BST eltromat Web Guiding System

EKR 1500
with analogue sensors and CCD 2004

Translation of the
Original Operating Manual

BST eltromat International GmbH

Heidsieker Heide 53
33739 Bielefeld, Germany

Telephone: +49 (0)5206 / 999 - 0

Fax: +49 (0)5206 / 999 - 999
E-Mail: [email protected]

Edition: EDV No.:

12.04.2011 V3D.010.01.03
 Definition of the symbols in this manual

Attention

Instructions with this symbol safeguard the operator from injury

Caution

Instructions with this symbol must be strictly adhered to failure to do so could result in
electrocution

press key

key combination; between the keys means that these

keys have to be actuated simultaneously

LED ‘OFF’

LED constantly lighted = activated phase

LED blinking
 0.0
Contents

Chapter 0 Contents

Chapter 1 Description
1.1 General
1.2 Connectable components
1.3 Operating elements
1.4 Significance of the keys on the front panel
1.5 Significance of the LEDs on the front panel
1.6 Safety instructions
1.7 Emissions

Chapter 2 Technical data

2.1 EKR 1500
2.2 Optical edge sensor IR 2001
2.3 Optical edge sensor IR 2002
2.4 Optical edge sensor IR 2005
2.5 Ultrasonic edge sensor US 2003, US 2008
2.6 Ultrasonic edge sensor US 2007
2.7 Ultrasonic edge sensor US 2009
2.8 Camera CCD 2004
2.9 Pneumo-electronic transducer ZT 6.008

Chapter 3 Transportation/Storage

Chapter 4 Mounting
4.1 Location requirements
4.2 Mounting plan
4.3 Installation
4.4 Installation of EMC-wiring
4.5 Installation of pneumatic edge sensor KF ...

Chapter 5 Start-up
5.1 Preparations for start-up
5.2 Adjustment of sensors
5.3 Start-up
5.4 Basic adjustment
5.5 Determine desired sense of rotation for manual operation
5.6 Starting automatic operation with sensor 1 (possibly sensor 2)
5.7 Electrical actuators
5.8 Hydraulic actuators
5.9 Pneumatic system BS 100 / pneumo-hydraulic transducer ZT 6.008
5.10 Start-up of camera CCD 2004

Chapter 6. Operation
6.1 Commander
6.2 Test of material contrast with optical sensors
6.3 Change of web material
6.4 Watchdog function

Chapter 7 Remote control

Chapter 8 Troubleshooting

Chapter 9 Maintenance

Chapter 10 De-commissioning

Annex Connection plan

Start-up of the actuator EMS 17

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 1.0

Please follow the instructions of

Start-up, maintenance and installation
as described in the operating instructions

1. Description
1.1 General
The EKR 1500 system is a microprocessor-controlled web guiding system. This guiding system
may be used for:
- web edge guiding (right or left)
- center-line guiding
- guiding on continuos or interrupted printed lines
- guiding on continuos or interrupted printed edges
- guiding to a printed line or edge with automatic change-over to edge or center-line
guiding when the printed line/edge is interrupted or has got lost (for example, in the
case of a web splice)

Please contact the producer for any different application.

The system has PLC-compatible inputs and also an ‘OK-relay’ with NO and NC contact.
Full integration into the machine control system via:

- I-O Module potential-free in- and outputs for extended PLC messages and
commands
- Intercon-Module direct, serial connection for integration of system results,
messages and commands into the machine control system.
- Interbus-S Module direct connection to Interbus-S Module as remote bus station
- PDP-Module for instantaneous communication with locally peripheral
equipment

Notice: Please find the connection plans of the nominated modules at the corresponding
operating instructions.

1.2 Connectable components

The following components have been discontinued. They are no longer available for new systems.
The corresponding sections of the operating instructions are only relevant to the operation of
existing systems.
Component replacement
CCD 2004 CLS Pro 600
IR 2001/5/30 L IR 2005/5/30
IR 2001/3/100 IR 2001/10/100
IR 2001/5/100 IR 2001/10/100
IR 2001/3/30 IR 2001/10/30 resp. IR 2005/3/30
US 2003/30 US 2010/40
US 2003/70 US 2010/70
US 2008/30 US 2007/40 resp. US 2009/40
US 2008/70 US 2009/70
EMS 6; 80 mm stroke none
EMS 16 EMS 18
EMS 17 EMS 18
ZT 6008 none
Profibus DP-Module for switching cabinet installation none
CAN-Module none
IO-Module none

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1.3 Operating elements

* The amplifier includes all necessary operating elements.

Option: - Remote control by external signals, sensors or keys

Attention! External keys will interlock the reverse function keys at the amplifier.

- If system locking is desired (e. g., in case of machine stop), this can be
achieved by means of external contacts or signals from the PLC.

* Connection of components via separated terminal compartment.

Advantage: quick and easy accessibility to the terminal parts.

* Indication of web edge position by two LED arrays

Advantage: - simple control of the web edge within the measuring range of sensors
- simple adjustment of the desired position of the web or edge sensors
- variations of web width exceeding via the admissible value

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1.4 Signification of the keys on the front panel

key and/or combination of keys function

AUTO (1) = automatic guiding

MAN (2) = manual positioning

S-C (3) = servo-center of the servo component

 / + (4) + MAN = manual shifting
+ AUTO = shifting of guiding point to the left *
+ SET UP + AUTO = increase of gain
 / - (5) + MAN = manual shifting
+ AUTO = shifting of guiding point to the right *
+ SET UP + AUTO = decrease of gain
SET UP (6) AUTO = release of gain with the keys (4) and (5).
+ MAN and/or S-C = SET UP when changing the material
ENTER (7) = storing of the adjustment and end of SET UP
functions
”SENSOR LEFT” (8) = guiding to the left web edge
”SENSOR RIGHT” (9) = guiding to the right web edge
Line/Printed edge (20) = guiding to a printed line or edge (also interrupted) with
CCD 2004
Watchdog (21) = automatic change-over to edge guiding when the
printed line or edge is interrupted or has got lost.
When the printed line or edge reappears, the guiding
function is taken over automatically by CCD 2004

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1.5 Signification of the LED´s on the front panel

* The LED’s on the keys indicate the switched-on function.

* The blinking of LED’s AUTO (1) , MAN (2) , S-C (3) , SET UP (6) or LED- arrays 10 - 14
and/or 15 - 19 indicate a fault message. Simultaneously, the OK-relay is switched-off. (see
also chapter 8)

* LED-No. 10, 14,15 and 19 (red) signalise the limits of the measuring band of the sensors.

* LED-No. 12 and 17 (green) signalise the center of the measuring band of the sensors.

* additional indications of the LEDs for gain and shifting of the guiding point see points 5.10.3,
6.1.3, 6.2 and 6.3.

10 11 12 13 14 15 16 17 18 19

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1.6 Safety instructions

* Installation of the BST eltromat equipment into the production machine according to the relevant
rules ( EN 294, EN 349) and the specific branch-oriented regulations for prevention of accidents,
such as:

- Safety distance between BST eltromat equipment and customer´s specification, e. g. machine
walls, construction etc.

- Installation of connecting cables between amplifier and controller and/or edge sensor
stumble-free, nontension and well anchored.

- Take care of free headroom. If the free passage is limited, respective building components
have to be stuffed and painted in yellow/black.

Assembly, installation and commissioning must be carried out by qualified personnel !

Please do not open the unit until the line voltage is switched off!

When operation at open unit is necessary, only protection class IP20 is present. There
will be an increased risk of danger by line voltage !

- Please do not use the guiding frame as a tread or a step ladder.

- Don’t remove any safety devices.

During functional testing outside of production machine and/or during the start-up
procedure the actuator will carry-out positioning movements!
Make relevant safety arrangements during performance check !
During start-up procedure, the total safety concept of the production machine will have to
be considered.

* Before commissioning remove transport safety devices (if present).

1.7 Emissions

The A-rated equivalent continuous sound level of the equipment is lower than 70 dB(A).

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2. Technical Data

2.1 EKR 1500

* Line voltage: 115V/230V +10% / -20% 50-60Hz

* Power consumption: approx. 80VA

* Fuses: 115V 1 AT
230V 0,5 AT

* Outputs: amplifier (adjustable, see also ‘Lay jumper according to

application’, chapter 5.0, point 5.1)
+/- 24V; max. 1A or
+/- 24V; max 0,33A or
+/- 300mA current source of electric power short circuit proof,
Dither amplitude adjustable

Supply to accessories
+/- 12V (min. +/- 11,4V) at max. 50mA
+ 24V non regulated supply max. 0,4A

Status signal (”system OK”)

potential-free change-over switch, max. 230V, 1A

* Inputs: remote inputs (signification see ”Truth table” chapter 7)

lock-out (controller interlock): possible by means of external
switch or PLC
limit switch inputs: (without cut-out)

Ri = 4,7 kOhm
active (1) > 8V
not active (0) < 4V

tlow > 30ms

Uin Max acc. to IEC 1,2kV / 50µs

analogue inputs (see also chapter 5, point 5.1 and connecting

plan)
2x 0...+ 5V or 0...+ 10V, individual adjustable
2x ± 9,75V or 0... + 9,75V, individual adjustable
2x ± 11,75V
1x NAMUR adaptation with output ± 11,75V

tacho input for motor powered actuator

* Interface: serial interface RS485 for BST eltromat module bus

* Protection class: IP 54

* Ambience conditions: temperature: 0 - max. 45 deg.C

atmospheric humidity: 0 - 90%, non-condensed

* Dimensions: W = 263mm, D = 214mm without screwed connections,

H = 115mm

* Weight: approx. 3kgs

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2.2 Edge sensor IR 2001

Power supply: by amplifier

Measuring band: 12mm, typical

Maximum sensing range: 15mm, typical

Output: analogue

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 40mm

H = 95mm
L = 107mm

2.3 Edge sensor IR 2002

Power supply: by amplifier

Measuring band: 8mm, typical

Maximum sensing range: 13mm, typical

Output: analogue

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 25mm

H = 57mm
L = 85,5mm

2.4 Edge sensor IR 2005

Power supply: by amplifier

Measuring band: 12mm, typical

Maximum sensing range: 15mm, typical

Output: analogue

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 25mm

H = 94mm
L = 69mm

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2.5 Ultrasonic sensor US 2003, US 2008

Power supply: by amplifier

Measuring band: 15mm, typical

Maximum sensing range: 15mm, typical

Output: analogue

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 25mm

H = 76mm
L = 113mm

2.6 Ultrasonic sensor US 2007

Power supply: by amplifier

Measuring band: 15mm, typical

Maximum sensing range: 15mm, typical

Output: analogue

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 25mm

H = 94mm
L = 69mm

2.7 Ultrasonic sensor US 2009

US 2009/40 US 2009/70
Power supply: by amplifier
Measuring band: 12 mm 14 mm
Maximum sensing range: 12 mm 14 mm
Output analogue analogue
Protection class: IP 67 IP 67
Ambience conditions: temperature: 0 ... +60 °C temperature: 0 ... +60 °C
atmospheric humidity: 5…90% atmospheric humidity: 5…90%
Dimensions: W: 96 mm W: 96 mm
H: 88 mm H: 118 mm
L: 39 mm L: 39 mm

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2.8 CCD 2004

Operating voltage: 15V to 24V (by amplifier)

Power consumption: 6W

Measuring band: 8mm, typical

Min. line width: 0,8mm

Sensor resolution: 2000 pixel

Exposure time: min. 1ms

max. 20ms

Interface: serial interface RS485 for BST eltromat module bus

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Weight: 845g

2.9 Pneumoelectric transducer ZT 6.008

Power supply: by amplifier

Signal inputs: 0 - 10 mbar

Output: ± 10V

Protection class: IP54

Ambience conditions: temperature: 0 - 45 deg.C

atmospheric humidity: 5 - 90%, non-condensed

Dimensions (standard application): W = 200mm

H = 70mm
L = 120mm (without air connections)

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 3.0
3. Transport/Storage

Depending upon the order, delivery will be carried out:

- completely built-in and connected with the actuator or

- as component parts in standard cardboard boxes with cellular lining material.

If the unit is not incorporated immediately, please storage it in a dry room until mounting.

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4. Mounting / Installation

4.1 Location requirements

The amplifier has to be installed in a dry, vibration-free area.

Ambient temperature: 0 - max. 45 deg.C

4.2 Mounting plan

262
180

M4 or Ø 5

housing EKR 1500

212 191

131

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4.3 Installation

Mounting plan see point 4.2

19
1 - Open terminal
compartment
AU TO Pull the two rear
mounting rails upward

150
SET UP ENTER

MA N SENSOR LEFT SENSOR RIGHT

and screw into the

mounting wall

214
S-C BRI GHT DARK

25
6 264 115
276
10

2 - Push the housing up-

ward so that the moun-
ting rails stay flush
AU TO

again in respect of the

MA N SENSOR LEFT SENSOR RIGHT
SET UP ENTER
upper edge of the
housing.
S-C BRI GHT DARK

3 - Apply the third fixing in

the terminal compart-
ment. Complete wiring
AU TO
and close terminal
SET UP ENTER
compartment.
MA N SENSOR LEFT SENSOR RIGHT

S-C BRI GHT DARK

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4.4 Installation of EMC-wiring

remove 90mm of
disk of the cable shield external insulation
fitting

black rubber
sealing-
parts conical sealing
(metal/rubber)

nut unscrew nut and

sealing parts and pin
them up to the end
of the cable

figure 1 figure 2

insulated cable leads

remove 60mm of shield, so galvanised washer

that 30mm remain visible 10 x 16 x 0,5 DIN 988
30mm
vanished shield

Fan the protective shield, so

that the individual wires of the
shield protrude evenly from
the cable, approx. at right angle.
Tread the individual insulated
leads through the galvanised
washer, included in delivery
and press the washer onto the
shield braiding.

figure 3 figure 4

only for connecting cable CCD 5000

up to hardware version G
and Interbus-S

ferrite core

Refold and twist the shield housing

braiding over the washer.
Tighten the cable in the cable
gland. Strip the lead ends cable gland
(eventually, use protective lugs)
and wire according to connection
diagram. Screw down the cable gland and
then pin up the ferrite core to the
end of the cable, according
to the drawing.

figure 5 figure 6

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 4.0
4.5 Installation of pneumatic sensing system

1. Pneumatic edge sensors have to be mounted in such a way that with horizontal web path the
connection S1, carrying the higher pressure, is placed below (air escape S1 turned towards
above).
2. Slip the hose ends onto the corresponding connection pieces S1 and S2.1at the pneumo-
electronic transducer ZT 6.008.
3. Connect the second edge sensor with the second connection piece S1 and the connection
piece marked S2.2. If only one sensor is present, seal the second connection S1 at the
ZT 6.008. S2.2 remains open and blows off.
4. The hose pipes towards the sensors should not exceed a length of 3m each and should have a
few ‘bends’ if possible.
5. Connect the air outlet at the BS 100 unit by means of single air hose with the connection piece
in the middle (not varnished) at the ZT 6.008 transducer.
When the ZT 6.008 is not directly mounted to the BS 100 unit, the length of the air hose may
be up to 6m (please contact the manufacturer for longer hoses).

Attention: Do not connect BS 100 with the connections S1, S2.1 or S2.2 at the ZT 6.008
transducer; such action will destroy the ZT 6.008!
Blowing in compressed air is inadmissible and will also destroy the unit!

The lateral channel compressor unit BS 100 has to be installed on even and plane surface either
vertically or horizontally.
In case of separate mounting, the pneumo-electronic transducer ZT 6.008 has to be attached to
a vibration-free surface. Make sure that free access to the interior of the box is possible after
having removed the cover.

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 5.0
5. Start-up

5.1 Requirements for Start-up

1. Set DIL-switches according to application.

Lageplan EKR 1500

EPROM

Prozessor RAM

TRAFO

S1.1
S1.2
S1.3
S T U V W X S1.4
S1.5
JX12 JX13 JX14 S1.6
I S1.7 H1
H J K L M N Z S1.8 H2
Y S2.1 H3
JX8 JX9 S2.2 H4 A
H11 S2.3 H5 B JX11
115V: F1= 1AT F1 S2.4 H6 C
230V: F1= 0,5AT OK 444546474950515253545556575859606162636465666768697071727374 S2.5 H7 D
O S2.6 H8 E JX10
P 404142 0 6 7 8 9 1011 0 13141516171820212224252628293132333435363738 S2.7 H10 H9 F
L N R Relais S2.8

Darstellung nicht maßstäblich! LED +5V

S1.1 = Inverse function Automatic

S1.2 = OFF = electric motor powered actuator
ON = lifting of zero level and Dither for hydraulic units
(from software version E0030401 see schedule 1)
S1.3 = Inverse function S-C
S1.4 = OFF = normal operation
ON = guiding to sensor 3 and 4 with scaling = 1:1 (e. g. Slave)
S1.5 = OFF = EMS1/plunger coil regulator
ON = EMS5 or EMS 1000 power module
S1.6 = ON = chase and follow system with camera CCD 5000
S1.7 = = inverse function CCD camera 3

S1.8 = OFF = EKR 1000, EKR 1500

ON = CCD Line Guider
Choice of lighting for CCD 2004
S2.3 S2.2 S2.1
OFF OFF OFF Lamp 1 and 2 always off
OFF OFF ON Lamp 1 always on, lamp 2 always off
OFF ON OFF Lamp 2 always on, lamp 1 always off
OFF ON ON Lamp 1 and 2 always on
ON OFF OFF Choice of the lamps automatically

S2.4 = OFF = ”Shifting of guiding point” via arrow keys is permitted

ON = ”Shifting of guiding point” via arrow keys is locked

S2.5 = = from software version E0030401 see schedule 1

S2.6 = ON = exposure time adjustment of ‘CCD 2004 from H’ is locked

S2.7 and S2.8 = see schedule 2

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 5.0
Schedule 1 Special functions of the DIL switches S1 and S2
from software version E0030401

S1.2 S2.5 function

OFF OFF electric motor powered actuator

 lifting of zero level OFF
 Dither OFF

OFF ON electric motor powered actuator

 lifting of zero level ON
 Dither OFF

ON OFF hydraulic actuator

 lifting of zero level ON
 Dither ON

ON ON hydraulic actuator
 lifting of zero level OFF
 Dither ON

Schedule 2 Signification of LED´s in the terminal box for service indication

The type of indication can be selected by means of S2.7 and S2.8.

LED S2.7 OFF S2.7 ON S2.7 OFF S2.7 ON

S2.8 OFF S2.8 OFF S2.8 ON S2.8 ON
H1 CCD1 locking from actuator fully
remote control stabilized
H2 CCD2 locking from external release of
CCD1 keyboard and remote
control interlock
H3 CCD3 locking from
CCD2
H4 INTERCON (1/2) locking from
CCD3
H5 INTERBUS-S module locking from external
command module
INTERBUS,
INTERCON,
I-O Modul
H6 I-O module (1/2) locking from
FVG 1000 module
H7 FVG 1000 module internal locking of the EKR
H8 blinker blinker blinker blinker

The blinker indicates a perfect program flow.

LED H11 indicates the correct function of the relay ‘system ok’ (LED is lighting)
LED extinguishes if a failure occurs (see also chapter 8 ‘Trouble shooting’)

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2. Lay jumper according to the application

The amplifier (standard version with electric motor powered actuator) is preset by manufacturer as
follows:

jumper O-P equipotential bonding carried out

jumper J-K signal input 0...10V
jumper M-N signal input 0...10V
jumper D-E tacho ‘OFF’
jumper A motor ± 24V
jumper S-T signal input ± 9,75V
jumper V-W signal input ± 9,75V

Modification/adjustment is only necessary by a different application.

Socket Jumper Function Comment

JX1 O-P equipotential bonding carry out equipotential bonding

P-R PE / 0V non equipotential bonding

JX8 H-J signal sensor 3 signal input 0...5V

J-K (terminal 56) signal input 0...10V

JX9 L-M signal sensor 4 signal input 0...5V

M-N (terminal 60) signal input 0...10V

JX10 D-E motor tacho + tacho ‘OFF’

E-F motor tacho - tacho ‘ON’

JX11 A servo component A motor ± 24 V

B servo component B (0V) plunger coil ± 300mA
C servo valve ± 1A

JX 12 S-T signal sensor 1 signal input ± 9,75V

T-U (terminal 11) signal input 0...9,75V

JX13 V-W signal sensor 2 signal input ± 9,75V

W-X (terminal 18) signal input 0...9,75V

JX14 I-Z reserved

Z-Y reserved

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3. Set line voltage

Make sure that the voltage on the name plate of the amplifier corresponds to the actual supply
voltage!
Correct in case of deviation.

XT1.1
XT1.2
XT1.3
XT1.4
230V Lageplan EKR 1000 H

EPROM

F1 = 0,5AT Prozessor RAM

TRAFO

S1.1
S1.2
S1.3
S T U V W X S1.4
XT1.1
XT1.2
XT1.3
XT1.4
S1.5
JX12 JX13 JX14 S1.6
I S1.7 H1
H J K L M N Z S1.8 H2
Y S2.1 H3
JX8 JX9 S2.2 H4 A

115V 115V: F1= 1AT

230V: F1= 0,5AT
F1
H11

O
OK 444546474950515253545556575859606162636465666768697071727374
S2.3
S2.4
S2.5
S2.6
H5

H7
H6

H8
D
E
B JX11
C

JX10
P 404142 0 6 7 8 9 1011 0 13141516171820212224252628293132333435363738 S2.7 H10 H9 F
L N R Relais S2.8

Darstellung nicht maßstäblich! LED +5V

F1 = 1AT

4. Connection of components according connection plan

Installation of EMC-wiring see point 4.4

5. Connection of remote control according connection plan (if present)

6. Switch-on line voltage.

5.2 Sensor adjustment

Using sensors of the type PLE ... or GL 240, adjustment of the sensors have to be carried before
start-up.

Sensor PLE ...

1) Switch on light source and amplifier

2) After 15 minutes warm up time the output signal of the PLE units should be adjusted (when
BME sensor frames are supplied the adjustment is made by manufacturer).

 Remove the cover plate with the cable gland and pull out the PCB
 Connect an AVO meter to the terminals 2 and 3
 Ensure that there is no obstruction between the light source and the PLE, then rotate
the PLE around its longitudinal axis until the meter gives maximum reading. With the
AVO still connected turn potentiometer on the PCB to give a reading of -5V
 Reposition the PCB and attach the cover plate

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Sensor GL 240

1) Switch on sensor

2) After 15 minutes warm up time carry out the compensation:

 Remove the upper housing cover. Both the fluorescent lamp and the electronics
are accessible.
 A measuring instrument with an internal resistance greater than 10 kOhm/V should be
connected between the connections 3 and 6.
 Cover receiver side with opaque material completely and check if the measuring
instrument shows ‘zero’. If this should not be the case, a correction of the zero point
should be made with the potentiometer 2.
 With free fork-shaped opening, a room temperature of 15...25°C and a lamp voltage of
220V, the measuring instrument must indicate 5V. Corrections can be carried out by
means of potentiometer 1.

5.3 Start-up

The system only admits operation with components actually present.

Regarding actions to be carried out, also see ‘components connected’.

5.4 Basic SET UP

Only necessary after installation or

change of components connected!

5.4.1 Conditions: - non material in viewing range of edge sensors

- clean the lenses of the edge sensors and camera CCD 2004
- set remote precision adjusting device to center position (if present)

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5.4.2 Basic initialisation

The basic initialisation has to be carry out once at first start-up. The amplifier recognised
hereby the connected components.
The LED array of the CCD 2004 indicates the exposure time (signification see point 5.4.3)

1. Actuate simultaneously keys ‘PLUS’ and ‘SET UP’

SET UP

2. Press key ‘ENTER’

ENTER

3. Clean existing edge sensor. Remove material out of the viewing range of the edge sensor
(if present)
Press key ‘ENTER’

ENTER

4. Cover the edge sensor completely, e. g. with card board

Press key ‘ENTER’

ENTER

5. Release present edge sensor

Press key ‘ENTER’

ENTER

6. Cover edge sensor completely again.

Press key ‘ENTER’

ENTER

The basic initialisation is completed and will only repeated when additional components
are connected.

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5.4.3 Indication of the CCD 2004 exposure time

LED array exposure time

 2ms

 4ms

 6ms

 8ms

 10ms
 12ms

 14ms

 14ms

= LED 'ON'
= LED 'OFF'

5.5 Determine desired sense of rotation for manual operation

1. Press key ‘MAN’

2. Press key ‘PLUS’ or Observe guiding device !

‘MINUS’ If opposed positioning movement is
desired interchange actuator polarity
or at terminals 28 and 29.

Attention: When actuator EMS 6 will be

employed, interchange the ter-
minals 65 and 66 in addition.

5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2)

5.6.1 Carry out material SETUP with sensor 1/sensor 2

The material SET UP is to carry out only in the presence of

- pneumatic sensor or
- transparent web material with optical sensing system or
- sound transmitting web material with ultrasonic sensing system

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5.6.1.1 Procedure for web edge guiding

1. Adjust guiding to ‘MAN’ or ‘S-C’

or

2. Select sensors
or

3. Press key ‘SET UP’

SET UP

4. Remove material from the sensor and clean the lenses!

Press key ‘ENTER’

ENTER

5. Cover the sensor with the material to be guided!

Press key ‘ENTER’

ENTER

The SET UP is now completed, and the guiding system may be put into operation.

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5.6.1.2 Procedure for guiding to web center-line

1.Adjust guiding to ‘MAN’ or ‘S-C’

or

2. Preselect both sensors

3. Press key ‘SET UP’

SET UP

4. Remove all material from the sensors and clean the lenses!
Press key ‘ENTER’

ENTER

5. Cover the sensors with the material to be guided!

Press key ‘ENTER’

ENTER

6. Remove material from both sensors and clean the lenses!

Press key ‘ENTER’

ENTER

7. Cover completely the sensors with the material to be guided!

Press key ‘ENTER’

ENTER

The SET UP is now completed, and the guiding system may be put into operation.

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5.6.2 Check and/or determine guiding direction

1) Press key ‘edge left’ (8)

2) Press key ‘AUTO’

If the actuator guides the material out of the viewing range, DIL switch S 1.1 has to be
switched over.

Setting is required only for the first start-up.

If the type of the web material requires reversion of the guiding direction, this happens auto-
matically during the material-SET UP.

5.6.3 Adjustment of gain for sensor 1 and sensor 2

condition: - material web is pulled in

- actuator is not in a stop position

1) Press key ‘AUTO’

2) Press key ‘SET UP’ SET UP The LED´s at the amplifier (LED 10 - 19)
reverse automatically and indicates the value of
gain..

3) Increase gain with key ‘PLUS’, until the guiding device starts
oscillating. The ‘light spot’ of LED indication at the amplifier
moves from LED 10 to LED 19.
(LED 19 = maximum of gain, we encouraged to leave the
maximum of gain, if there is non oscillating)

4) Decrease adjustment of gain with key ‘MINUS’, until the guiding

operates ‘stable’. If slow guiding reaction is desired, the gain
may still be reduced further.

5) Press key ‘ENTER’

ENTER Gain has been stored.

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5.6.4 Start-up of servo-center operation

Press key ‘S-C’ The servo component must move towards the center a
and stop there. If the servo component is moving into t
the final position, DIL switch S1.3 has to be switched
over.

Attention: If using an analogue servo-center transducer (CK 37, BI 5 G....) preselect

the adjustment of gain.

Procedure:
1) Press simultaneously key ‘S-C’ and ‘SET UP’

+ SET UP
LED indication at EKR 1000 switch
over and indicate the value of gain.

2) Increase adjustment of gain with key ‘PLUS’, until the guiding

device starts oscillating. ‘Light spot’ moves from LED 10 to
LED 19 (LED 19 = maximum of gain).

3) Decrease adjustment of gain with key ‘MINUS’, until the

oscillating stops. If slow guiding reaction is desired, the gain
may still be reduced further.

4) Press key ‘ENTER’

The adjustment is finished.

ENTER

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5.7 Electric powered actuators

Attention! During the start-up the actuator will carry out positioning movements !
The machine must be protected against danger of injury according to the
relevant rules and regulations!

5.7.1 Use of limit switches

Limit switches for limitation of the regulating distance (stroke) can be used only with electric
motor powered actuators.

The motor is switched off when reaching the end of stroke by means of an alarm contact of the
limit switch. The output will be switched off by a software program.
The motor will be switched off without cutout.

When reaching the end of stroke, the LED on the controller corresponding to the mode of
operation selected (AUTO, S-C or MAN) will start blinking.
When activating the opposite direction the alarm message will reset automatically.

When using a Power Module the alarm message ”thermal protection active” will be generated by
the alarm signal ”both limit switches activated”. The output will then be switched off.
The alarm message will keep up also after ‘power off’.
The alarm message can only be reset by pressing the key ”ENTER” at the commander.

function terminal 71 terminal 73

limit switch 1 1 0

limit switch 2 0 1

thermal protection (output OFF) 1 1

5.7.2 Positions of the DIL switches and jumpers

Actuator EMS 1 and EMS 10 Actuator EMS 5

S1.2 = OFF S1.2 = OFF

S1.5 = OFF S1.5 = ON
Set jumper ‘A’ Set jumper ‘A’
Set jumper ‘D-E’ Set jumper ‘D-E’

Actuator EMS 6 Power module (EMS 3 and EMS 4)

S1.2 = OFF S1.2 = OFF

S1.5 = OFF S1.5 = OFF
Set jumper ‘A’ Set jumper ‘A’
Set jumper ‘E-F’ Set jumper ‘D-E’

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5.8 Hydraulic powered actuators

5.8.1 Zero point adjustment

Also by adjustment of DIL switches, carry out a zero point adjustment when using an
electrical-hydraulic guiding unit with plunger coil regulator

Procedure:
1) switch on electrical-hydraulic guiding unit and EKR 1500

2) Press key ‘MAN’ at EKR 1500

3) Press key ‘SET UP’ at EKR 1500

4) Bring actuating cylinder by means of arrows keys (4) and/or (5) into center position.

5) Remove metal cover of the plunger coil regulator and unlock the knurled wheel
arranged in the upper area.

6) Turn knurled wheel into one direction - at maximum 5 rotations - until the actuating
cylinder starts moving. Record position.

7) Turn knurled wheel into the opposite direction - at maximum 10 rotations - until the
actuating cylinder starts moving into the opposite direction. Record position.

8) Turn knurled wheel into the center of the a/m two positions and lock it. Close again the
cover of the plunger coil regulator.
From software version E00304-01 Dither amplitude
and zero point adjustment can be varied

5.8.2 Adjustment of Dither amplitude

Attention: Dither amplitudes are significant for output setting = ± 300mA only.

Software Software version from E00304-01

version up to S1.2 has to be set to ON
E00303-01
mode of operation terminal 71=X terminal 71=0 terminal 71=1 terminal 71=0 terminal 71=1
EKR... terminal 73=X terminal 73=0 terminal 73=0 terminal 73=1 terminal 73=1
MAN 41 Hz 50Hz 50Hz 50Hz 50Hz
without Set up 5mA 5mA 10mA 25mA 50mA
MAN 41Hz 50Hz 50Hz 50Hz 50Hz
with Set up 25mA 5mA 10mA 25mA 50mA
AUTO or 41Hz 50Hz 50Hz 50Hz 50Hz
S-C 25mA 25mA 10mA 25mA 50mA

5.8.3 Lifting of zero level

Special application of the DIL switches S1.2 and S2.5.

Only significant from software version E00304-01.

S1.2 S2.5

ON OFF lifting of zero level ON

Dither ON
ON ON lifting of zero level OFF
Dither ON

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5.8.4 Adjustment of DIL switches and jumper

S1.2 = ”ON”
S1.5 = ”OFF”
Set jumper ”B”
Set jumper ”D-E”

5.9 Preparation for BS 100 and ZT 6.008

1) Switch on lateral channel compressor unit BS 100 and check sense of rotation (see arrow
marking on compressor housing) if necessary, correct sense of rotation.

Note: The LED diodes Pmin, Pmax and OK as well as the adjusting screw for regulating the air
flow are located in the ZT 6.008 box. For adjustment, remove cover of the ZT 6.008.

2) The pressure of the air flow can be adapted to the respective application by means of the
adjusting screw in the ZT 6.008 while the sensors are free from material.

* The air pressure is within the admissible tolerance when only the green LED ‘OK’ is
lighted.
* Should the red LED Pmin be lighted, screw in the adjusting screw until Pmin gets
extinguished and the green LED OK lighted.
* If the red LED Pmax is lighted, screw out the adjusting screw until Pmax gets
extinguished and the green LED OK lighted.

Attention: Never clean the edge sensor with compressed air!

It will destroy the pressure pick up!

5.10 Start-up of camera CCD 2004

5.10.1 Adjust the CCD 2004 camera to the scanning distance

The distance is correct when both lamps shine on the common light spot.

During operation, there will be no need to alter the distance.

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5.10.2 White balance

In the presence of critical material contrasts, the scanning qualities of the CCD 2004 sensor
Can possibly be optimized by a white balance.
For standard applications the adjustment made at the factory will be okay.

Attention: * the white balance must carried out at working temperature of the sensor
(abt. 3min. after having been switched on, the sensor will have working
temperature)
* use clean white paper, e.g. a business card
* The light spot of lamps and the scanning distance of CCD 2004 sensor to
the material to be detected must be adjusted according 5.4.1

Procedure:

1) Press simultaneously the keys ‘SETUP’ and ‘PLUS’

SET UP +

2) Press simultaneously the keys ‘PLUS’ and ‘MINUS’

+ The LED array on the

camera is blinking.

3) Lay clean white and not shining paper (e.g. business card) onto the stretched web
within the viewing range of CCD 2004 camera

Example 1

white paper fixed at

scanning position

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Example 2

white paper fixed at

scanning position

Important: Please note that the paper is positioned exactly as the web will run in
the machine. The paper must be without wrinkles or washboard marks. While
carrying out the white balance, make sure that the paper is not moving.

4) Press key 'SET UP line' or 'SET UP edge' at the CCD 2004 camera.

The LED array at the CCD 2004 indicates the process of the white balance (three
LED blocks will get 'ON', one after the other). Upon completion of the white
balance, the entire LED array at the CCD 2004 camera is blinking again.

5) Press key 'SET UP' at the commander

SET UP

The white balance is finished.

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5.4.3 Sensor SET UP

1) Position the CCD 2004 camera laterally over the web so that the desired line or
printed edge is situated in the light spot

Edge scanning CCD 2004 Line scanning CCD 2004

LED display LED dispaly LED display LED display

edge bright/dark edge dark/bright line dark line bright

LED ‘ON’
LED ‘OFF’
2) Press and release the key 'SET UP line and/or 'SET UP edge' at the CCD 2004
camera

While pressing the key, the corresponding operating mode will be indicated at the LED array.
'Automatic SET UP' is carried out.
When SET UP is completed, the LED array indicates the selected type of guiding and position of
line/edge according to the above figure.

Attention: If the LEDs display is thus , this indicates that no

sufficient contrast has been found. The SET UP must be carried out again.

5.10.4 Check and/or determine of guiding direction

Press key 'AUTO'

AUTO

If the actuator guides the material out of the viewing range of the CCD 2004 camera;
DIL switch S1.1 has to be switched over.

Setting is required only for the first start-up.

If the web of material requires reversal of the guiding direction, this happens automatically at the
material SET UP of the sensor with material.

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5.10.5 Adjustment of gain for sensor 3

Condition: - web is drawn-in

- actuator is not moved into a limit position

1) Press key 'AUTO' AUTO

2) Press key 'SET UP' SET UP

3) Increase gain with key 'PLUS', until the guiding device

starts oscillating (rough adjustment by holding the key
pressed, fine adjustment by touching the key)

4) Decrease adjustment of gain with key 'MINUS', until the

guiding operates 'stable'. If slow guiding reaction is desired,
the gain may still be reduced further.

The maximum gain is achieved after 25 seconds. We encourage to leave the maximum of gain, if
there is no oscillating.

ENTER
5) Press key 'ENTER'

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6. Operation

The system only admits operation with

the components actually present!

Function key and control symbols on the front panel

Operating functions = green coloured area

Preset functions = red coloured area

Setting and control functions = blue coloured area

6.1 Operating functions

Select the desired operating functions as follows:

Automatic

- Press key ’ AUTO’

Manual positioning

- Press key ‘MAN’

Manual positioning of the actuator

1) Press key ‘MAN’

2) Adjust positioning with key ‘PLUS’ or

or ‘MINUS’.

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Servo-Center S-C

- Press key ‘S-C’

6.1.2 Preset functions

Web edge guiding, left web edge*

Web edge guiding, right web edge*

* in running direction of the material

Web center-line guiding

6.1.3 Setting and control functions

Adjustment of gain

* basic adjustment: automatically after material SET UP

* optimisation: during operation see point 5.6.3

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shifting of guiding point

1) Press key ‘AUTO’

2) Shifting of guiding point with key ‘PLUS’ or

or ‘MINUS’. The indication of shifting occurred
via EKR display.

The possible shifting of guiding point is max. 80% and/or. +/- 40% from the
max. viewing range of the sensors.

Note: If the ‘remote precision adjustment EFE 1’ is connected, the shifting of guiding point will
be occurred only via EFE 1.
Key ‘PLUS’ and ‘MINUS’ are then out of function!

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6.2 Test of material contrast and scanning with optical sensors

Press simultanously key ‘SET UP’ and ‘PLUS’

The LED arrays indicates the absolute

SET UP
senor signals. Clean lenses of the sensors
and determine the contrast according to the
graph below.

indication indication
left sensor right sensor

contrast
smaller or the same

4,3%
5,1%
6,3%
15%
30%
50%
60%
70%
90%
= LED ‘ON’
= LED ‘OFF’

6.3 Change of web material

With optical sensing system or ultra sonic sensors, sensor SET UP has to be carried out each
time when running web material is changed. The set-up process includes check of contamination of
the sensors as well as automatic calibration of the commander to the present properties of the
material, and - if occasion arises - a contamination warning will be transmitted.
With pneumatic sensing system, the afore mentioned procedure has to be carried out from time
to time, in order to adapt the system to the degree of contamination of the filter at the lateral
channel compressor BS 100 for obtaining eventually contamination warning.

6.3.1 Procedure for web edge guiding or center-line guiding

Sensor SET UP has to be carried out according to point 5.6.1.1 or 5.6.1.2.

6.3.2. Material set-up with CCD 2004

The set-up can be carried out to a line or edge by pressing the corresponding key
at the CCD 2004.
It is possible to choose between digital and analog operation.

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6.3.2.1 Digital mode of operation

Advantages
 guiding to,interrupted edges is possible
 locking occurs automatically
 very thin lines can be detected (minimum 0,5mm)
 an additional edge sensor can be used for the watchdog function
 width of lines will be checked, other printings will be ignored
 an automatic compensation and warning of contamination

Disadvantages
 weak contrasts need a uniform background (errors by ‘smoky’ backgrounds)
 reflexions may cause guiding errors, e.g. due to wrinkles in high-gloss web material
 the capture range is limited to the viewing range of CCD 2004 (8mm is typical)

Material SET UP

1) Press key ‘MAN’ Taste or ‘S-C’ Taste

or

2) Set material or sensor on desired line or edge

3) Carry out the desired set-up ‘line’ or ‘edge’ by shortly pressing the corresponding key
(shorter than 1 second).
After set-up, the LEDs are blinking according to the working mode selected:

digital SET UP edge

LED ‘OFF’ (dark)

digital SET UP line LED is blinking

Thereafter the LEDs indicate the position of the line or edge.

4) Set-up is finished.

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6.3.2.2 Analog mode of operation

Advantages
 disturbing influences such as reflexions are suppressed to a large extent
 with edge guiding, the capture range is unlimited. The material will be guided back even when
leaving the viewing range of the CCD 2004 sensor
 an average value will be established automatically in the presence of ‘smoky’ backgrounds or
contrasts

Disadvantages
 when guiding to interrupted printed edges, the guiding system will drift out of accuracy in the
spaces without the printing
 no signal ‘no edge/line in viewing range’ will be issued
 the line width will not be checked
 automatic compensation and warning of contamination are not possible

Material SET UP

a) Material SET UP ‘Line’

1) Press key ‘MAN’ or ‘S-C’

or

2) Bring the desired line into the center of the front half of the luminous spot.

connector on the
side face

line

measuring range

3) Press key ‘SET UP line’ for at least 2 seconds.

The LEDs are blinking during SET UP as follows:

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4) Position sensor and/or material in such manner that the line is situated in the middle of the
light spot

5) The LED on the face indicates the analog mode.

The remaining LEDs indicate the position of the line.

6) SET UP is completed.

b) Material SET UP ‘edge’

1) Press key ‘MAN’ or ‘S-C’

or

2) Position the desired edge in the middle of the light spot.

3) Press key ‘SET UP edge’ for at least 2 seconds.

The LEDs are blinking during SET UP as follows:

4) The LED on the face indicates the analog mode.

The remaining LEDs indicate the position of the edge.

5) SET UP is completed.

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EXAMPLES FOR MATERIAL SET UP AND RESULTING TYPE OF GUIDING:

During the material setup, the system is adjusted automatically to the first line or edge detected
within the light spot

The scanning direction is from left to right, as shown by the arrow.

CCD 2004
Scanning direction

Line outside the Line outside the

light spot light spot

2. line inside the light spot

1.line inside the light spot (will be ignored during setup
(thereupon, follows setup

WEB

LED display LED display

Edge bright/dark Edge dark/bright

WEB

LED display
LED display
Line dark
Line bright

WEB

LED display LED display

Edge bright/dark First bright line

= LED ‘ON’ = LED ‘OFF’

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6.4 Watchdog function

6.4.1 General

This function will be used to control the position of the web edge when guiding to a reflection or line
sensor.
The edge sensor detects the actual web position when the printed line or edge is interrupted or has
got lost. The value will be stored. After that, the guiding changes over automatically to edge guiding.
When the printed line or edge reappears, the guiding function will be taken over again automatically
by the reflection or line sensor.
The LED of the key 'watchdog' (21) is blinking when the watchdog function is activated.
The sensing range of the watchdog sensor is limited to 80% when the watchdog function is
activated. That means:

Watchdog sensor covered

0% to 10% 10% is taken over as guiding point
10% to 90% the present web position is taken over as guiding point
90% to 100% 90% is taken over as guiding point

6.4.2 Conditions

The watchdog function is only applicable with commander EKR 1500. One edge sensor and one
reflection/line sensor are necessary at least.
The watchdog sensor (edge sensor) has to be level with or behind the reflection/line sensor in
running direction of the web material (from software version EKR 1500 E0030401 and
CCD 2004 G00402-01).

printing

measuring range
running direction

reflection sensor
of web material

measuring range
edge sensor

Attention: The watchdog function can't be activated with:

- center-line guiding
- CCD 2004 in analog mode (function will be automatically switched off)

The watchdog function can be activated with Analog Interface module from
software version L0010201.

Remark: The function can be activated for applications with T62D1 (line) but is not operative for
the time being.

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6.4.3 Preparations

- Carry out separate start-up for guiding with reflection/line sensor and guiding with edge sensor.
Optimize gain for both sensors (only necessary for first start-up).

Attention: A change of gain is only effective on the reflection/line sensor when the
watchdog function is switched on. Gain of the edge sensor remains constant.

- Carry out material set up for both sensors

6.4.4 Activation of the watchdog function

- Position reflection/line sensor to printing

- Press key 'AUTO' (1)

- Place the web on the desired position (e.g. via mechanical displacement of the reflection/line
sensor)

- With analog sensors: position edge sensor centric at the web edge
(position can be determined by means of the LEDs on the front panel of
the commander).
- With CCD 5000: positioning is not necessary

- Press key 'watchdog' (21)

Watchdog function is activated.

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7. Remote control

Truth table for the remote control inputs EKR1000 (e.g. activation by PLC):

Terminal 31 = +24V non regulated supply

Terminal 38 = GND (0V)
Terminal

32 33 34 35 36 37 72 70 71 73

function

Automatic X 1 0 X X 0 X X X X

Manual X 0 0 X X 1 X X X X

Servo-Center (S-C) X 0 1 X X 0 X X X X

Edge left (watchdog ‘OFF’) X X X 1 0 X 0 X X X

Edge right (watchdog ‘OFF’) X X X 0 1 X 0 X X X

Servo-center guiding (watchdog‘OFF’) X X X 1 1 X 0 X X X

Guiding to a printed line / edge
without watchdog X X X 0 0 X 1 X X X

Guiding to a printed line / edge;

watchdog edge left X X X 1 0 X 1 X X X

Guiding to a printed line / edge;

watchdog edge right X X X 0 1 X 1 X X X

Guiding to a printed line / edge;

watchdog web center line X X X 1 1 X 1 X X X
(still out of operation)

X 1 0 X X 1 X X X X

X X 1 X X 1 X X X X

Controller lock-out 1 X X X X X X X X X

External SET UP X 1 1 X X 0 X X X X

Electrical coupling FVG 1000 X X X X X X X 1 X X

Interface conditions:

1 = ”high” U in high: Min. +8V, Max. +35V

0 = ”low” U in low: Min. -30V, Max. +4V
X= not relevant

t low, t high : min. 30ms

U in Max. : acc. IEC 1.2kV/50µs

Attention: Please ensure, that terminals 33 / 34 are locked-out against each other when
switching from AUTO to Servo-Center

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8. Trouble shooting

When an error is detected, the relay ”System OK” falls off. When pressing

ENTER
Note : key , the error message is switched off, and the relay ”System OK”
is re-energised, provided that no further error is present.

Error Responsible Remedy

actuator / guiding device guiding system overdrive * optimise gain
‘trembles’ * carry out ‘material SET UP’
* possibly new ‘basic SET UP’
+ material SET UP
+ optimise gain
actuator too slow gain was decreased * optimise gain
and/or guiding operates * ‘carry out ‘material SET UP’
not correctly * possibly new ‘basic SET UP’
+ material SET UP
+ optimisation of the gain

MAN * actuating device has moved activate into the opposite

or into a final position and blocked direction. Error message will be
cleared automatically.
* limit switch was activated (if
present)
or

* actuating device has been

activated into one direction for
a longer period of time

* with connected power module

working temperature of the Check the actuating motor. Error

actuating motor is too high. message can be cleared by
Motor was switched off. pressing the key ‘ENTER’

lenses of the sensors are * clean sensors

or strongly contaminated * carry out ‘material SET UP’

Attention: Message of contamination only at material SET UP

after basic SET UP faulty ‘Basic SET UP’ was carry repeat ‘Basic SET UP’ according
all LED`s are blinking out to point 5.4

Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 8.0

with analogue sensors and CCD 2004 Date: 12.04.2011 Page: 1/2
 8.0

Error Responsible Remedy

LEDs at the commander With connected FVG 1000

are blinking as follows: During shifting of guiding point actuate shifting into opposite
via arrow keys a limit stop was direction
reached. Displacement of the web
will be stopped.

LEDs at the commander With connected FVG 1000

are blinking as follows: During edge seeking or after restart the seeking operation
web tear, the inner limit switch was with present web or confirm
reached. Commander switched in action temporarily by pressing
operation mode ‘Retraction’. the key ‘ENTER’

= LED blinking
= LED off

Indication of errors at LED array of CCD 2004 sensor

Errors will be indicated by fast blinking of the LED’s. Error indication can be reset by pressing one of the
two keys on the top of the camera.

Indication Responsible Remedy

The contrast determined during material Repeat material set-up

set-up is not admissible (< 5%).
The values will be taken over. Eventually, the error may be
A perfect function cannot be ensured. avoided by choosing another
working mode during sensor
set-up.

A failure of the lighting device of the camera or Repeat white balance

a saturation were determined during white according to point 5.10.2.
balance. again.
The white balance is useless.

The contrast determined during material Repeat material set-up

set-up is critical (< 15%). or press one of the keys
The values will be taken over. on the top of the camera
A perfect function is normally ensured.

The line width determined during material Press one of the keys on the
set-up is critical (>60% of the measuring range). top of the camera
The values will be taken over.
Please note that eventually the line width
cannot be inspected at any time (the line leaves
the measuring range temporary because of
movements of the guiding device or incoming
big error)

The set-up values stored in the camera Repeat white balance and
are obsolete. The error can be material set-up
caused by a faulty camera for example.

Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 8.0

with analogue sensors and CCD 2004 Date: 12.04.2011 Page: 2/2
 9.0
9. Maintenance

9.1 Amplifier

The amplifier is maintenance-free.

The cleaning of the keyboard should be carried out with a dry, clean and smooth cloth.
For high contamination, use for cleaning a usual liquid cleaner, benzene or spirit.

Amplifier has to be switched off!

9.2 Camera CCD 2004

BST eltromat can deliver spare lamps if lamp(s) within the camera CCD 2004 break down.
For replacement of lamp(s) have to be used separate instructions:
* CCD 2004 up to hardware version G: V3D.011.01.01
* CCD 2004 from hardware version H: V3D.012.01.01

9.3 Optical and ultrasonic sensors

For optimum guiding results, the sensors have to be kept clean; at latest they have to be cleaned
when contamination is signalized.

9.4 Pneumatic sensing system

Depending on environment, the air filter of the lateral channel compressor BS 100 has to be
cleaned from time to time; at latest when contamination warning is signalized.

9.5 Electric motor powered actuator

The electric motor powered actuator is maintenance-free.

Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 9.0

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 10.0
10. De-commissioning

De-commissioning (scrapping) of the guiding system must be carried out only as a complete unit.
The procedure used has to be defined by the OEM.
Regarding the guiding equipment, please bear in mind that mainly electric/electronic components are
involved. The disposal of which is subject to the relevant legal rules and regulations.
Returning the equipment to BST eltromat International GmbH is possible by prior arrangement.

Web guiding system EKR 1500 EDV-No.: V3D.010.01.03 Chapter: 10.0

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 Connecting Plan EKR 1500 with analog sensors and CCD 2004

Power supply Sensors Components EKR 3000 Commander

Remote electronic precision adjusting Operation with connecting box

115 / 230 V; +10% -20%; 50 / 60 Hz

  EFE 1
US 2003
US 2007 US 2009
US 2008

 EFE 1000
US 2009
 Stationary operation
US 2003
Remote control (PLC inputs) US 2007
US 2008
acc. to chap. 7
Set jumpers JX12 and JX13 to 0 – 9.75 V. If the functional direction of the EFE 1 External
remote control (right/left) shall be reversed, keyboard
When using FVG 1000: the connections at the terminals 20 and 21
set FVG 1000 switch S5.2 = OFF EKR 3000
have to be interchanged.

Servo-center components
 Additional
IR 2001 module bus
IR 2002 subscriber’s
IR 2005
OMG 4

Remote
control

 OMG 6
IR 2001 OMG 7
IR 2002 OMG 8
IR 2005 CK 37
Bi5G  These components have been partially discontinued;
Modules see also Chapter 1, Section 1.2

Oscillation Attention: from EKR ... software version E0030603

Shift the EFE 1 and/or OZ3 over the complete range
during the basic set-up tto ensure the recognition of the
isolated component.
OZ 3  The service LED H7 is lighting after successful
 recognition.
CCD 2004

Connection of the
Analog Interface Module - Not required components will fall away!
see separate manual The corresponding terminals stay free!
R1 = 680 Ohm / 0,3 W

R2 = 2,7 kOhm / 0,3 W

- Shields are pinched in the screwing.

(see installation of EMC-wiring).
R = 10 kOhm

Connection of BST eltromat module bus with cable

FVG 1000 Module Pneumo-  Twisted Pair Unitronic-Bus LD 3x2x0,22.
IO-Module  isolated elektronischer
Wandler Please contact the manufacturer for setting of
Interbus-S Module
ZT 6008 cross-bonding boxes.
C2M coupler

CLS Pro 600

Intercon Module
Setting of DIL switches and position of the jumpers see
PDP-Module 
chapter „Start-up“.
CAN-Module
R = 10 kOhm

If only one edge sensor connected, the not used

Commissioning EKR 1500 with C2M coupler and CLS Pro 600: connection piece S1 in ZT will be locked with a plug. The
See also description MD.351.01.xx not used connection piece S2 will be always unlocked.

V3D.010.01.A04 / 12.04.2011
page 1/2
Connecting Plan EKR 1500 with analog sensors and CCD 2004
Actuators

electric hydraulic

Limit switch 2 Pneumo

electronic
transducer
EMS 1 ZT 6008
EMS 5
EMS 10 EMS 6 
EMS 16 

Limit switch 1
The signal direction of the tachometer generator has to be adapted
to the direction of rotation of the motor. Therefore switch over the Servo valve SV 1-10
commander to mode MAN. Press one of the arrow keys.
If the actuator is moving to the end of the guiding device,
interchange the terminals 65 and 66.

74 Metal plate
KIB-M12Pö/002-KL2
73

71
KIB-M12Pö/002-KL2
67
31

29 EMS 16P  Limit switches

28

Attention: Both limit switches must be covered by the

The allocation of the limit switches can be adapted to the sense of  These components have been partially discontinued;
metal plate during normal operation. see also Chapter 1, Section 1.2
rotation of the motor by inter-changing the terminals 71 and 73 if
(limit switches are carried out as break
necessary.
contacts).
- Not required components will fall away! The
corresponding terminals stay free!
- Shields are pinched in the screwing.
(see installation of EMC-wiring).

Connection of BST eltromat module bus with cable

Twisted Pair Unitronic-Bus LD 3x2x0,22.
Please contact the manufacturer for setting of
cross-bonding boxes.
EMS 17  EMS 18
Setting of DIL switches and position of the jumpers see
chapter „Start-up“.

V3D.010.01.A04 / 12.04.2011
page 2/2
Start-up of the Actuator EMS 17 / EMS18
Connected to EKR 1500 / EKR 1000 / CCD Line Guider

1. Requirements for Start-up

Start-up is carried out according to chapter 5 of the appropriate

operating manual. For the connection of the actuator EMS 17 /
EMS 18 the following additional adjustments have to be executed.

1.1 Set DIL Switches

 S1.2 = OFF
 S1.5 = OFF

1.2. Lay Jumpers

 Socket JX11: Set jumper "A"

 Socket JX10: Set jumper "DE"

2. Setup

2.1 Activate Manual Stroke Setup

 Press key "MAN" and hold it.

SET UP

 Press key "SETUP" in addition.

+  Release both keys. The LED of the key "SETUP" is blinking and
the LED of the key "ENTER" is off.

2.2 Determine Sense of Motor Rotation

Stroke setup is active.

or  Press one arrow key.

 Observe guiding device!
The guiding device must move slowly in one direction. If the
guiding device moves on a stop, then change position of DIL
switch S1.3, from "ON" to "OFF" or vice versa.

2.3 Setting of Stroke Limitation

Stroke setup is active.

1. Move the guiding device to the desired final position via one of
the arrow keys. The final position limits the guiding movement
in this direction.

Start-up EMS 17 / EMS 18 EDV No.: MD.154.01.04

Date: 23.08.11 Page: 1/2
 Attention! The adjustment of the guiding device is
carried out very slowly!

ENTER 2. Press key ‘ENTER‘. The final position is stored.

3. Move the guiding device to the desired final position via the
other arrow key. The final position limits the guiding movement
in this direction.
ENTER
4. Press key ‘ENTER‘. The final position is stored.

The controller sets the "servo-center position" (SC) automatically

to the center between the two final positions. If necessary this
servo-center position can be displaced in operating mode "S-C" via
the arrow keys.

The adjustment of stroke limitation is completed. The LED of the

key "SETUP" gets extinguished.

The settings are not overwritten during basic

setup.

Erasing of the final positions can be carried out as follows:

Attention! Do not press any arrow key between

SET UP
step 1 and 2!
+ 1. Press key "MAN" and hold it.

2. Press key "SETUP" in addition.

ENTER ENTER ENTER
3. Press key "ENTER" three times.

The adjustment of gain for the S-C transducer must be set depend-
ing on the application if necessary.

3. Electrical Connection

29 white
EKR 1000 28 brown
EKR 1500 26 yellow
25 pink EMS 17
CCD Line Guider 24 grey
38 green

29 green + pink
EKR 1000 28 brown + grey
EKR 1500 26 blue
25 white EMS 18
CCD Line Guider 24 red
38 yellow

Start-up EMS 17 / EMS 18 EDV No.: MD.154.01.04

Date: 23.08.11 Page: 2/2