensor 1 (left web edge)
= Sensor 2 (right web edge)
The following is valid in respect of the sensor mounting positions:
The sensor, which is located to the left of the material in the
web running direction (when looking from the material top
side), is sensor 1.
The material top side is the side of the material web which is not in
direct contact with the deflection pulleys of the guiding device.
Example 2:
Example 1:
Example 3:
Deflection pulley
Pivot
Sensor 2
Sensor 1
Sensor 2
Sensor 1
Sensor 1
Sensor 2
Guiding device
As standard, sensor 1 must be connected to terminal strip X1,
while sensor 2 must be connected to terminal strip X2 of the
controller (see terminal assignments, chapter 5.5).
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Description
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1.6
Control panel
The control panel contains all of the operating and display controls
needed to operate the web guiding system.
The signal settings on the controller’s remote
control inputs block any keys on the control panel
that have counter functions.
1.6.1 Graphical display
The different operating statuses and all the relevant control
parameters are displayed on the control panel’s graphics display
during operation.
The symbol significances are described in chapter 7.1.
1.6.2 Control panel
Located on the control panel are four different key groups that
have the following functions:
Green keys:
Operating mode selection
Grey keys:
Guiding mode selection
Blue keys:
Setup mode
White keys:
Manual positioning of the guiding device,
Guiding setpoint and gain adjustment,
Changing of parameter values
You will find the separate key significances listed in the table on
the following page.
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Description
12
Function
Key
Designation
Automatic
Operating mode
selection
Guiding mode
selection
Description
Automatic web guiding
Manual mode
Manual positioning
of the guiding device
Servo-center
Center positioning
of the guiding device
Sensor 1
Guiding to the left web edge
Sensor 2
Guiding to the right web edge
Web center-line guiding
Manual positioning
of the guiding
device
Arrow key
left / right
Operating mode “Manual“:
• Manual positioning of the guiding
device to the left/right
Shifting of the
guiding setpoint
Arrow key
left / right
Operating mode “Automatic“:
• Shifting of the guiding setpoint
to the left/right
Operating mode “Manual“:
• Call up setup selection menu
SETUP
Operating mode “Automatic“:
• Activate gain adjustment
Setup mode
ENTER
Arrow key
ekr 500 web guiding controller
with removable control panel
• Store value
and exit setup mode
• Decrease/increase
parameter value
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1
Description
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12
1.7
Safety information
The safety relevant information in accordance with DIN EN 294,
DIN EN 349 and the industry specific safety regulations must be
taken into consideration when installing the BST equipment in the
production machine, these include:
• There must be a safe distance between the BST equipment and
the machinery already installed on-site, such as machine
panels, building structure, etc.
• Connection lines between the individual system components
must be laid so that nobody can trip over them, not pulled tight
and well anchored down.
• Ensure that there is sufficient free headroom.
If the height of free passage is restricted, the relevant building
components causing the restrictions must be padded and a
danger warning signs must be attached to them (yellow/black).
• As a matter of course, cable connectors (e. g. between
controller and sensors) should only be disconnected when the
system is no longer connected to the mains supply (mains plug
has been removed). Any infringements will result in the
warranty claim being invalidated.
• In principle, the controller does not have ATEX certification, i.e.
you are not permitted to use it in area where the danger of an
explosion exists!
• Any transport safety devices that were used must be removed
prior to commissioning.
ekr 500 web guiding controller
with removable control panel
!
Only trained specialist personnel are permitted to
undertake the assembly, installation and
commissioning!
!
Danger of cuts!
Never touch the edges of moving webs of material!
!
Danger of crushing!
Never reach inbetween the fixed lower frame and the
moving upper frame of the guiding device (rotating
frame guide or swivel roll guide).
Never reach into the moving rolls!
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Description
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12
Please do not open the controller until the line voltage
is switched off.
When operation at open unit is necessary, only
protection class IP 20 is present.
There will be an increased risk of danger by line
voltage!
Before starting work, ensure the equipment is
electrically isolated. To this end always carry out the
following measures:
1.
2.
3.
4.
5.
Switch off.
Prevent switching back on.
Check the equipment is isolated.
Earth.
Cover or shield any adjacent parts that are still live.
Only then you can carry out the relevant work.
!
!
ekr 500 web guiding controller
with removable control panel
Please do not use the guiding frame as a tread or a
Stepp ladder.
Do not remove any safety devices.
Positioning movements will be undertaken by the
actuator during functional testing away from the
production machine and/or during the commissioning!
The relevant safety arrangements must be
implemented during performance checks!
Monitor the overall safety concept of the production
machine during commissioning!
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Description
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12
1.8
ESD protection
Attention!
Hazards caused by electrostatic discharge
(ESD = Electro Static Discharge).
The device contains components which can be damaged by
electrostatic discharge. This component can receive permanent
damage, which can lead to loss of performance, failure or destruction
of the part, if it contacts electrostatically-charged persons or objects.
System component housings may only be opened at an ESDprotecting workplace (ESD workplace in accordance with
DIN EN 61340-5-1). If there is no ESD-protected workplace
available, ESD precautionary measures in accordance with
DIN EN 61340-5-1 must be taken to ensure that electrostatic
charges are carefully discharged.
If making return shipments of electronic components or assemblies,
regulations in accordance with DIN EN 100 015 “Protection of
electrostatically-endangered components“ must be observed.
You should therefore only use the electrically conductive ESD
packaging provided for transport, and label it correctly.
BST International GmbH is not liable for any damages caused
by the nonobservance of the ESD protective measures
described here.
1.9
Emissions
The A-related equivalent continuous sound level of the equipment
is less than 70 dB(A).
1.10 RoHS conformity
We hereby declare that the ekr 500 web guiding controller does not
exceed the hazardous substance limits stipulated in EU Directive
2002/95/EU*.
*
ekr 500 web guiding controller
with removable control panel
EU Directive for restricting the use of specific hazardous
substances used in electrical and electronic equipment,
“RoHS Directive“ (Restriction of Hazardous Substances).
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Technical Data
2
8
2 Technical Data
2.1
Controller
2.1.1 Ambient conditions
Environment temperature
in operation:
0 ... 45°C
Storage temperature:
- 10°C ... + 70°C
Air humidity in operation:
5 ... 90%, without condensing
Protection class:
IP 54
(considering the installation site
requirements, see chapter 4.1)
Voltage:
24 V DC ± 10% (including ripple)
Power consumption:
max. 4 A (including actuator)
Connection:
plugged in from the outside using a
3-pin plug as per CEN 175301-803
(DIN 43650)
2.1.2 Protection class
2.1.3 Power supply
(terminal strip X6)
2.1.4 Analogue inputs
(terminal strip X1, X2, X3)
Sensors (terminal strip X1, X2)
Signal input sensor 1/2:
0 ... 10 V, ± 10 V or 0 ... 20 mA
(selectable via DIL switch)
Power supply:
± 12 V ± 5%
< 50 mA (+12 V)
< -50 mA (-12 V)
+24 V DC / max. Σ 0,5 A
IR pulses:
for IR 2001, IR 2002, IR 2005
+5 V (length ≈250 µs)
Connection:
internal on cage clamp
Position feedback EMS 17/21/22, servo-center transducer OMG 4,
remote precision adjustment EFE 1 (terminal strip X3)
ekr 500 web guiding controller
with removable control panel
Signal input:
± 10 V
Power supply:
± 12 V
Connection:
internal on cage clamp
Maximum power supply
(X1 + X2 + X3)
max. Σ +12 V: 150 mA
max. Σ -12 V: 100 mA
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Technical Data
2
8
Servo-center transducer OMG 8 (terminal strip X10)
Signal input:
according to Namur specification
Power supply:
according to Namur specification
Connection:
internal on cage clamp
2.1.5 Digital inputs
(terminal strip X14)
Remote control, remote
precision adjustment EFE 1000: < 4 V (Low), > 8 V (High)
(terminal 74 – 81)
Controller interlock:
< 4 V (Low), > 8 V (High)
Switched via the hardware, i.e. not
via the processor or the software.
Galvanic isolation:
none!
Connection:
internal on cage clamp
Voltage:
± 24 V DC
(reduces the actuator’s maximum
actuating force if a lower supply
voltage is used)
Power consumption:
max. 1.2 A (peak current 4 A)
Protection:
Automatic electric switching off
after approx. 400 ms if overcurrent
occurs with motor current in one
direction (no polarity change):
> 1.9 A (EMS 21, EMS 22)
> 1.1 A (EMS 10, EMS 16, EMS 17)
> 0.4 A (EMS 5)
Connection:
internal on cage clamp
Voltage:
max. +24 V AC/DC
Power consumption:
max. 1 A
Connection:
internal on cage clamp
2.1.6 Ouput motor output stage
(terminal strip X7)
2.1.7 Output fault relay
(terminal strip X10)
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Technical Data
2
8
2.1.8 Control panel interface
(terminal strip X8)
Voltage:
+ 24 V DC
(corresponds to the supply voltage)
Power consumption:
max. 0.5 A
(protected by Polyfuse)
Bus interface:
500 kBaud,
no galvanic isolation
Connection:
plugged in from the outside using a
4-pin micro style M8 connector
Weight:
approx. 1.18 kg
(controller without control panel)
Dimensions:
See page 17
2.1.9 Weight, dimensions
ekr 500 web guiding controller
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Technical Data
2
8
2.2
Control panel
2.2.1 Ambient conditions
Environment temperature
in operation:
0 ... 45°C
Storage temperature:
- 10°C ... + 70°C
Air humidity in operation:
5 ... 90%, without condensing
Protection class:
IP 54
Protection class:
IP 50
2.2.2 Protection class
If the controller is installed with
mounted control panel the whole
unit is classed as protection class
IP 54.
2.2.3 Power supply
Voltage:
+ 24 V DC
(power supplied by the controller)
Resolution:
128 x 64 pixel,
LED background illumination
Weight:
approx. 0.26 kg
Dimensions:
See page 17
2.2.4 Display
2.2.5 Weight, dimensions
ekr 500 web guiding controller
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2
Technical Data
8
Dimensions (details in mm)
61
182
6
130
6
45
Controller
with mounted
control panel:
169
182
55
130
6
45
Controller
without
control panel:
169
105
Control panel:
6
93
105
93
21
ekr 500 web guiding controller
with removable control panel
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Technical Data
2
8
2.3
Sensors
2.3.1 Infrared sensors
IR 2001
IR 2002
Power supply
IR 2005
from the controller
Gap (standard)
30 mm
30 mm
30 mm
Measuring range, typical
12 mm
6 mm
12 mm
Max. sensing range, typical
15 mm
8 mm
15 mm
Output
analogue
Protection class
IP 54
Ambient conditions
• Temperature
0 to a max. 45 °C
5 – 90%, no condensation
• Air humidity
2.3.2 Ultrasonic sensors
US 2003
US 2007
Power supply
US 2008
US 2009
from the controller
Gap (standard)
30 mm
40 mm
30 mm
40 mm
70 mm
Measuring range, typical
12 mm
12 mm
6 mm
12 mm
14 mm
Max. sensing range, typical
15 mm
15 mm
7 mm
13 mm
15 mm
Output
Protection class
analogue
IP 54
IP 67
0 to a max. 45 °C
5 – 90%,
no condensation
0 to a max. 60 °C
5 – 90%,
no condensation
Ambient conditions
• Temperature
• Air humidity
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Technical Data
2
8
2.4
Electric-motor-driven
actuators
Type
Stroke
Gear
ratio
[mm]
EMS 5
Spindle
Max.
Max.
dimensions actuating force actuating speed
[mm]
[N]
[mm/s]
20
1:1
8x1
80
17
1:1
12 x 2
420
20
2,4 : 1
420
20
5:1
840
10
420
20
840
10
2,4 : 1
420
20
5:1
840
10
2,4 : 1
420
20
5:1
840
10
420
20
840
10
2,4 : 1
420
20
5:1
840
10
2,5 : 1
840
20
1680
10
840
20
5:1
1680
10
2,5 : 1
1125
20
2250
10
40
EMS 10
16
32
46
56
76
96
146
EMS 16
50
100
200
EMS 17
50
100
200
EMS 21
100
200
EMS 22
200
2,4 : 1
5:1
2,4 : 1
5:1
5:1
2,5 : 1
16 x 5
16 x 5
20 x 5
20 x 5
5:1
ekr 500 web guiding controller
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Technical Data
2
8
2.5
Power pack
For the power supply for the controller including the connected
BST components only the following power packs may be used:
• Power pack supplied by Puls GmbH, type ML100.100,
BST order number 103 837
or
• Power packs with the following specifications:
- Output voltage:
- Output power:
24 V DC
± max. 10% (including ripple)
max. 100 W
The power packs must meet all requirements of IEC 61010-1
for energy-limited circuits (section 9.3).
If used in countries, which have defined discrepancies from
IEC 61010-1, then these are to be observed.
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Transport
3
1
3 Transport
3.1
Transport
The equipment will be shipped in accordance with the details
stipulated in the order:
• completely assembled and interconnected to the web guiding
system
• as component parts in standard cardboard boxes with cellular
lining material
The unit must only be transported when it is packed in the original
BST transport packing.
BST International GmbH cannot be held liable for damage to
the controller or control panel which is caused by an
inappropriate transport packaging!
3.2
Storage
If the controller and the control panel will not be incorporated
immediately, they should be stored in a dry room until installation.
Storage conditions:
ekr 500 web guiding controller
with removable control panel
Temperature:
Air humidity:
EDV No.: MD.299.01.06
Date:
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10°C to a max. 70°C
10 - 90%,
no condensation
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Assembly
4
9
4 Assembly
4.1
Installation site
requirements
Adhere to the following points when choosing the location of the
controller and the control panel:
• The controller and the control panel must be installed in a dry,
vibration-free area and be ergonomically positioned.
The operator must be able to access the control panel easily.
Sunrays or external light sources must not cause reflections on
the display.
• The controller and the control panel must be installed on a
vertical surface (upright).
Installation on a horizontal surface (horizontal ) is not permitted!
Upright installation
Horizontal installation
(not permitted!)
• Strong electromagnetic fields in the vicinity of the controller, the
control panel or the sensors might cause operating failures.
• Take note of the permitted ambient conditions.
Temperature: 0 to a max. 45°C
Air humidity:
5 - 90%, no condensation
See chapter 2.1.1 as well.
• The controller and the control panel do not have ATEX
certification, i.e. you are not permitted to use them in area
where the danger of an explosion exists!
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Assembly
4
9
4.2
Assembly of
the controller
4.2.1 General
This chapter describes the procedure for installing a controller with
a mounted control panel.
4.2.2 Mounting plan
182
M5 or Ø 6
Controller
housing
130
45
169
4.2.3 Space needed to open the
enclosure cover
The necessary space around the enclosure must be maintained so
that the enclosure cover can be fully opened (see illustration).
Enclosure cover
ekr 500 web guiding controller
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Controller
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Assembly
4
9
4.2.4 Mounting
1. Drill the securing holes as
shown in the mounting plan
(see chapter 4.2.2).
2. Unscrew the enclosure cover
screw and then open the cover
carefully.
3. Screw on the enclosure using
two securing screws
(M5 hexagon socket screws).
Enclosure cover
Securing screw
4. Wire in the electric cables
(if required) or plug in the
necessary cable connections
(see chapter 5).
Take note of the EMC wiring
instructions (see chapter 5.3)!
5. Close the enclosure cover and
screw it in place.
6. If necessary you can position
the control panel so that it is
aligned with the controller
installation position
(see chapter 4.2.5).
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4
Assembly
9
4.2.5 Turning the control panel
The controller can be installed in four different positions
(see illustration).
Upright mounting
Horizontal mounting
1
2
3
4
BST
BS T
BS T
BST
BST
BST
Cable feeds
The controller is prepared for installation in position 1 when it is
delivered to you. The control panel is mounted at the front of the
controller.
If the controller has to be installed in another position then the
position of the control panel must be moved accordingly.
The relevant procedure is described in the following.
Securing screws
1. Unscrew the four control panel
securing screws.
2. Pull the control panel carefully
away from the front of the
controller.
3. Turn the control panel into the
required position
(see illustration above).
Securing screws
3
C
2
4
B
A
4. Feed the connecting cable into
the new installation position on
the back of the control panel.
There are four recesses in the
control panel enclosure that the
cable can be fed out through.
5. Use the four securing screws to
secure the control panel to the
controller.
1
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Assembly
4
9
4.3
Assembly of the
control panel
4.3.1 General
This chapter describes the procedure for installing the control
panel when using the controller with the control panel removed
(see chapter 1.4.1.3).
Strong electromagnetic fields in the vicinity of the
control panel might cause operating failures.
When installing in a control console or a control
station you must ensure that the control panel is
not mounted close to components that use mains
power or power lines.
Always maintain a minimum clearance of 100 mm!
4.3.1.1
Installation versions
The control panel enclosure enables the following installations
versions to be used:
1. Wall mounting
Mount the control panel on a level surface.
See chapter 4.3.2 for the procedure.
2. Control console mounting
Mount the control panel in an existing on-site control console or
a control station.
See chapter 4.3.3 for the procedure.
The ekr 500 installation kit (available as an option)
is required (BST order number 133 459) for
console installation.
4.3.1.2
Cable extension
An extension cable (optional extra) is required for connection of the
control panel to the controller.
Cable extensions are available in the following lengths:
Cable length
BST order number
2m
131 993
5m
131 994
10 m
131 995
It is also possible to combine different cable lengths.
The maximum permitted 20 m full length between
the controller and control panel must never be
exceeded!
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Assembly
4
9
4.3.2 Wall mounting
4.3.2.1
Mounting plan
105
4.3.2.2
4x M3
Control panel
housing
93
105
93
Installation
1. Unplug the connecting cable
connection from the control
panel on the controller
(plug X100).
Plug X100
Control panel
connecting cable
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with removable control panel
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Assembly
4
9
Securing screws
2. Unscrew the four control panel
securing screws and put them
in a safe place.
These screws will be needed
for the wall mounting later on.
3. Pull the control panel away
from the front of the controller.
Pull the connecting cable and
the plug carefully through the
hole in the controller enclosure.
Securing screws
Plug
Enclosure hole
4. Drill and thread the M3 holes as
per the mounting plan
(see chapter 4.3.2.1).
5. Use the four M3 screws to
screw the control panel on.
The four hexagon screws that
secured the control panel to the
controller when the unit was
delivered can be used for this.
Securing screws
6. Fit the extension cable (option)
to connect the control panel to
the controller
(see chapter 4.3.1.2).
7. Plug the extension cable
connector into the X100 socket
on the controller.
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with removable control panel
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Assembly
4
9
4.3.3 Control console mounting
4.3.3.1
Installation cut-out
+1
4.3.3.2
101
Installation cut-out
+1
101
Installation
The optional installation kit is needed for the
control console mounting
(BST order number 133 459, see chapter 4.3.1.1).
1. Unplug the connecting cable
connection from the control
panel on the controller
(plug X100).
Plug X100
Control panel
connection cable
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with removable control panel
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Assembly
4
9
Securing screws
2. Unscrew the four control panel
securing screws and put them
in a safe place.
These screws will be needed
for the control console
mounting later on.
3. Pull the control panel away
from the front of the controller.
Pull the connecting cable and
the plug carefully through the
hole in the controller enclosure.
Securing screws
Plug
Enclosure hole
Threaded
pin
4. Cut out the section
(see chapter 4.3.5.1).
5. Carefully push the control panel
into the cut-out section.
6. Use the two screws to screw the
two securing plates (part of the
installation kit) onto the back of
the control panel.
The four hexagon screws that
secured the control panel to the
controller when the unit was
delivered can be used for this.
7. Screw the four threaded pins
into the securing plates until the
control panel is held in place
firmly.
Securing plates
Threaded pin
Securing plates
Control panel
ekr 500 web guiding controller
with removable control panel
Threaded pin
max. 15 mm
Top view:
8. Fit the extension cable (option)
to connect the control panel to
the controller
(see chapter 4.3.1.2).
9. Plug the extension cable
connector into the X100 socket
on the controller.
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Installation
5
13
5 Installation
5.1
General
!
Attention!
Electrical connection must be carried out by qualified
personnel.
The system must be wired according to the accompanying
connection plan or plugged into the appropriate cable sockets.
Standard wiring sleeves with collars (DIN 46228/Part 4)
must be used with all cable connections up to 0.75 mm².
Wiring sleeves must not be used with cables from
0.75 mm² up to a maximum of 1.5 mm².
Metal bush
Using wiring sleeves:
The crimping is also gas-tight (no cross crimping), i.e. there is no
space inbetween the conductor and the wiring sleeve.
We recommend using VarioCrimp-4 206-204 crimping tongs made
by WAGO. The metal bush of the wiring sleeve must have a length
of at least 8 mm.
Using cable without wiring sleeves:
For fine and multi-core cable and for fine-wired cable, whose kink
resistance is not sufficient due to its small diameter, in order to
overcome the contact force of the clamping springs, the clamp
must be correctly opened using a screwdriver.
Check that all the cables are fitted tightly after the connections
have been made (in both cases).
5.2
Fitting the cable
connections
!
Attention!
All connecting cables must be laid without being tight
and you must ensure that there is no danger of
tripping over them.
• Install the cables between the system components (controller,
sensors, actuator, ...) as per the connecting plan.
Connecting plan see appendix A1.
• Take note of the EMC installation instructions (see chapter 5.3).
• Tighten all the securing screws on the plug connections.
• Ensure that the voltage supply has the correct potential
equalisation in accordance with the local regulations.
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with removable control panel
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Installation
5
13
5.3
Installation instructions
for EMC-wiring
Housing wall
Union nut
1. Unscrew in the union nut for the cable
screw-in cable glands.
Internediate supports
2. Pull out the clamping insert from the
intermediate supports.
Clamping insert
Attention! Do not bend the
clamping insert when you withdraw
it (do not press down on it).
3. Strip cable back by 8 mm so that the
screen braiding is uncovered.
4. Pull the union nut onto the cable.
5. Feed the cable into the cable clamp
and bend the screening back over the
cable clamp.
6. Push the clamping insert to the
intermediate support.
7. Fit the screws.
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with removable control panel
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Installation
5
13
5.4
Overview
processor board
The illustration below shows the position of the terminal strips
(X...), switches (S...), and service LEDs (H...) on the processor
board of the controller.
Type plate
Hardware version
ekr 500 web guiding controller
with removable control panel
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Installation
5
13
5.5
Terminal assignment
5.5.1 Terminal overview
Plug
(connecting plate)
Terminal strip
(processor board)
Function
Remarks
Signal input sensor 1
Guiding mode
Signal input sensor 2
Guiding mode
Signal input
servo-center transducer
(position feedback
EMS 17/21/22)
Operating mode
X1
X1
1
2
3 4
5 6
7 8
X2
X2
9 10 11 12 13 14 15 16
X3
X3
Signal input
electronic remote precision Operating mode
adjustment EFE 1
44 45 46 47 48 49
X70
X6
X6
Power supply 24 V DC
40 41
X7
X7
Actuator
42 43
X100
X8
X8
Connection control panel
88 89 90 91 92
Enable controller,
Servo-center transducer
OMG 8,
Relay contact
X10
X10
51 52 53 54 55 56 57 58
Digital inputs
Remote control,
electronic remote
precision adjustment
EFE 1000
Programming interface
Programming
in the factory
RS232 interface
Program update
X14
X14
72 73 74 75 76 77 78 79 80 81 82 83
X40
X40
X41
X41
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Installation
5
13
5.5.2 Terminal assignment
5.5.2.1
Terminal strip X1; Signal input sensor 1
Terminal
X1
5.5.2.2
Function
IR …
Wire colours
US 2003, US 2009
US 2007,
US 2008
1
+24 V
2
Synchronisation
for US… sensor
3
IR pulse +5 V
brown
4
IR pulse GND
white
5
+12 V
pink
pink
6
GND
green
green
7
-12 V
yellow
yellow
8
Analogue input
grey
grey
Remarks
brown
brown
black
Internal connection
to terminal 8
Output +12 V
blue
Output -12 V
white
Terminal strip X2; Signal input sensor 2
Terminal
X2
Function
IR …
Wire colours
US 2003, US 2009
US 2007,
US 2008
9
+24 V
10
Synchronisation
for US… sensor
11
IR pulse +5 V
brown
12
IR pulse GND
white
13
+12 V
pink
pink
14
GND
green
green
15
-12 V
yellow
yellow
16
Analogue input
grey
grey
ekr 500 web guiding controller
with removable control panel
Remarks
brown
brown
black
Internal connection
to terminal 1
Output +12 V
blue
Output -12 V
white
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Installation
5
13
5.5.2.3
Terminal strip X3; Signal input position feedback EMS 17/21/22,
servo-center transducer OMG 4, electronic remote precision adjustment EFE 1
Terminal
X3
5.5.2.4
5.5.2.6
Wire colours
EMS
OMG 4
EFE 1
17/21/22
44
+24 V
45
+12 V
pink
46
GND
green
47
-12 V
48
Analogue input
servo-center transducer
49
Analogue input
remote precision
adjustment EFE 1
Remarks
pink
pink
Output +12 V
yellow
yellow
yellow
Output -12 V
grey
grey
OMG 4,
position feedback
EMS 17/21/22
grey
The lines on terminals
45 and 47 must be
swapped over to
change the EFE 1
working direction.
Terminal strip X6; Power supply
Terminal
X6
5.5.2.5
Function
Function
Wire colours
40
GND
white
41
+24 V
brown
Remarks
Fed out
through plug X70.
Terminal strip X7; Actuator
Terminal
X7
Function
Wire colours
EMS 5
Wire colours
EMS 10/16/17/21/22
42
Actuator A
brown/white
brown
43
Actuator B
pink/grey
white
Terminal strip X8; Connection control panel
Terminal
X8
Function
Wire colours
88
Bus_GND
blue
89
Bus_L
black
90
Bus_SHLD
91
Bus_H
white
92
Output +24 V
brown
ekr 500 web guiding controller
with removable control panel
Remarks
Fed out
through plug X100.
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Installation
5
13
5.5.2.7
Terminal strip X10; Enable controller / Servo-center transducer OMG 8 (Namur) / Relay contact
Terminal
X10
5.5.2.8
Function
Wire colour
51
OMG 8 (Namur A)
brown/black
52
OMG 8 (Namur B)
blue
53
GND
GND for enable actuator
54
+24 V
Output +24 V
for enable actuator
55
Enable actuator
(controller interlock)
Input enable actuator.
Link to terminal 54 if not used.
56
Relay –
closed contact
57
Relay –
change-over contact
58
Relay –
contact that opens
Remarks
The open contact is normally
closed when working correctly.
white (only EFE 1000)
Terminal strip X14; Digital inputs, electronic remote precision adjustment EFE 1000
Terminal
X14
Function
Wire colour
EFE 1000
72
GND
brown
73
GND
74
Input 0
75
Input 1
76
Input 2
77
Input 3
78
Input 4
79
Input 5
yellow*
80
Input 6
pink*
81
Input 7
82
+24 V
Link to terminal 57
(X10).
83
+24 V
green
GND for inputs 0 ... 7
See truth table
(chapter 8)
Link to terminal 82 to activate
the keyboard lock.
*
ekr 500 web guiding controller
with removable control panel
Remarks
Output +24 V
Max. 200 mA
The lines on terminals 79 and 80 must be swapped over to change
the EFE 1000 working direction.
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Installation
5
13
5.5.2.9
Terminal strip X40; Programming interface
The X40 terminal strip is used for programming the controller in the
factory.
5.5.2.10 Terminal strip X41; RS232 interface
The RS232 interface is used for loading firmware updates.
Changing or loading firmware on this system must
be carried out exclusively by BST personnel or
personnel duely authorised to do so by BST.
Non observance of this may cause the loss of the
warranty rights!
5.5.3 Plug assignments
5.5.3.1
Plug X70; Connection power supply
The power supply is connected to the controller via a 3-pin
connector as per CEN 175301-803 (DIN 43650).
Contact assignments in the plug connector:
Connector
Contact
Signal
Wire colours
1
+24 V
brown
2
GND
white
Potential equalization
green
Coupling
Remarks
Feeds in to terminal strip X6.
Connected to the enclosure
The contact marked by the symbol
is solely used
for providing the potential equalisation (working
earth).
This is not a protective earth when the contact is
made. This unit does not need protective earthing.
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with removable control panel
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Installation
5
13
5.5.3.2
Plug X100; Connection control panel
The control panel is connected to the controller via a 4-pin M8
micro style connector.
Contact assignments in the plug connector:
4
View X
2
X
3
2
Socket
(female)
View X
1
4
X
1
Contact
Signal
Plug
(male)
3
Wire colours
Woodhead cable
1
Output +24 V
brown
2
Bus_H
white
3
Bus_GND
green
4
Bus_L
yellow
ekr 500 web guiding controller
with removable control panel
Remarks
Feeds in to terminal strip X6.
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Installation
5
13
5.6
Set DIL switches
The DIL switches on the controller’s processor board must be set
up for the relevant application prior to commissioning.
Danger from mains voltage!
Never open the controller before switching off the
mains!
5.6.1 DIL switch S4
ON
DIP
DIL switch S4 is used to reverse the guiding direction, to activate
the electronic remote precision adjustment EFE 1 and to select the
actuator and servo-center transducer that are being used.
1 2 3 4 5 6 7 8
DIL switch S4
DIL switch Reversion of the guiding direction/activation EFE 1
S4.1
Reversion of the guiding direction for automatic mode
(sensor 1, sensor 2, web center-line guiding)
S4.2
Reversion of the guiding direction
for the servo-center transducer
S4.3 = ON
S4.4
ekr 500 web guiding controller
with removable control panel
Electronic remote precision adjustment EFE 1
DIL switch
S4.5 S4.6
Selection of the used actuator
OFF
OFF
OFF
EMS 10, EMS 16, EMS 17
ON
OFF
OFF
EMS 5
OFF
ON
OFF
reserved
ON
ON
OFF
CompactGuide
OFF
OFF
ON
EMS 21, EMS 22
DIL switch
S4.7 S4.8
Selection of the used
servo-center transducer
OFF
OFF
Position feedback EMS 17, EMS 21, EMS 22
(potentiometer)
ON
OFF
OMG 8
OFF
ON
No servo-center transducer
(Center position cannot be selected)
ON
ON
OMG 4
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Installation
5
13
5.6.2 DIL switch S5
ON
DIP
DIL switch S5 matches the control parameters to the sensors that
are being used.
It also activates or deactivates the remote control.
1 2 3 4 5 6 7 8
DIL switch S5
DIL
switch
S5.1
S5.2
S5.3
S5.4
S5.5
S5.6
S5.7*
S5.8
Function
Status
Description
Remarks
OFF
Voltage input
0 V ... +10 V
US 2009 (S5.7 must be ON)
ON
Voltage input -10 V ... +10 V
IR 2001, IR 2002, IR 2005,
US 2003, US 2007, US 2008
(S5.7 must be OFF)
OFF
Voltage input
0 V ... +10 V
US 2009 (S5.7 must be ON)
ON
Voltage input -10 V ... +10 V
IR 2001, IR 2002, IR 2005,
US 2003, US 2007, US 2008
(S5.7 must be OFF)
OFF
Voltage input, see S5.1
ON
Current input 4 mA ... 20 mA
OFF
Voltage input, see S5.2
ON
Current input 4 mA ... 20 mA
S5.2 must be OFF
OFF
Sensor 1 is not present
Guiding mode
selected
cannot be
ON
Sensor 1 is present
Guiding mode
selectable
OFF
Sensor 2 is not present
Guiding mode
selected
cannot be
ON
Sensor 2 is present
Guiding mode
selectable
OFF
Bright voltage < dark voltage
IR 2001, IR 2002, IR 2005,
US 2003, US 2007, US 2008
ON
Bright voltage > dark voltage
US 2009
OFF
Enabled (active)
ON
Inhibited (inactive)
Sensor 1
Sensor 2
Sensor 1
S5.1 must be OFF
Sensor 2
Sensor 1
Sensor 2
Sensor 1/
Sensor 2
Remote
control
*
ekr 500 web guiding controller
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As the switching of the signal polarity is always made for
both sensors (sensors 1 and 2), only sensors with he same
polarity (bright voltage to dark voltage) should be connected.
It is not possible to use an ultrasonic sensor US 2007 as
sensor 1 and an ultrasonic sensor US 2009 as sensor 2.
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Installation
5
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5.7
Service indications
There are four groups of service LEDs located on the processor
board of the controller that have the following significances:
LED H1 – H8:
Indication of the bus status,
indication of the device status
LED H9 – H16:
Remote control
LED H20 – H22:
Power supply
LED H53, H64:
Controller interlock, OK signal
5.7.1 LEDs “Bus status”
LED
H1
H2
Name
RUN
ERR
Status
Designation Bus
OFF
STOPPED
BLINKER
Signification
The device is in initialization phase.
No data transfer takes place.
The device is in PREOPERATIONAL mode.
PREOPERATIONAL Initialization is completed.
The device can be started.
ON
OPERATIONAL
OFF
NO ERROR
3x FLICKER
SYNC ERROR
ON
BUS OFF
The device is in OPERATIONAL mode.
The device runs “OK“.
No error is recognized.
No SYNC message was received.
The interface controller is in Bus OFF mode.
5.7.2 LEDs “Device status“
LED
Name
Status
OFF
H3
PROG
BLINKER
ON
H4
H5
H6
H7
Signification
The device is in an indefinite status.
The program in the module runs “OK“.
The device is in an indefinite status.
Automatic guiding
Display of the
currently
selected
operating
mode and
guiding mode
H8
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Manual positioning
Center positioning
Guiding to the left web edge
Guiding to the right web edge
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5.7.3 LEDs “Power supply“
LED
Name
Status
H20
+12V
OFF
internal + 12 V not existing
ON
internal + 12 V existing
OFF
internal – 12 V not existing
ON
internal – 12 V existing
OFF
internal + 5 V not existing
ON
internal + 5 V existing
H21
H22
-12V
+5V
Signification
5.7.4 LEDs “Controller interlock“/
“OK signal“
LED
Name
Status
H53
Enable
OFF
Controller is blocked
(motor output stage is switched off)
ON
Controller is enabled
OFF
Error
ON
No error
H64
Relay
Signification
5.7.5 LEDs “Remote control“
LED
Signification
H9
Signal 1 (+24 V) at terminal 74
H10
Signal 1 (+24 V) at terminal 75
H11
Signal 1 (+24 V) at terminal 76
H12
Signal 1 (+24 V) at terminal 77
H13
Signal 1 (+24 V) at terminal 78
H14
Signal 1 (+24 V) at terminal 79
H15
Signal 1 (+24 V) at terminal 80
H16
Signal 1 (+24 V) at terminal 81
The terminal assignment of the remote control inputs can be found
in chapter 5.5.2.8.
The truth table for the remote control inputs can be found in
chapter 8 of this operating manual.
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Start-up
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11
6 Start-up
Attention!
Start-up must be carried out by qualified personnel.
!
Danger from mains voltage!
Never open the controller before switching off the
mains!
Conditions:
• The web guiding system is completely wired in, i.e. the cable
connections between the individual web guiding system
components (controller, sensors, actuator, servo-center
transducer, ...) are made (see chapter 5.1 to 5.5).
• The controller is connected to the power supply.
• The DIL switches S4 and S5 on the processor board of the
controller are set according to the application
(see chapter 5.6).
6.1
Start-up actuator
6.1.1 General
!
Attention!
During the start-up the actuator will carry out
positioning movements.
The equipment must be protected in accordance with
the machinery directives so that no danger of the
personnel being injured exists (e.g. by suitable
barriers)!
Actuator operation in generator mode
The controller is not equipped with a brake chopper.
Therefore you are not permitted to drive the interconnected
actuator in generator mode.
If the interconnected actuator is quasi statically driven in generator
mode (e.g. when using a forklift for inserting the rolls in winding
applications) then suitable measures must be taken to dissipate or
convert the power generated (e.g. external brake chopper or
electrically isolating the actuator from the controller).
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6.1.2 Determine sense
of motor rotation
During start-up the assignment of the arrow keys to the actuating
direction (sense of motor rotation) of the actuator must be checked.
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
or
2. Press arrow key “left“ or “right“.
Observe guiding device!
When pressing arrow key “left“ the guiding device must move
towards sensor 1.
When pressing arrow key “right“ the guiding device must move
towards sensor 2.
If the guiding device moves in the opposite direction then the
motor connection lines on terminal strip X7 (terminal 42 and 43)
must be swapped over.
The assignment of the sensors (sensor 1 / sensor 2) is described
in chapter 1.5.2.
6.1.3 Determine guiding direction
During start-up the assignment of the selection buttons for the
guiding mode to the actuating direction (sense of motor rotation) of
the actuator must be checked.
or
1. Press key “Sensor 1“ or “Sensor 2“.
The selected guiding mode is active.
The LED of the key lights.
2. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
3. Cover scanning area of the selected sensor with material
(e.g. thick paper).
Observe guiding device!
If there is still material in the sensor scanning area then the
guiding device must move away from the selected sensor.
If the material is removed from the sensor scanning area then
the guiding device must move in the direction of the selected
sensor.
If the guiding device moves away from the selected sensor
whilst the material is being removed, then change position of
DIL switch S4.1 on the processor board (see chapter 5.6.1).
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6.1.4 Actuator without
position feedback
(EMS 5 / 10 / 16)
6.1.4.1
Determine guiding direction
for center positioning
(OMG 4, OMG 8)
If you are using a servo-center transducer OMG 4 or OMG 8 the
guiding direction for operating mode “center positioning“ must be
checked.
1. Press key “Servo-center“.
The LED of the key lights.
Observe guiding device!
The guiding device must move towards its center position.
If the guiding device moves to one of its stop positions, then
change position of DIL switch S4.2 on the processor board
(see chapter 5.6.1).
6.1.4.2
Adjust gain of the
servo-center transducer
(OMG 4, OMG 8)
If you are using a servo-center transducer OMG 4 or OMG 8,
preselect the adjustment of gain.
1. Press key “Servo-center“.
The LED of the key lights.
2. Press key “SETUP“.
The set gain for the servo-center transducer is shown
graphically (bar display) and as numerical value on the lower
edge of the display.
Gain
(graphical display)
Gain
(numerical display)
3. Increase gain by means of the arrow key “right“, until hunting
occurs (the guiding device starts oscillating).
The display of the gain value rises step by step.
Pressing the arrow key longer than 3 seconds increases the
pulse width until the key is released.
We recommend setting the gain to maximum if hunting does not
occur.
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Start-up
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4. Decrease gain by using the “left“ arrow key, until the hunting
ceases (stable guiding operation).
If a slower guiding reaction is desired, the gain may still be
reduced further.
Simultaneously pressing the two arrow keys will
reset the gain to “0.5”.
5. Press key “ENTER“.
Adjustment of gain is completed.
The gain setting will be terminated automatically
after a pre-set time-out period initiated after the
last key operation has expired.
The gain setting has now been saved.
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Start-up
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6.1.5 Actuator with
position feedback
(EMS 17, EMS 21, EMS 22)
6.1.5.1
Determine guiding direction
for center positioning
If you are using an actuator with position feedback the guiding
direction for operating mode “center positioning“ must be checked.
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
or
2. Press arrow key “left“ or “right“.
Observe position indicator in the display!
Position indicator
When pressing arrow key “left“ the bar display must move to
the left.
When pressing arrow key “right“ the bar display must move to
the right.
If the bar display moves in the opposite direction then change
position of DIL switch S4.2 on the processor board
(see chapter 5.6.1).
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Start-up
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6.1.5.2
Adjust stroke limitation
and servo-center position
The actuator stroke limitation (adjustment of the software limit
switches) and the adjustment of the servo-center position are
carried out using a special setup menu.
The settings are sub-divided into the following steps:
Step 1: Activating the setup menu
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
2. Press key “SETUP“.
The controller changes to setup mode.
The setup selection menu appears in the display.
Setup menu
EMS 17 / 21 / 22
or
3. Select the setup menu symbol for actuators EMS 17, EMS 21
and EMS 22 using the arrow keys.
4. Press key “ENTER“.
The setup menu is active.
The LED of the key “SETUP“ lights.
The significances of the individual display symbols are
described on the following page.
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1
2
3
5
4
6
7
8
Meaning of the symbols and numerical values
1
Symbol sensor 1 (software limit switch 1)
2
Symbol servo-center position
3
Symbol sensor 2 (software limit switch 2)
4
Set position for software limit switch 1
5
Set servo-center position
6
Set position for software limit switch 2
7
Actual position of the actuator (graphical display)
8
Actual position of the actuator (numerical display)
When the controller is delivered the position for
software limit switch 1 will display “-2048“ and the
position for software limit switch 2 will display “2047“.
The factory default settings will be overwritten by the
new settings when teach-in is run.
The relevant symbol (sensor 1, sensor 2 or servocenter position) will be displayed as inverted after
the teach-in of a new setting has been run.
Inverted symbol display
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Start-up
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Step 2: Set position for software limit switch 1
or
5. Move guiding device to the desired position for software limit
switch 1 (towards sensor 1) using the arrow keys.
The position indicator for software limit switch 1
shows the actual value supplied by the position
feedback of the actuator.
6. Press key “Sensor 1“.
The position for software limit switch 1 is stored.
The symbol “sensor 1“ is represented inversely.
Step 3: Set position for software limit switch 2
or
7. Move guiding device to the desired position for software limit
switch 2 (towards sensor 2) using the arrow keys.
The position indicator for software limit switch 2
shows the actual value supplied by the position
feedback of the actuator.
8. Press key “Sensor 2“.
The position for software limit switch 2 is stored.
The symbol “sensor 2“ is represented inversely.
Step 4: Set servo-center position
or
9. Move actuator to the desired center position for the guiding
device using the arrow keys.
The position indicator for the servo-center position
shows the actual value supplied by the position
feedback of the actuator.
10.Press key “Servo-center“.
The actual position is stored as servo-center position.
The symbol “servo-center“ is represented inversely.
Step 5: Exiting the settings
11.Press key “ENTER“.
The setup menu will be closed.
All modified parameter values are stored.
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Start-up
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6.2
Carry out
material setup
A material setup should be carried out during the first start-up of
the web guiding system in order to realise optimum guiding results.
During material setup an automatic adjustment of the controller to
match the characteristics of the material to be scanned is carried out.
The procedure for carrying out a material set-up is described in
detail in chapter 7.2.
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Start-up
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6.3
Adjustment of gain
The controller gain must be optimised to ensure optimal guiding
results.
This function is used to set individual gain values for the different
guiding modes.
Requirements:
or/
and
- Web of material is pulled in
- Guiding device is not in a stop position
1. Select the desired guiding mode.
2. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
3. Press key “SETUP“.
The set controller gain is shown graphically (bar display) and as
numerical value on the lower edge of the display.
Controller gain
(graphical display)
Controller gain
(numerical display)
4. Increase gain by means of the arrow key “right“, until huntings
appear (the guiding device starts oscillating).
The display of the gain value rises step by step.
Pressing the arrow key longer than 3 seconds increases the
pulse width until the key is released.
We recommend leaving the gain set to maximum if hunting
does not occur.
5. Decrease gain by using the “left“ arrow key until the hunting
ceases (stable guiding operation).
If a slower guiding reaction is desired, the gain may still be
reduced further.
Simultaneously pressing the two arrow keys will
reset the control gain to “0.5”.
6. Press key “ENTER“.
Adjustment of gain is completed.
The gain setting will be terminated automatically
after a pre-set time-out period initiated after the
last key operation has expired.
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Start-up
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6.4
Start-up electronic
remote precision
adjustment (option)
If an optional electronic remote precision adjustment EFE 1 or
EFE 1000 is connected to the controller, then the assignment of
the sense of rotation of the potentiometer (EFE 1) or of the arrow
keys (EFE 1000) to the actuating direction of the actuator must be
checked during start-up.
1. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
2. Adjust the web set point as follows:
EFE 1:
Potentiometer
• Turn the
potentiometer
clockwise
(in arrow direction).
EFE 1000:
Arrow key “right“
• Press arrow key
“right“.
Monitor the display on the control panel!
Guiding setpoint
Turning the potentiometer clockwise (EFE 1) or pressing the
“right” arrow key (EFE 1000) will move the guiding setpoint
indicator to the right (the displayed number value increases).
If the indicator moves in the opposite direction (the displayed
number value becomes smaller) you will have to change the
connector cables for the remote precision adjustment on
terminals 45 and 47 in terminal strip X3 (EFE 1) or on terminals
79 and 80 in terminal strip X14 (EFE 1000)
(see chapters 5.5.2.3 or 5.5.2.8).
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Operation
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7 Operation
7.1
Operation display
7.1.1 Basic display
The basic operation display of the control panel shows the various
operating statuses and all relevant guiding parameters via graphical
symbols and as numerical values.
You will find the significances for the individual symbols in the
following illustration.
Actuator zero position
(only with actuator EMS 17/21/22 or
servo-center transducer OMG 4/8)
Actual servo-center position
(only with actuator EMS 17/21/22 or
servo-center transducer OMG 4/8)
Guiding setpoint
for sensor 1
Guiding setpoint
for sensor 2
Relative scanning
area coverage
of sensor 1
Relative scanning
area coverage
of sensor 2
Controller gain
Status message
“System OK“
(heart “beats“)
Guiding setpoint
(numerical display)
Center of scanning
area sensor 2
Relative actuator position,
related to the stop positions
(only with actuator EMS 17/21/22 or
servo-center transducer OMG 4/8)
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Operation
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7.1.2 Special displays
7.1.2.1
Active limit switch
(EMS 17, EMS 21, EMS 22)
This special display only appears if an actuator with position
feedback (EMS 17, EMS 21, EMS 22) is connected to the controller.
If the actuator has reached a software limit switch, the driving of
the actuator in the corresponding direction is prevented automatically.
The symbol “Active limit switch“ appears in the display above the
actuator position indicator.
Symbol
“Active limit switch“
Limit switch 1
Limit switch 2
After driving the actuator into the opposite direction the symbol will
be deleted automatically.
Also see chapter 10, position 7.
7.1.2.2
Motor overcurrent
If the actuator is blocked, e.g. when the guiding device has moved
into a stop position, the warning symbol “Motor overcurrent“ appears
in the display next to the actuator position indicator.
Symbol
“Motor overcurrent
After driving the actuator into the opposite direction the symbol will
be deleted automatically.
Also see chapter 10, position 6.
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Operation
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7.1.2.3
Supply voltage outside
the permissible range
If the controller supply voltage lies outside the permissible range,
the warning symbol “Supply voltage“ appears in the display next to
the actuator position indicator.
Symbol
“Supply voltage“
Once the supply voltage again falls within the permissible voltage
range, the symbol will be deleted automatically.
Also see chapter 10, position 15.
7.1.2.4
Timeout motor activation
If the actuator is run in the same direction for more than 50 seconds
during operation of the web guiding system, then the motor output
stage is switched off.
The warning symbol “Timeout motor activation“ appears in the
display next to the actuator position indicator.
Symbol
“Timeout motor activation“
After driving the actuator into the opposite direction the symbol will
be deleted automatically.
Also see chapter 10, position 9.
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Operation
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7.1.2.5
Active controller interlock
If controller interlock is active, a warning symbol with a padlock
appears in the display next to the actuator position indicator.
Symbol
“Active controller interlocking“
The controller interlock (e.g. if the machine stops) can be activated
via the digital inputs using an external switch or a PLC signal
(see chapter 5.5.2.7).
If the controller interlock is activated, the output from the actuator’s
output stage is switched off. The actuator will not carry out any
guiding movements. This is valid for all operating modes
(automatic guiding, manual positioning, center positioning).
Also see chapter 10, position 8.
7.1.2.6
Keyboard interlock
A key symbol will be displayed in the centre of the bottom edge of
the display if the keyboard interlock is active.
Symbol
“Active keyboard lock“
If keyboard interlock is activated, all keys of the control panel are
locked. Keyboard interlock is activated by a 24V signal on terminal
81 (see chapter 8).
Also see chapter 10, position 16.
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Operation
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7.1.2.7
Bus connection fault
If a fault occurs in the bus connection between the controller and
control panel the “Bus connection fault“ warning symbol will be
displayed.
Symbol
“Bus connection fault“
Also see chapter 10, position 18.
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Operation
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7.2
Material Setup
7.2.1 General
Danger of cuts!
Never touch the edges of moving webs of material!
You are only allowed to carry out the material setup
when the production machine is stopped.
!
During material setup an automatic adjustment of the controller to
match the characteristics of the material to be scanned is carried out.
A material setup should be carried out when any of the following
work is undertaken in order to realise optimum guiding results:
• During initial commissioning of the web guiding system
• With infrared sensors
(IR 2001, IR 2002, IR 2005):
After changing over to a material with other contrast
characteristics (e.g. film with a different material transparency)
• With ultrasonic sensors
(US 2003, US 2007, US 2008, US 2009):
After changing over to a material with different sound
absorption properties
• After cleaning a dirty sensor
Material setup can be carried out either automatically or manually.
• Automatic material setup describes the standard
procedure for storing the bright/dark values of the sensors.
• Manual material setup should always be used if the
contrast that has to be scanned is critical.
Procedure for generating the bright/dark values
Bright value
• Remove material from the sensor scanning area
(no material in the sensor scanning area).
Dark value
• Completely cover the sensor scanning area with the material to
be scanned.
If using highly transparent material you must
ensure when you cover the scanning window
that there are no folds in the material in the
sensor scanning area (the material must be
tensioned).
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7.2.2 Activate material setup
The selection of the desired setup type (manual or automatic) is
carried out in the setup selection menu.
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
2. Press key “SETUP“.
The controller changes to setup mode.
The setup selection menu appears in the display.
or
3. Select the desired setup type (manual or automatic) using the
arrow keys.
The selected symbol will be displayed "inversely".
Automatic material setup
or
Manual material setup
4. Press key “ENTER“.
Material setup is active.
The LED of the “SETUP“ key lights.
The detected bright/dark value for the selected sensor is shown
in the display under the sensor symbol.
Dark value (graphical display)
Actual value (graphical display)
Bright value (graphical display)
The wrench symbol indicates
that manual material setup is active.
Bright value (minimum value = lowest detected value)
Actual value
Dark value (maximum value = highest detected value)
5. Press key “SETUP“ to abort the material setup.
The detected bright/dark value is not stored.
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7.2.3 Procedure for
web edge guiding
7.2.3.1
Automatic material setup
This chapter describes the standard procedure for storing the
bright/dark values of the sensors for web edge guiding.
1. Remove material from the connected sensors and clean the
sensor scanning areas.
or
2. Select the desired sensor by pressing the corresponding key
“Sensor 1“ or “Sensor 2“.
The LED of the key lights.
3. Activate automatic material setup in the setup selection menu
(see chapter 7.2.2).
The display shows the accompanying screen
(here with sensor 1 selected).
The animation shows the required operation steps for creating
the bright and dark value:
The hand moves the material into the sensor scanning area
(dark value) and back out again (bright value).
4. Remove material from the selected sensor
(no material within the sensor scanning area).
The detected bright value is shown in the display.
5. Cover scanning area of the selected sensor with the material to
be scanned for at least 2 seconds.
The detected dark value is shown in the display.
6. Press key “ENTER“.
The material setup for the selected sensor is completed.
The detected bright and dark value is stored.
The operating screen is displayed.
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7.2.3.2
Manual material setup
This chapter describes the procedure for storing the bright/dark
values of the sensors for web edge guiding with critical contrasts.
1. Remove material from the connected sensors and clean the
sensor scanning areas.
or
2. Select the desired sensor by pressing the corresponding key
“Sensor 1“ or “Sensor 2“.
The LED of the key lights.
3. Activate manual material setup in the setup selection menu
(see chapter 7.2.2).
The display shows the required operation step for creating the
bright value for the selected sensor (here sensor 1).
4. Remove material from the selected sensor
(no material within the sensor scanning area).
The detected bright value is shown in the display.
5. Press key “ENTER“.
The bright value is stored.
The display shows the required operation step for creating the
dark value for the selected sensor (here sensor 1).
6. Cover scanning area of the selected sensor with the material to
be scanned and keep it covered.
The detected dark value is shown in the display.
7. Press key “ENTER“.
The dark value is stored.
The material setup for the selected sensor is completed.
The operating screen is displayed.
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Operation
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7.2.4 Procedure for
web center-line guiding
7.2.4.1
Automatic material setup
This chapter describes the standard procedure for storing the
bright/dark values of the sensors for web center-line guiding.
1. Remove material from the connected sensors and clean the
sensor scanning areas.
2. Select both sensors by pressing keys “Sensor 1“ and
“Sensor 2“ simultaneously.
The LEDs of both keys light.
3. Activate automatic material setup in the setup selection menu
(see chapter 7.2.2).
The display shows the accompanying screen for sensor 1.
The animation shows the required operation steps for creating
the bright and dark value for sensor 1:
The hand moves the material into the sensor scanning area
(dark value) and back out again (bright value).
4. Remove material from sensor 1
(no material within the sensor scanning area).
The detected bright value is shown in the display.
5. Cover scanning area of sensor 1 with the material to be
scanned for at least 2 seconds.
The detected dark value is shown in the display.
6. Press key “ENTER“.
The detected bright and dark values for sensor 1 are stored.
The display shows the accompanying screen for sensor 2.
The animation shows the required operation steps for creating
the bright and dark value for sensor 2:
The hand moves the material into the sensor scanning area
(dark value) and back out again (bright value).
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Operation
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7. Remove material from sensor 2
(no material within the sensor scanning area).
The detected bright value is shown in the display.
8. Cover scanning area of sensor 2 with the material to be
scanned for at least 2 seconds.
The detected dark value is shown in the display.
9. Press key “ENTER“.
The detected bright and dark values for sensor 2 are stored.
The material setup is completed.
The operating screen is displayed.
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Operation
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7.2.4.2
Manual material setup
This chapter describes the procedure for storing the bright/dark
values of the sensors for web center-line guiding with critical
contrasts.
1. Remove material from the connected sensors and clean the
sensor scanning areas.
2. Select both sensors by pressing keys “Sensor 1“ and
“Sensor 2“ simultaneously.
The LEDs of both keys light.
3. Activate manual material setup in the setup selection menu
(see chapter 7.2.2).
The display shows the required operation step for creating the
bright value for sensor 1.
4. Remove material from sensor 1
(no material within the sensor scanning area).
The detected bright value is shown in the display.
5. Press key “ENTER“.
The bright value for sensor 1 is stored.
The display shows the required operation step for creating the
dark value for sensor 1.
6. Cover scanning area of sensor 1 with the material to be
scanned and keep it covered.
The detected dark value is shown in the display.
7. Press key “ENTER“.
The dark value for sensor 1 is stored.
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The display shows the required operation step for creating the
bright value for sensor 2.
8. Remove material from sensor 2
(no material within the sensor scanning area).
The detected bright value is shown in the display.
9. Press key “ENTER“.
The bright value for sensor 2 is stored.
The display shows the required operation step for creating the
dark value for sensor 2.
10.Cover scanning area of sensor 2 with the material to be
scanned and keep it covered.
The detected dark value is shown in the display.
11.Press key “ENTER“.
The dark value for sensor 2 is stored.
The material setup is completed.
The operating screen is displayed.
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Operation
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19
7.3
Operating mode
selection
7.3.1 Manual positioning
The guiding device position can be manually adjusted in this
operating mode.
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
or
2. Move the guiding device into the desired position using the
arrow keys.
7.3.2 Automatic guiding
Automatic web edge guiding (guiding to the left or right web edge)
or web center-line guiding is carried out in this operating mode
depending on the selected guiding mode.
The assignments of the guiding mode selector buttons
are described in chapter 1.5.2.
1. Select the desired guiding mode.
• Guiding to the left web edge (sensor 1)
Press key “sensor 1“.
The LED of the key lights.
or
• Guiding to the right web edge (sensor 2)
Press key “sensor 2“.
The LED of the key lights.
or
• Web center-line guiding
Press keys “Sensor 1“ and “Sensor 2“ simultaneously.
The LEDs of both keys light.
2. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
7.3.3 Center positioning
The guiding device is automatically moved to its center position in
this operating mode.
1. Press key “Servo-center“.
The guiding device moves to its center position.
The LED of the key lights.
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Operation
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7.4
Setting the web set point
In operating mode “Automatic“ shifting of the guiding setpoint for
the selected guiding mode is possible via the arrow keys.
This method is used to set up the required web edge position
within the sensor scanning area.
If the optional electronic remote precision adjustment
EFE 1 is connected to the controller, then the shifting
of the guiding setpoint is carried out exclusively via
the potentiometer on the EFE 1 (see chapter 7.7).
In automatic mode the arrow keys on the control
panel are then out of function! Pressing an arrow
key on the control panel, causes the message “EFE“
to be displayed on the bottom edge of the display.
or
1. Select the desired guiding mode.
2. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
or
3. Press arrow key “left“ or “right“.
The actual guiding setpoint is shown graphically (bar display)
and as numerical value on the lower edge of the display.
The white triangle in the sensor symbol
marks the actual guiding setpoint.
Center sensor
scanning area
Guiding setpoint
(numerical display)
Guiding setpoint
(graphical display)
or
4. Shift the guiding setpoint to the desired position using the two
arrow keys. The new guiding setpoint will have an immediate
effect on the control. Press the arrow key down for longer than
3 seconds and the pulse width will be increased until the key is
released. Simultaneously pressing the two arrow keys will reset
the guiding setpoint to “0”.
The guiding setpoint adjustment will be terminated
automatically after a pre-set time-out period
initiated after the last key operation has expired.
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Note:
The guiding setpoint is saved separately for
each guiding mode.
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Operation
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19
7.5
Optimise gain
The controller gain is usually set once during start-up of the system
(see chapter 6.3).
This function is used to set individual gain values for the different
guiding modes.
If huntings appear during operation (the guiding device oscillates),
then the controller gain can be optimised as follows.
or/
and
1. Select the desired guiding mode.
2. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
3. Press key “SETUP“.
The set controller gain is shown graphically (bar display) and as
numerical value on the lower edge of the display.
Controller gain
(graphical display)
or
Controller gain
(numerical display)
4. Decrease gain by means of the arrow key “left“ or increase gain
by means of the arrow key “right“ until the guiding operates
stable.
The new setting will have an immediate effect on the control.
Press the arrow key down for longer than 3 seconds and the
pulse width will be increased until the key is released.
Simultaneously pressing the two arrow keys will reset the
controller gain setting to “0.5”.
5. Press key “ENTER“.
Adjustment of gain is completed.
The gain setting will be terminated automatically
after a pre-set time-out period initiated after the
last key operation has expired.
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7.6
Display of system
information
Display of the installed hardware and firmware versions for the
controller and the control panel.
Where error messages or problems occur that
cannot be rectified by the customer alone, and
therefore require support from BST International GmbH,
please have the installed hardware and software
versions ready.
Procedure:
1. Press key “Manual mode“.
The controller changes to manual mode.
The LED of the key lights.
2. Press key “SETUP“.
The controller changes to setup mode.
The setup selection menu appears in the display.
or
3. Select the info symbol using the arrow keys.
The selected symbol will be displayed "inversely".
4. Press key “ENTER“.
The display shows the installed hardware and firmware
versions for the controller and the control panel.
Controller
Control panel
Firmware version
Hardware version
The information display will be terminated
automatically after a pre-set time-out has
expired. The operating screen is displayed.
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Operation
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7.7
Electronic remote
precision adjustment
(option)
Depending on the conditions surrounding the machine or the
production demands, it may be necessary to adjust the web
position far from the guiding device.
The optional electronic remote precision adjustments EFE 1
(analogue) and EFE 1000 (digital) allow the correction of the web
position from any place on the machine.
If the optional electronic remote precision adjustment
EFE 1 is connected to the controller, then the
shifting of the guiding setpoint is carried out
exclusively via the potentiometer on the EFE 1.
In automatic mode the arrow keys on the control
panel are then out of function! Pressing an arrow
key on the control panel, causes the message “EFE“
to be displayed on the bottom edge of the display.
1. Press key “Automatic“.
The controller changes to automatic mode.
The LED of the key lights.
2. Adjust the guiding setpoint as follows:
EFE 1:
Potentiometer
• Set up the required
guiding setpoint by
turning the
potentiometer.
The set value of
the guiding setpoint
is briefly portrayed
in reverse highlighting on the
control panel
display after each
modification.
EFE 1000:
• Set up the required
guiding setpoint
using the two
arrow keys.
Arrow keys
The current web guiding setpoint setting will be displayed in the
basic operation display (see chapter 7.1.1).
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8
Remote control
1
8 Remote control
The controller’s remote control inputs enable the functions to be
remotely controlled via external switches or PLC signals.
!
Attention!
External switches block any keys on the control
panel that have counter functions.
If a remote control signal is set at the relevant terminals then you
can no longer switch over the assigned functions from the control
panel!
One of the remote control inputs being set to a 1 signal (+24V) will
be indicated by the associated LED (H9 - H16) mounted on the
processor board of the controller (see chapter 5.7.5).
Truth table remote control inputs
Function
Terminal
LED
55
72
73
74
75
76
77
78
79
80
81
H53
—
—
H9 H10 H11 H12 H13 H14 H15 H16
Automatic guiding
X
0
0
1
X
X
X
X
X
Manual positioning
X
1
0
0
X
X
X
X
X
Center positioning
X
0
1
0
X
X
X
X
X
Web edge guiding
sensor 1
X
X
X
X
1
0
X
X
X
Web edge guiding
sensor 2
X
X
X
X
0
1
X
X
X
Web center-line guiding
X
X
X
X
1
1
X
X
X
Arrow key left
(only in manual mode)
X
X
X
X
X
X
1
0
X
Arrow key right
(only in manual mode)
X
X
X
X
X
X
0
1
X
Keyboard interlock
X
X
X
X
X
X
X
X
1
Enable actuator
(controler interlock)
1
GND
X
82
83
—
—
+24 V
+24 V
terminal 54
Interface conditions:
1 = +24 V
0 = 0 V (GND) or terminal open
X = not relevant
The remote control function can be deactivated via
DIL switch S5.8 in order to make the commissioning
easier (see chapter 5.6.2).
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Default settings
9
5
9 Default settings
9.1
Device addresses
The device addresses of the controller and the control panel are
preset by manufacturer.
The settings usually do not have to be modified.
Check the device address settings if faulty operation or nondefined controller or control panel processes occur.
9.1.1 Device address
of the controller
The device address of the controller is preset to “1“ by
manufacturer (delivery state).
You are only allowed to modify the device address
if authorised to do so by the manufacturer!
The setting of the device address of the controller is carried out via
the rotary switch S1 on the processor board.
78
23
901
456
Rotary switch S1
Danger from mains voltage!
Never open the controller before switching off the
mains!
Set device adress:
1. Switch off controller line voltage.
2. Open the controller enclosure cover.
3. Check that the rotary switch S1 on the processor board is set
correctly. The rotary switch S1 must be set to position “1“.
4. Switch the rotary switch S1 to position “1“ if necessary.
5. Close the controller enclosure cover.
6. Switch on controller line voltage again.
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Default settings
9
5
9.1.2 Device address of
the control panel
Setting the control panel device address is carried out via the
rotary switch S1 on the control panel board.
The rotary switch S1 is mounted behind stop B on the back of the
control panel.
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456
Rotary switch S1
Stop B
The device address of the control panel is preset to “1“ by
manufacturer (delivery state).
You are only allowed to modify the device address
if authorised to do so by the manufacturer!
Danger from mains voltage!
The plug of the control panel connection cable must
be disconnected from the controller before you open
the control panel!
Set device adress:
1. Unplug the connecting cable connection from the control panel on
the controller.
2. Carefully remove stop B from the back of the control panel.
3. Check the setting of the rotary switch S1 on the control panel
board. The rotary switch S1 must be set to position “1“.
4. Switch the rotary switch S1 to position “1“ if necessary.
5. Replace the stop.
6. Plug the control panel connecting cable plug back in to the
controller.
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Default settings
9
5
9.2
Keyboard bus
terminating resistors
The internal terminating resistors of the controller and control panel
are switched on in the factory.
The settings usually do not have to be modified.
Check the terminating resistor settings if faulty operation or nondefined controller or control panel processes occur.
9.2.1 Controller terminating
resistor
OFF
ON
The controller’s internal terminating resistor can be switched on or
off using switch S3 on the processor board.
Switch S3
The terminating resistor should only be switched
off after first obtaining agreement from the
manufacturer!
Switch
S3
Function
OFF
Internal terminating resistor switched off
ON
Internal terminating resistor switched on
(default setting)
Danger from mains voltage!
Never open the controller before switching off the
mains!
Setting up the terminating resistor:
1. Switch off controller line voltage.
2. Open the controller enclosure cover.
3. Check switch S3 setting on the processor board.
The switch S3 must be set to the “ON“ position.
4. Switch S3 to the “ON“ position if necessary.
5. Close the controller enclosure cover.
6. Switch on controller line voltage again.
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Default settings
9
5
9.2.2 Control panel
terminating resistor
DIL switch S2.4 on the control panel board is used to switch the
control panel’s internal terminating resistor on or off.
DIL switch S2 is mounted behind the stop A on the back of the
control panel.
ON DIP
1 2 3 4
DIL switch S2
Stop A
The terminating resistor should only be switched
off after first obtaining agreement from the
manufacturer!
DIL switch
Status
S2.1, S2.2, S2.3
Function
Remarks
Reserved for function enhancements
OFF
Internal terminating resistor switched off
ON
Internal terminating resistor switched on
S2.4
Default setting
Danger from mains voltage!
The plug of the control panel connection cable must
be disconnected from the controller before you open
the control panel!
Setting up the terminating resistor:
1. Unplug the connecting cable connection from the control panel on
the controller.
2. Carefully remove stop A from the back of the control panel.
3. Check the setting of DIL switch S2.4 on the control panel board .
DIL switch S2.4 must be set to the “ON“ position.
4. Switch DIL switch S2.4 to the “ON“ position if necessary.
5. Replace the stop.
6. Plug the control panel connecting cable plug back in to the
controller.
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Default settings
9
5
9.3
Generating the
default settings
Attention!
All settings made whilst working (e.g. controller
gain, guiding setpoint, bright/dark values of the
sensors, etc.) will be overwritten by the factory
default settings if you reload the default settings.
!
Processor board
78
23
901
456
Procedure:
Rotary switch S1
1. Switch-off controller line voltage.
2. Open the controller enclosure cover.
78
23
901
456
78
23
901
3. Set rotary switch S1 on the processor board to “0“.
4. Switch-on controller line voltage.
All of the relevant settings for the controller will be overwritten
with the factory default settings.
5. Switch-off controller line voltage.
6. Set S1 rotary switch S1 on the processor board to “1“.
7. Close the controller enclosure cover.
456
8. Switch on controller line voltage again.
The rotary switch S1 must be immediately reset to
device address “1” after the default factory settings
have been reloaded (see chapter 5.2.2.1).
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Trouble shooting
10
4
10 Trouble shooting
Pos. Fault
1
The actuator/guiding device
“trembles“.
Possible cause
Solution
• Guiding system overdrive.
• Optimise gain
(see chapter 7.5).
• Carry out material setup
(see chapter 7.2).
2
3
4
5
6
7
The actuator/guiding device
responds too slow and/or
guiding operates not
correctly.
• Gain has been set too low.
• Optimise gain
(see chapter 7.5).
The actuator/guiding device
does not carry out any
guiding movement.
• During start-up a wrong
actuator has been selected.
• Check adjustment of DIL switch
S4 in the controller
(see chapter 5.6.1).
• Gain has been set too low.
• Optimise gain
(see chapter 7.5).
• Carry out material setup
(see chapter 7.2).
In operating mode
• A material setup was not run
“Automatic“ the actuator/
after the material was
guiding device moves to an
changed.
end position and remains
• The actuator guiding direction
there (when the web of
material is being threaded in). has been set up wrongly.
• Reverse guiding direction of the
actuator (see chapter 6.1.3).
• The actuator guiding direction
has been set up wrongly.
• Reverse guiding direction of the
actuator (see chapter 6.1.3).
In operating mode “Center
positioning“ the actuator/
guiding device moves to an
end position and remains
there.
The actuator/guiding device
does not carry out any
guiding movement.
The display shows the
following warning symbol
(see chapter 7.1.2.2):
• The servo-center transducer
• Check mounting position of the
(OMG 4 , OMG 8) being used
servo-center transducer.
has been incorrectly installed.
• The guiding device has
moved into a stop position or
blocks the electric-motordriven actuator.
• Activate the actuator in the
opposite direction.
The warning symbol will be
deleted automatically.
• The guiding device is not
moving smoothly.
• Check the guiding device’s ball
castors.
• The material setup for the
connected sensors was
implemented incorrectly.
• Carry out material setup
(see chapter 7.2).
An actuator with position
• The actuator has reached a
feedback (EMS 17, EMS 21,
software limit switch.
EMS 22) does not carry out
Driving the actuator in the
any guiding movement.
corresponding direction is
The display shows one of
prevented.
the following symbols
(see chapter 7.1.2.1):
ekr 500 web guiding controller
with removable control panel
• Carry out material setup
(see chapter 7.2).
• Activate the actuator in the
opposite direction.
The warning symbol will be
deleted automatically.
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Trouble shooting
10
4
Pos. Fault
Possible cause
Solution
• Deactivate controller interlock.
For this purpose insert jumper
on terminal 54-55
(see chapter 5.5.2.7).
8
The actuator/guiding device
does not carry out any
guiding movement.
The display shows the
following warning symbol
(see chapter 7.1.2.5):
• The controller interlock is
active.
9
The actuator/guiding device
does not carry out any
guiding movement.
The display shows the
following warning symbol
(see chapter 7.1.2.4):
• The actuator has been
• Activate the actuator in the
activated for more than 50
opposite direction.
seconds without interruption in
• Check for broken parts within
the same direction.
the actuator (e.g. broken spindle).
• No web of material has been
threaded.
• Thread the web of material.
• No web tension exists.
• Check the web tension.
10
The actuator/guiding device
has moved to an end
position and the motor
switch-off device is not
working.
The LEDs of the keys
or
on the control panel
and the display flash.
• The supply voltage (24V DC)
has dropped out of the
permitted voltage range due
to the actuator’s increased
current consumption
(see chapter 2.1.3).
• Check the power supply.
11
The center position of the
guiding device is not
correctly moved to.
• If an actuator with position
feedback (EMS 17/21/22) is
used, then the servo-center
transducer OMG 4 was
incorrectly selected.
• Check adjustment of DIL
switches S4.7 and S4.8
(see chapter 5.6.1).
12
All the settings for actuator, • The controller gain was
sensors, servo-center
inadvertently reduced to the
transducer, etc. are correct,
minimum value (0.2).
but the unit does not control.
No guiding takes place in
operating mode “automatic“.
• Adjust the controller gain
(see chapter 7.5).
13
A connected edge sensor is
not working.
14
Guiding mode
or
cannot be activated.
ekr 500 web guiding controller
with removable control panel
• Wrong settings were made
during start-up for the
connected edge sensor.
• Check adjustment of DIL switch
S5 (see chapter 5.6.2).
• Two edge sensors with
different signal polarity (bright
voltage to dark voltage) are
connected to the controller.
• Connect edge sensors with the
same signal polarity
(see chapter 5.6.2).
• During start-up the
corresponding sensor
(sensor 1 or sensor 2) has not
been activated.
• Check adjustment of DIL switch
S5 (see chapter 5.6.2).
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Trouble shooting
10
4
Pos. Fault
Possible cause
Solution
The display shows the
following warning symbol
(see chapter 7.1.2.3):
• The controller supply voltage
lies outside the permissible
range.
• Check the power supply.
16
The controller does not
respond to any operation.
The display shows the
following key symbol
(see chapter 7.1.2.6):
• The keyboard interlock is
active.
• Deactivate keyboard interlock.
Remove jumper from terminal
81-82 (see chapter 5.5.2.8).
17
A shifting of the guiding
setpoint via the arrow keys
of the control panel is not
possible.
Pressing an arrow key on
the control panel, causes
the message “EFE“ to be
displayed on the bottom
edge of the display.
• The optional electronic remote
precision adjustment EFE 1 is
connected to the controller.
• Shift guiding setpoint via the
potentiometer on the electronic
remote precision adjustment
EFE 1 (see chapter 7.7).
18
The controller does not
respond to any operation.
The display shows the
following symbol
(see chapter 7.1.2.7):
• Fault in the bus connection
between controller and control
panel.
• Check cable connection
between controller and control
panel.
15
• Check the mains wiring.
• Check cable connections are
correct at terminal strip X8
(see chapter 5.5.2.6).
• The device address of the
controller or control panel is
set incorrectly.
• Check setting of the rotary
switch S1 in the controller and
the control panel
(see chapter 9.1.1).
• The internal terminating
• Switch on the internal
resistor in the controller and/or
terminating resistor in the
in the control panel is not
controller and in the control
switched on.
panel
(see chapter 9.2.1 and 9.2.2).
19
20
The controller does not
respond to any operation.
The controller cannot be
switched via the remote
control function.
ekr 500 web guiding controller
with removable control panel
• A remote control is connected
to the controller.
The keys of the control panel
are locked.
• Deactivate remote control
(see chapter 5.6.2).
• The device address of the
controller or control panel is
set incorrectly.
• Check setting of the rotary
switch S1 in the controller and
the control panel
(see chapter 9.1.1).
• The remote control function is
deactivated.
• Check adjustment of DIL switch
S5.8 (see chapter 5.6.2).
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: 10
Page:
82/86
Trouble shooting
10
4
Pos. Fault
21
Undefined controller
process.
ekr 500 web guiding controller
with removable control panel
Possible cause
Solution
• The length of the connection
cable between controller and
control panel is longer than
20 m.
• Ensure that the maximum
permitted length of the control
panel connection cable is not
exceeded.
• The controller or the control
panel has been installed close
to a component that uses
mains power or power lines.
• Ensure that there is a minimum
clearance of 100 mm from the
component that uses mains
power or the power lines.
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: 10
Page:
83/86
Maintenance
11
2
11 Maintenance
11.1 General
Attention!
You are only allowed to undertake maintenance or
cleaning of the controller or the control panel and of
all connected components after the mains voltage has
been switched off.
Before any maintenance or cleaning work ensure the system is
electrically isolated and at zero potential!
To this end always carry out the following measures:
1.
2.
3.
4.
5.
Switch off.
Prevent switching back on.
Check the equipment is isolated.
Earth.
Cover or shield any adjacent parts that are still live.
The maintenance or the cleaning of the system can only take
place, after carrying out these steps.
The maintenance or cleaning intervals depend on the ambient
conditions at the installation site.
If the customer is processing very dusty materials then the
maintenance/cleaning intervals must be reduced accordingly.
As a matter or course, cable connectors (e.g. between controller
and actuator) should only be disconnected when the controller is
no longer connected to the mains supply. Any infringements will
result in the warranty claim being invalidated.
11.2 Controller
The controller is maintenance-free.
Cleaning of the controller housing should be carried out using a
dry, clean and soft cloth.
A commercial liquid cleaner may be used if the housing is very dirty.
Adhere to protection class IP 54!
11.3 Control panel
The control panel is maintenance-free.
Cleaning of the control panel housing should be carried out using a
dry, clean and soft cloth.
A commercial liquid cleaner may be used if the housing is very dirty.
Adhere to protection class IP 50!
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: 11
Page:
84/86
Maintenance
11
2
11.4 Sensors
The sensor lenses of infrared sensors or the transmitter and
receiver capsules of ultrasonic sensors have to be kept clean to
ensure optimum guiding results.
A material setup must be run after the sensor lenses or receiver
and transmitter capsules have been cleaned (see chapter 6.2).
11.5 Electric-motor-driven
actuator
The electric-motor-driven actuator is maintenence-free.
.
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: 11
Page:
85/86
Decommissioning
12
1
12 Decommissioning
Decommissioning (scrapping) of the guiding system must be
carried out in together with the entire machine.
The necessary procedures must be prepared by the manufacturer
of the machine. You must take into consideration that the web
guiding equipment is generally considered to be an electrical/
electronic device, which must be disposed of in accordance with
the current legal requirements.
You might also be able to return the system to
BST International GmbH, but the corresponding agreement must
be made first.
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: 12
Page:
86/86
Index
I
1
Index
Actuator
Determine sense of motor rotation...................... 45
Maintenance ....................................................... 85
Operation in generator mode .............................. 44
Selection of the used actuator ............................ 40
Servo-center position EMS 17/21/22 ............ 49, 51
Software limit switches EMS 17/21/22 .... 49, 51, 56
Start-up ............................................................... 44
Stroke limitation EMS 17/21/22..................... 49, 51
Technical Data.................................................... 19
Ambient conditions .......................................... 22
ATEX ......................................................... 10, 22
Automatic guiding ............................................ 68
Bright value...................................................... 61
Bus connection fault ........................................ 59
Bus status ........................................................ 42
Cable connections ............................... 10, 31, 84
Cable extension........................................... 4, 26
Center positioning............................................ 68
Connectable components.................................. 5
Control panel ................................................. 4, 8
Ambient conditions ............................................. 16
Assembly ............................................................ 26
Cable guide......................................................... 25
Connecting cable .................................................. 4
Control console mounting ............................. 26, 29
Dimensions ......................................................... 17
Display ................................................................ 16
Installation cut-out............................................... 29
Installation kit ...................................................... 29
Installation versions ............................................ 26
Key functions ........................................................ 9
Maintenance ....................................................... 84
Mounting plan ..................................................... 27
Plug assignments ............................................... 39
Power supply ...................................................... 16
Protection class .................................................. 16
Securing kit ......................................................... 26
Set device address ............................................. 76
Technical data .................................................... 16
Terminating resistor ............................................ 78
Turning the control panel .................................... 25
Wall mounting ............................................... 26, 27
Weight................................................................. 16
Controller ........................................................... 4
Ambient conditions ............................................. 13
Analogue inputs .................................................. 14
Assembly ............................................................ 23
Control panel interface........................................ 15
Digital inputs ....................................................... 14
Dimensions ......................................................... 17
ekr 500 web guiding controller
with removable control panel
LEDs ................................................................... 42
Maintenance ....................................................... 84
Mounting ............................................................. 24
Mounting plan ..................................................... 23
Output fault relay................................................. 14
Output motor output stage .................................. 14
Plug assignments................................................ 38
Power supply ...................................................... 13
Processor board.................................................. 33
Protection class................................................... 13
Service indications .............................................. 42
Set device address ............................................. 75
Space needed to open the enclosure cover........ 23
Technical data .................................................... 13
Terminal assignment..................................... 34, 35
Terminal strips .................................................... 34
Terminating resistor ............................................ 77
Weight................................................................. 15
Controller gain
Adjustment of gain .............................................. 53
Controller interlock .......................................... 58
Dark value ....................................................... 61
Decommissioning ............................................ 86
Default settings.......................................... 75, 79
Generate default settings.................................... 79
Device addresses............................................ 75
Device status................................................... 42
DIL switches .................................................... 40
DIL switch S4 ...................................................... 40
DIL switch S5 ...................................................... 41
Dimensions...................................................... 17
Display....................................................... 16, 55
Display of system information ......................... 72
EFE 1............................................................... 73
Start-up ............................................................... 54
EFE 1000 ........................................................ 73
Start-up ............................................................... 54
Electrical connection ....................................... 31
Electro static discharge ................................... 12
Electronic remote precision adjustment .......... 73
Start-up ............................................................... 54
EMC-wiring...................................................... 32
Emissions ........................................................ 12
ESD ................................................................. 12
ESD protection.................................................... 12
Factory settings ............................................... 75
Firmware
Display firmware version..................................... 72
Load firmware ....................................................... 2
Functional principle ........................................... 5
EDV No.: MD.299.01.06
Chapter: I
Date:
29.07.08
Page:
1/2
Index
I
2
Gain ................................................................. 53
Optimize gain...................................................... 71
Graphical display ............................................... 8
Guiding direction
Determine guiding direction ................................ 45
Guiding direction for center positioning............... 48
Reverse guiding direction ................................... 40
Guiding modes ................................................ 68
Guiding setpoint
Set guiding setpoint ............................................ 69
Hardware
Display hardware version.................................... 72
Infrared sensors............................................... 18
Installation ....................................................... 31
Installation site................................................. 22
Intended use...................................................... 3
Interlock ........................................................... 58
Keyboard interlock..................................... 58, 74
Limit switches .................................................. 56
Maintenance .................................................... 84
Manual positioning........................................... 68
Material setup ............................................ 52, 60
Activate material setup........................................ 61
Automatic material setup .................................... 62
Manual material setup................................... 63, 66
Procedure for web center-line guiding ................ 64
Procedure for web edge guiding ......................... 62
Motor overcurrent ............................................ 56
Operating manual
Symbols ................................................................ 1
Utilisation .............................................................. 2
Operating modes ............................................. 68
Automatic guiding ............................................... 68
Center positioning ............................................... 68
Manual positioning .............................................. 68
Operation display............................................. 55
Overcurrent...................................................... 56
Potentially explosive areas ................................ 3
Power pack...................................................... 20
ekr 500 web guiding controller
with removable control panel
Power supply................................................... 20
Programming interface .................................... 38
Protection class ............................................... 11
Remote control ............................................ 8, 74
Activate remote control ....................................... 41
Interface conditions............................................. 74
Remote control inputs ......................................... 74
Truth table........................................................... 74
Remote precision adjustment.......................... 73
Start-up ............................................................... 54
RoHS ............................................................... 12
RS232 interface............................................... 38
Safety instructions ....................................... 2, 10
Sensors
Definition sensor 1/sensor 2 ................................. 7
Infrared sensors .................................................. 18
Maintenance ....................................................... 85
Selection of the used sensors ............................. 41
Signal polarity ..................................................... 41
Technical Data .................................................... 18
Ultrasonic sensors .............................................. 18
Servo-center transducer
Adjust gain .......................................................... 46
Determine center position ................................... 46
Selection of the used servo-center transducer.... 40
Set position........................................................ 6
Start-up............................................................ 44
Storage............................................................ 21
Supply voltage................................................. 57
Technical data ........................................... 13, 16
Terminating resistors....................................... 77
Terms used ....................................................... 6
Timeout motor activation ................................. 57
Transport ......................................................... 21
Trouble shooting (FAQ)................................... 80
Ultrasonic sensors........................................... 18
Web center-line guiding................................... 68
Web edge guiding ........................................... 68
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: I
Page:
2/2
Connecting plan
A1
A1 Connecting plan
Overview processor board
Type plate
Power supply (plug X70)
Contact assignments in the plug connector:
Connector
Coupling
Contact
Signal
1
+24 V
2
GND
Potential equalization
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
1/9
Connecting plan
A1
Sensors
+24V
US…Sync.
IR Pulse +5V
IR Pulse GND
+12V
GND
-12V
Analogue IN
X1 = Sensor 1
X1
S4
X1
S5
1 2 3 4 5 6 7 8
brown
white
pink
green
yellow
grey
3 4 5 6 7 8
DIL Switch S5
S5
ON
IR 2001,
IR 2002,
IR 2005
2
5 6 7 8
brown
pink
green
yellow
grey
7 = OFF
DIL Switch S5
S5
ON
US 2003,
US 2007,
US 2008
5 = ON
3 = OFF
1 = ON
1 2 3 4 5 6 7 8
1 2
6
8
brown
black
blue
white
7 = OFF
5 = ON
3 = OFF
1 = ON
1 2 3 4 5 6 7 8
DIL Switch S5
ekr 500 web guiding controller
with removable control panel
*1 When connecting a second
sensor (X2), only type
US 2009 is to be used!
7 = ON
5 = ON
1 2 3 4 5 6 7 8
1 = OFF
US 2009
S5
ON
3 = OFF
*1
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
2/9
Connecting plan
A1
Sensors
+24V
US…Sync.
IR Pulse +5V
IR Pulse GND
+12V
GND
-12V
Analogue IN
X2 = Sensor 2
X2
S4
X2
S5
9 10 11 12 13 14 15 16
brown
white
pink
green
yellow
grey
11 12 13 14 15 16
DIL Switch S5
S5
DIL Switch S5
US 2003,
US 2007,
US 2008
S5
ON
*2
US 2009
7 = ON
6 = ON
4 = OFF
1 2 3 4 5 6 7 8
2 = OFF
16
white
14
blue
DIL Switch S5
9 10
brown
black
7 = OFF
6 = ON
4 = OFF
2 = ON
1 2 3 4 5 6 7 8
ekr 500 web guiding controller
with removable control panel
13 14 15 16
S5
ON
*2 When connecting a second
sensor (X1), only type
US 2009 is to be used!
10
pink
green
yellow
grey
7 = OFF
6 = ON
4 = OFF
2 = ON
1 2 3 4 5 6 7 8
IR 2001,
IR 2002,
IR 2005
brown
ON
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
3/9
Connecting plan
A1
Actuator
X7 = Actuator
Actuator A
Actuator B
1* Reversion of the guiding direction AUTO see 6.1.3
X7
42 43
X7
brown+white
pink+grey
42 43
DIL Switch S4
EMS 5
ON
S4
4 = ON
5 = OFF
6 = OFF
1=*
1 2 3 4 5 6 7 8
brown
white
42 43
DIL Switch S4
EMS 7
ON
S4
4 = OFF
5 = ON
6 = OFF
1=*
1 2 3 4 5 6 7 8
brown*
white*
42 43
* For former applications,
the following wire colours
are applicable:
brown = brown+white
white = pink+grey
EMS 10 / EMS 16
DIL Switch S4
ON
S4
ekr 500 web guiding controller
with removable control panel
4 = OFF
5 = OFF
6 = OFF
1=*
1 2 3 4 5 6 7 8
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
4/9
Connecting plan
A1
Actuator
1* Reversion of the guiding direction
AUTO see 6.1.3
2* Reversion of the guiding direction
SC see 6.1.4.1
Actuator A
Actuator B
+24V
+12V
GND
-12V
Analogue SC
EFE 1
X7
X3
42 43
44 45 46 47 48 49
42 43
45 46 47 48
pink
green
yellow
grey
X3 = Position feedback (SC)
brown
white
X7 = Actuator
X3
X7
DIL Switch S4
EMS 17
ON
S4
EMS 21/22
ON
6 = OFF
7 = OFF
8 = OFF
4 = OFF
5 = OFF
1=*
2=*
1 2 3 4 5 6 7 8
S4
ekr 500 web guiding controller
with removable control panel
6 = ON
7 = OFF
8 = OFF
4 = OFF
5 = OFF
1=*
2=*
1 2 3 4 5 6 7 8
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
5/9
Connecting plan
A1
Actuator
1* Reversion of the guiding direction AUTO see 6.1.3
Actuator A
Actuator B
X7 = Actuator
X7
42 43
X7
brown
white
42 43
DIL Switch S4
CompactGuide
ON
S4
ekr 500 web guiding controller
with removable control panel
6 = OFF
7 = ON
8 = OFF
5 = ON
4 = ON
1=*
1 2 3 4 5 6 7 8
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
6/9
Connecting plan
A1
Servo-center transducer
X10 = Servo-center transducer OMG 8 (Namur)
2* Reversion of the guiding direction SC see 6.1.4.1
Namur A
Namur B
GND
X10
X10
51 52 53 54 55 56 57 58
brown
blue
51 52
DIL Switch S4
OMG 8
S4
ON
8 = OFF
2=*
7 = ON
1 2 3 4 5 6 7 8
+24V
+12V
GND
-12V
Analogue SC
EFE 1
X3 = Servo-center transducer OMG 4
X3
X3
45
47 48
pink
yellow
grey
44 45 46 47 48 49
OMG 4
DIL Switch S4
S4
ON
ekr 500 web guiding controller
with removable control panel
8 = ON
7 = ON
2=*
1 2 3 4 5 6 7 8
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
7/9
Connecting plan
A1
Remote control, enable controller, relay contact
X14 = Remote control
H16
H15
H14
H13
H12
H11
H10
H9
GND
GND
Input 0
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
+24V
+24V
H9 - H16: LED allocated to inputs 0-7
X14
X14
72 73 74 75 76 77 78 79 80 81 82 83
Keyboard lock
X10
Namur A
Namur B
GND
+24V
Controller interlock
X10 = Enable controller, relay contact
Relay
X10
51 52 53 54 55 56 57 58
Enable
actuator
output stage
ekr 500 web guiding controller
with removable control panel
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
8/9
Connecting plan
A1
+24V
+12V
GND
-12V
Analogue SC
EFE 1
Electronic remote precision adjustment EFE (option)
X3 = EFE 1*
X3
X3
45
47
49
pink
yellow
grey
44 45 46 47 48 49
DIL Switch S4
EFE 1
21 0 1 2
3
1 2 3 4 5 6 7 8
4
5
6
7
8
9
10
3 = ON
3
4
5
6
7
8
9
10
S4
ON
EFE 1
H16
H15
H14
H13
H12
H11
H10
H9
GND
GND
Input 0
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
+24V
+24V
Namur A
Namur B
GND
+24V
Controller interlock
X14 = EFE 1000*
Relay
X14
X10
72 73 74 75 76 77 78 79 80 81 82 83
51 52 53 54 55 56 57 58
79 80
83
brown
yellow
pink
green
red
72
2
6
EFE 1000
efe 1000
ekr 500 web guiding controller
with removable control panel
4
3
white
1
* Either an EFE 1 or an EFE 1000
can be connected.
Simultaneous connection of an EFE 1
and an EFE 1000 is not possible!
EDV No.: MD.299.01.06
Date:
29.07.08
Chapter: A1
Page:
9/9