Web Guiding System

Operating Manual

ekr 500 digital Unit Touch

MD.492.EN.07

Translation of the Original Manual

BST GmbH
Remusweg 1
D-33729 Bielefeld
Tel.: +49 (0) 521 400 70 0
Fax: +49 (0) 5206 999 999

E-Mail: [email protected]
Internet: www.bst.group

This documentation is protected by copyright. The translation as well as reproduction and distribution in any form is forbidden without the approval
of the rights holder and will be pursued under civil and criminal law. Technical modifications reserved.
 Table of contents

Table of contents
1 About This Document........................................................................................ 6
1.1 What You Need to Know............................................................................................... 6
1.2 Target Group................................................................................................................. 6
1.3 Storage and Distribution ............................................................................................... 6
1.4 Meanings of the Safety Instructions and Symbols ........................................................ 6
1.4.1 Safety Instructions ........................................................................................................ 6
1.4.2 Symbols......................................................................................................................... 7
1.4.3 Operation Using Keys.................................................................................................... 7
1.5 More Detailed Information ........................................................................................... 8

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

2.1 Intended Use................................................................................................................. 9
2.2 Non-intended Use....................................................................................................... 10
2.2.1 Non-intended Infringement of Guidelines.................................................................. 10
2.2.2 Non-intended Operation............................................................................................. 10
2.2.3 Non-intended Modification of Electronic Data........................................................... 11
2.3 Safety Instructions ...................................................................................................... 12
2.3.1 General Safety Instructions......................................................................................... 12
2.4 Qualification of the Personnel .................................................................................... 14
2.5 Duties of the Operating Company and Personnel ...................................................... 15
2.5.1 Duties of the Operating Company .............................................................................. 15
2.5.2 Duties of the Personnel............................................................................................... 16
2.6 Conduct in the Event of Danger and Accidents .......................................................... 16
2.7 Personal Protective Equipment .................................................................................. 17
2.8 Guarantee and Liability............................................................................................... 17
2.8.1 Disclaimer ................................................................................................................... 17
2.8.2 Exceptions to the Disclaimer....................................................................................... 18
2.8.3 License and Liability for Software Supplied ................................................................ 18

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

3.1 Design ......................................................................................................................... 19
3.1.1 Controller .................................................................................................................... 19
3.1.2 Control Panel .............................................................................................................. 19
3.2 Function ...................................................................................................................... 20
3.3 Guiding Modes............................................................................................................ 21
3.4 Special Guiding and Monitoring Functions ................................................................. 21
3.4.1 Watchdog.................................................................................................................... 21
3.4.2 Overlaid Web Edge/Web Center-Line Guiding with CLS CAM 100 Object Sensor ...... 22
3.4.3 Speed Dependent Guiding .......................................................................................... 22
3.4.4 Oscillation ................................................................................................................... 22
3.4.5 Speed-Dependent Oscillation ..................................................................................... 22
3.4.6 Master-Slave Guiding.................................................................................................. 22
3.4.7 Tear-Off Detection ...................................................................................................... 23
3.4.8 Web Width Measurement .......................................................................................... 23
3.4.9 Line Width Measurement ........................................................................................... 23
3.5 Motorized Sensor Positioning ..................................................................................... 24
3.5.1 Sensor Positioner ........................................................................................................ 24
3.5.2 Positioning Unit........................................................................................................... 24
3.6 Control and Display Elements ..................................................................................... 25
3.6.1 Touchscreen Display ................................................................................................... 25
3.6.2 Keys............................................................................................................................. 25
3.7 Designation of the Sensors ......................................................................................... 26
3.7.1 Edge Sensors (Sensor 1/2) .......................................................................................... 26
3.7.2 Line, Contrast and Object Sensor (Sensor 3)............................................................... 27
3.7.3 CCD Cameras (Sensor 1/2) .......................................................................................... 28
3.8 Nameplates ................................................................................................................. 29

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 Table of contents

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

5 Operation ........................................................................................................ 31
5.1 Safety Instructions ...................................................................................................... 31
5.2 ekr commander Control Panel .................................................................................... 31
5.3 Touchscreen Operation .............................................................................................. 33
5.3.1 Switching Functions On / Off ...................................................................................... 33
5.3.2 Editing Numerical Values ............................................................................................ 33
5.4 Access to the Online Documentation ......................................................................... 35
5.5 Operation Display ....................................................................................................... 35
5.5.1 Overview ..................................................................................................................... 35
5.5.2 Edge Sensors Operation Display (Sensor 1/2)............................................................. 42
5.5.3 CLS Pro 600 Line and Contrast Sensor Operation Display (Sensor 3).......................... 43
5.5.4 CLS CAM 100 Object Sensor Operation Display (Sensor 3) ......................................... 45
5.5.5 CCD Cameras Operation Display ................................................................................. 47
5.5.6 Actuator Operation Display ........................................................................................ 51
5.6 Configurable Displays and Setting Menus................................................................... 52
5.7 Performing the Material Setup ................................................................................... 54
5.7.1 Overview ..................................................................................................................... 54
5.7.2 Activating the Material Setup ..................................................................................... 57
5.7.3 Cancelling Material Setup ........................................................................................... 58
5.7.4 Automatic Material Setup........................................................................................... 58
5.7.5 Manual Material Setup ............................................................................................... 59
5.8 Selecting the Operating Mode for the IR 2011/40 Edge Sensor ................................. 60
5.8.1 Function ...................................................................................................................... 60
5.8.2 Requirements.............................................................................................................. 60
5.8.3 IR 2011/40 Operating Modes...................................................................................... 60
5.8.4 Operating Mode Selection .......................................................................................... 62
5.9 Selecting the Guiding Mode........................................................................................ 63
5.10 Selecting the Operating Mode .................................................................................... 64
5.10.1 Manual Mode.............................................................................................................. 64
5.10.2 Automatic ................................................................................................................... 65
5.10.3 Center Positioning....................................................................................................... 65
5.11 Setting the Guiding Setpoint....................................................................................... 66
5.11.1 Adjusting the Guiding Setpoint with the Arrow Keys.................................................. 69
5.11.2 Adjusting the Guiding Setpoint with the Setting Menu .............................................. 70
5.11.3 Accepting Current Position of a Web Edge as Guiding Setpoint ................................. 71
5.11.4 Saving and Loading the Guiding Setpoint ................................................................... 73
5.11.5 Entering an Offset Value for the Guiding Setpoint ..................................................... 75
5.12 Optimizing the Controller Gain ................................................................................... 77
5.12.1 Adjusting the Controller Gain with the Arrow Keys .................................................... 78
5.12.2 Adjusting the Controller Gain via the Touchscreen .................................................... 78
5.13 Special Guiding and Monitoring Functions ................................................................. 79
5.13.1 Watchdog.................................................................................................................... 79
5.13.2 Overlaid Web Edge/Web Center-Line Guiding with CLS CAM 100 Object Sensor ...... 82
5.13.3 Speed-Dependent Guiding.......................................................................................... 85
5.13.4 Master-Slave Guiding.................................................................................................. 86
5.13.5 Tear-Off Detection ...................................................................................................... 89
5.13.6 Oscillation ................................................................................................................... 91
5.13.7 Speed-Dependent Oscillation ..................................................................................... 97
5.13.8 Web Width Measurement ........................................................................................ 100
5.13.9 Line Width Measurement ......................................................................................... 108
5.14 Sensor Positioner ...................................................................................................... 110
5.14.1 Utilization.................................................................................................................. 110
5.14.2 Operation Display ..................................................................................................... 111
5.14.3 Operation.................................................................................................................. 112
5.15 Positioning Unit......................................................................................................... 115
5.15.1 Utilization.................................................................................................................. 115
5.15.2 Requirements............................................................................................................ 116

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 Table of contents

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

5.16 Calling up the Setup Menu........................................................................................ 120
5.17 Switching the Configurable Displays and Setting Menus On/Off.............................. 123
5.18 Service Displays......................................................................................................... 124
5.18.1 Displaying System Information ................................................................................. 125
5.18.2 Displaying System Components................................................................................ 126
5.18.3 Displaying Switch Positions....................................................................................... 128
5.18.4 Displaying a Link to the Company Website............................................................... 129
5.18.5 Displaying Service QR Code....................................................................................... 130
5.19 Fault Displays ............................................................................................................ 132
5.19.1 Limit Switch Active.................................................................................................... 132
5.19.2 Actuator Blocked (Motor Overcurrent) .................................................................... 132
5.19.3 Supply Voltage Outside the Permissible Range ........................................................ 133
5.19.4 Motor Control Timeout............................................................................................. 133
5.19.5 Controller Interlock Active ........................................................................................ 134
5.19.6 Keyboard Interlock Active ......................................................................................... 135
5.19.7 Setup Lock Active ...................................................................................................... 135
5.19.8 Bus Connection Fault ................................................................................................ 136
5.19.9 Edge Sensor Malfunction .......................................................................................... 136
5.19.10 Loss of the Line / Contrast Transition (Sensor CLS Pro 600) ..................................... 137
5.19.11 Loss of the Guiding Criterion (Object Sensor CLS CAM 100)..................................... 137
5.19.12 Loss of the Web Edge (CCD Camera) ........................................................................ 138
5.19.13 External Motor Output Stage Fault (Drive Module 160)........................................... 138
5.20 Electronic Remote Precision Adjustment (Option) ................................................... 139
5.20.1 EFE 1.......................................................................................................................... 139
5.20.2 EFE 1000.................................................................................................................... 139
5.21 Extended Device Settings.......................................................................................... 140
5.21.1 Editing the Parameter Value ..................................................................................... 140
5.21.2 Public Parameters Lists ............................................................................................. 142
5.22 Restoring Factory Default Settings............................................................................ 147

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

6.1 Safety Instructions .................................................................................................... 148
6.2 Maintenance Table ................................................................................................... 149
6.3 Maintenance and Cleaning work .............................................................................. 149
6.3.1 Cleaning the Controller Housing ............................................................................... 149
6.3.2 Cleaning the Control Panel Housing.......................................................................... 149
6.3.3 Cleaning the Edge Sensor Housing............................................................................ 150
6.3.4 Cleaning the Housing of the CLS Pro 600 Line and Contrast Sensor ......................... 150
6.3.5 Cleaning the Housing of the CLS CAM 100 Object Sensor ........................................ 150
6.3.6 Cleaning the Housing of the CCD Camera................................................................. 150
6.3.7 Cleaning the Electric Motor Powered Actuator Housing .......................................... 150
6.3.8 Cleaning the Sensor Positioner Housing ................................................................... 151

7 Troubleshooting............................................................................................. 152
8 Customer Services.......................................................................................... 158
9 Shutting Down and Disposal........................................................................... 159
Index.............................................................................................................. 160

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 1 About This Document

1 About This Document

1.1 What You Need to Know

These instructions help you to work with the system in a safe,
simple and successful manner.
The following instructions must be observed in order to avoid
hazards and incorrect operation:
■ Every user must have read these instructions in full before
working with or on the system.
■ Every user must follow the safety information in these instruc-
tions.

1.2 Target Group

These instructions are directed to all persons that work with or on
the system. The operating company of the entire system and
supervising personnel must also be familiar with these instructions.

1.3 Storage and Distribution

These instructions must be stored at the workplace in such a
manner that the user has access to them at all times.
These instructions and all other applicable documents are a com-
ponent of the product and must be handed over to the operating
company of the system.

1.4 Meanings of the Safety Instructions and Symbols

1.4.1 Safety Instructions

DANGER
Danger that will lead to death or severe injuries!
► Here you can find how to avoid the danger.

WARNING
Danger that may lead to death or severe injuries!
► Here you can find how to avoid the danger.

CAUTION
Danger that may lead to medium or minor injuries!
► Here you can find how to avoid the danger.

NOTICE
Danger that may lead to damage to assets!
There is no risk of injury.
► Here you can find how to avoid the danger.

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 About This Document 1

1.4.2 Symbols
Information that is essential for successful operation.

Information that makes operation easier.

Action requirements may include the following symbols:

›› Requirements that must be fulfilled for the action steps.
1. Prompt for you to act. Namely ...
2. ... in the listed sequence.
► Requirement for you to take actions - without any certain
sequence.

1.4.3 Operation Using Keys

Operations using the keys are indicated by the following symbols:

► Press key ①.

► Press key ① or key ②.

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

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 1 About This Document

1.5 More Detailed Information

► Observe the accompanying documents (e.g. order confirmation)
for this system and the operating instructions of the entire sys-
tem.
The latest version of these instructions in all available languages
as well as further documents on this system can be found in the
Internet on our help portal BST.Help. Simply click on the docu-
ment number in the table. The link will lead you directly to the se-
lected document on BST.Help.
Document Document
Number
Installation and commissioning manual
MD.497
ekr 500 digital Unit Touch
Installation and operating manual
ekr 500 digital Unit Touch - MD.503
Application with Wide Array Edge Sensors
Operating manual
ekr 500 digital Unit Touch - MD.535
Master-Slave Guiding with Sensor Positioner
Interface description
ekr 500 digital Unit Touch - MD.520
CANopen User Gateway

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 About Safety 2

2 About Safety
The system has been designed according to the state of the art
and fulfils the latest safety standards.
When using the system, risks may occur that could threaten your
life or health or lead to material damage. In order to avoid these
risks, all instructions in this manual concerning safety and all
relevant documentation of the entire system must be observed.

2.1 Intended Use

The system is only determined for web guiding. It permits guiding
according to the web edges, web center-line, printed lines,
contrast edges or print features.
The system is integrated in a machine or connected with another
machine to form a machine as defined by machinery directive
2006/42/EC. All machines and the overall machine line must meet
the requirements of the machinery directive after integration of
the system.

The system and all of its components are exclusively intended for
commercial use in an industrial environment.
Moreover, the system may only be started up, if the following
regulations are adhered to:
■ The product must only be installed or operated in a non-
explosive atmosphere.
■ The product and all components may only be used while in
perfect condition.
■ All safety devices must be in perfect condition.
■ The product may only be operated with the components
belonging to the system. The only third-party components
exempt from the above are those supplied by BST or explicitly
approved for use with the system.
■ Parts that are not in perfect condition must immediately be
replaced with original spare parts.
■ All work on or with the product may only be performed by in-
structed and qualified personnel, see chapter Qualification of
the Personnel, page 14.
■ Always adhere to this operating manual and all safety instruc-
tions.
■ The operating conditions and performance limits indicated in
the technical data must be observed.

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 2 About Safety

2.2 Non-intended Use

Every use is non-intended, that is not described in the chapter
Intended Use or does not comply with the guidelines specified
there, see Intended Use, page 9.

2.2.1 Non-intended Infringement of Guidelines

■ Infringement of operating, maintaining or installation instructions
■ Unsuitable, incorrect or unauthorized use of the product
■ Operating the product in an environment not intended for its
use
■ Operating the product in breach of the legal safety guidelines
relevant at the location of use
■ Neglecting the warning and safety instructions in the relevant
documents for the product
■ Operating the product under faulty safety and protective condi-
tions

2.2.2 Non-intended Operation

■ Operation by unauthorized or insufficiently qualified personnel
■ By-passing, disassembling, switching off or manipulation of
safety equipment
■ Incorrect or negligent handling by the customer
■ Any intervention, modification or conversions on the product
without the express approval of BST GmbH
■ The use of unsuitable operating materials or spare parts
■ Operation of the product near to sources of interference, e.g.
electro-magnetic fields (high voltage lines) or sources of heat
■ Operation of the product under the influence of chemical,
electro-chemical or electrical factors

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 About Safety 2

2.2.3 Non-intended Modification of Electronic Data

■ No virus scanners, firewalls or similar items may be installed on
any products of BST GmbH. Virus scanners or other scan or
registration programs must not (be able to) access products via
networks.
■ Writing, deleting and editing of system data / files on BST
products is not permitted. Exempt from this is service work
carried out at the instruction of BST GmbH.
■ Access of any external software to BST products via networks is
not permitted.
■ USB memory sticks may only be used together with BST
products if they are free of viruses and harmful software.
■ Products or supplied software from BST GmbH must never be
modified without permission.
■ All software supplied is protected by copyright and must not be
edited, copied or made available to third parties. Except where
explicit approval has been sought from BST GmbH or the
respective owner of the copyright.

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 2 About Safety

2.3 Safety Instructions

Every user must read and follow the safety instructions in these
instructions before working with or on the system.
The following contains general safety instructions that always
have to be observed. Special safety information that must be
observed for certain work will be specified at the start of the
respective chapter of these instructions.

2.3.1 General Safety Instructions

DANGER
Danger of death when operated in potentially explosive areas!
► The system must not be installed or operated in potentially
explosive areas.

DANGER
Danger to life due to moving machine components!
Crushing, shearing, scraping, pulling in or impact injuries of body
parts may occur.
► Never reach into the area containing moving rollers or machine
components.
► Do not wear necklaces, scarves or similar near moving rollers/
machine components.
► Never stay within the swivel/movement range of moving
machine components or reach into these areas.
► Prior to set-up/operation of the system, ensure that no persons
are in the operating range of moving machine components.

DANGER
Danger to life due to electrocution!
Fatal injuries due to incomplete shut-down or residual currents.
► If insulation defects or defects on live components occur,
immediately shut down the power supply and have the system
repaired by a qualified electrician.
► Completely switch off the system, disconnect it from the power
supply and wait for ten minutes before carrying out any main-
tenance, repair, cleaning or assembly work.
► Secure the system against being switched on again.

WARNING
Danger of cutting on sharp edges of the material web!
Severe cutting injuries caused by the edges of the moving material
web.
► Never touch the edges of moving material webs.

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 About Safety 2

WARNING
Danger to life caused by movements of the setting drive!
If position control is active, the setting drive may execute auto-
matic movements in manual mode . Body parts could be crushed,
sheared or impacted.
► Ensure that no persons remain in the swivel or positioning
range of machine components positioned by the actuator.

WARNING
Danger of falling and damage to assets caused by stepping/climb-
ing onto components!
Stepping/climbing onto components (e.g. traverse bars or camera
housing) can lead to life-threatening falling accidents and to the
destruction of the components.
► Never climb or step onto components.

WARNING
Danger to life due to missing Emergency Stop devices!
Severe injuries may occur, if no Emergency Stop device (Emer-
gency Stop button) is installed on the overall machine line. Only an
Emergency Stop device permits an immediate stop of the machine
line in emergencies. It is not permitted to operate the overall ma-
chine line without an Emergency Stop device.
► If one is not already installed, have an Emergency Stop button
and Emergency Stop systems installed by the owner/user/
machine manufacturer prior to using the machine line.

WARNING
Severe injuries due to unfamiliarity with/non-observance of
Emergency Stop devices and safety information!
► Prior to starting work, familiarize yourself with the Emergency
Stop and rescue devices of the overall machine line, e.g. Emer-
gency Stop button.
► Prior to starting work, ensure that all safety regulations and
instructions are observed.

NOTICE
Damage to electronic components caused by ESD (electrostatic
discharge)!
Destruction/loss of capacity of electronic assembly elements
caused by contact with electro-statically charged persons/objects.
► Only open system components at ESD-compliant workplaces
(according to 61340-5-1).
► If there is no ESD-compliant workplace, take ESD protection
measures (according to DIN EN 61340-5-1) to discharge electro-
static charges in a controlled manner.
► When returning electronic assembly elements, adhere to DIN
EN 100015 (“Protection of protection of electrostatic-sensitive
devices”).
► To transport electronic components, only use suitably marked,
electrically conductive ESD packaging.

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 2 About Safety

NOTICE
Damage to the touchscreen due to faulty operation!
Use of sharp, strong or coarse objects (e.g. pens, gloves) may dam-
age the surface of the touchscreen.
► Touch the touchscreen only using bare fingers or a special input
pen (touchpen).

2.4 Qualification of the Personnel

The qualifications required by the personnel are defined as follows:

Instructed personnel have been instructed comprehensively by

the operating company and informed about the following points:
■ Tasks assigned
■ Possible hazards when carrying out the tasks
■ Possible hazards in the event of incorrect conduct
■ Measures for avoiding the hazards

Moreover, qualified personnel have sufficient experience or

practice in the safe implementation of the tasks assigned.

Specialists are in addition in the position to deal with the follow-

ing tasks by themselves due to their training, knowledge and ex-
perience as well as knowledge in the relevant regulations:
■ Carrying out the tasks assigned to them
■ Recognizing possible hazards
■ Undertaking appropriate measures for avoiding the hazards
Specialists must only carry out tasks according to their profes-
sional training.

Qualified electricians have in addition an electrical engineering

training according to the applicable guidelines (in Germany,
DIN VDE 1000-10).

Moreover, all personnel must satisfy all requirements that are

derived from the following documentation or directives:
■ Operating instructions for the entire system
■ National guidelines, laws and applicable guidelines for protecting
employees, general safety at workplaces and for accident pre-
vention

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 About Safety 2

2.5 Duties of the Operating Company and Personnel

2.5.1 Duties of the Operating Company

The operating company of the entire system is responsible for
safety in the workplace as well as for the information and training
of the personnel. In particular, for the entire life-cycle of the system
and the entire system, the operating company must ensure that:
■ All relevant legal safety, accident prevention and environ-
mental guidelines are maintained
■ All hazards are determined that result from the special operating
conditions at the operating location of the system and from the
construction of the entire system
■ All hazards determined are avoided. This means, in particular:
- Constructive prevention of hazards
- Assembly of protection and safety equipment and checking
that these are working properly
- Mounting of warning signs at hazard sites and checking their
correct condition
- Information and training of the personnel for safe conduct,
intended use, safety equipment, prevention of hazards and
conduct in the event of emergencies
- Provision of the necessary personal protective equipment
- Supervision of the personnel with regard to safety-relevant
conduct
■ The system is integrated into the safety concept of the entire
system
■ The system is stopped immediately if the safety of people or
the environment is endangered or changes occur that could
impair the safety
■ All employees have read and understood these instructions
before working on or with the system
■ Only personnel are assigned that are qualified and trained for
the respective task
■ The responsibility of the personnel is determined for the task
to be completed and that the personnel are informed

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 2 About Safety

2.5.2 Duties of the Personnel

Each and every employee is responsible for their own safety. In
particular, each and every employee must abide by the following
instructions:
► Read these instructions completely before working on or with
the system and follow all safety instructions.
► Observe all warning instructions on the system and entire system.
► Observe the operating instructions for the entire system and
the separate machines as well as all safety instructions included
in it.
► If required, wear the necessary personal protective equipment.
► Before starting work, check if the safety equipment is intact.
► Stop the system immediately if the safety of people is at risk
and secure against being switched back on unintentionally.
► The system must be visually inspected for any recognizable
damage or problems at least once per shift.
► If sections of these instructions are unclear, inform your super-
visor and ensure for clarification.

2.6 Conduct in the Event of Danger and Accidents

Preventative Measures
Emergency and rescue equipment must be ready for use in every
company. These include, for example, emergency stop buttons,
fire extinguisher, first aid kit and equipment for reporting acci-
dents.
► Always be prepared for emergencies, accidents and fire.
► Familiarize yourself as to where the emergency and rescue
equipment is located and how to use it.
► Keep emergency and rescue equipment at hand and ready for
use.
► Ensure all access routes for rescue vehicles and escape routes
are kept free.

If an emergency is impending or has occurred

1. Press the emergency stop button immediately.
2. Make sure that the system cannot be switched on again.
3. Rescue the persons from the danger zone if your personal
safety is not at risk.
4. Initiate first aid measures.
5. Warn the emergency doctor and / or fire brigade.
6. Inform the responsible person at the operating location.
7. Clear the access route for the emergency vehicles.

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 About Safety 2

2.7 Personal Protective Equipment

When carrying out certain activities, you have to wear personal
protective equipment in order to avoid accidents and injuries.
Personal protective equipment includes, depending on the activity:
■ Protective clothing
■ Safety helmet
■ Safety shoes
■ Safety gloves
■ Eye protectors
■ Ear protectors
► Observe the safety information in these instructions and the in-
formation signs on the system for personal protective equip-
ment.

2.8 Guarantee and Liability

The warranty terms are specified in the sales documentation.

2.8.1 Disclaimer
BST GmbH is not liable for damage or defects arising from any
incorrect or non-intended use of the product, see Non-intended
Use, page 10.
Liability for defects does also not apply if the fault originates from
one or more of the following causes:
■ Catastrophic events and force majeure
■ Natural wear
■ Incorrect operation of the product resulting from the effect of
connected or neighboring third party devices
■ Malfunction of the product due to unsuitable operating
resources, spare parts, chemical, electro-chemical or electrical
factors.
■ Unsuitable or faulty execution of the maintenance work
described by the operating company, see Maintenance and
Cleaning, page 148.

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 2 About Safety

2.8.2 Exceptions to the Disclaimer

In the cases listed above BST GmbH shall also not be liable (for
damages) unless:
■ The damage results from a willful or grossly negligent breach of
duty on the part of BST GmbH or its legal representatives or
vicarious agents
■ The damage is associated with injury to life, body or health and
results from a willful or grossly negligent breach of duty on the
part of BST GmbH or its legal representatives or vicarious agents
■ The form of damage can usually and typically be insured
against by means of third-party liability insurance taken out by
BST GmbH on reasonable conditions
This applies in particular to claims for damages associated with
fault or negligence occurring before or upon conclusion of the
contract, the infringement of secondary obligations and claims
associated with impermissible actions; this does not affect claims
asserted in accordance with the German Product Liability Act or
those associated with a guarantee.
Otherwise, the specific terms of license of BST GmbH apply.

2.8.3 License and Liability for Software Supplied

Software supplied that has not been produced by BST GmbH
underlies the respective liability and license agreements of the
manufacturer.

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 Design and Function 3

3 Design and Function

3.1 Design
The ekr 500 digital Unit Touch comprises the controller and the
removable ekr commander control panel.

3.1.1 Controller
The housing of the controller includes the entire control electrics
and connections for all necessary web guiding components
(sensors, actuator, servo center transducer, remote controls, etc.).

3.1.2 Control Panel

Controller with control panel fitted

The ekr commander control panel is fitted on the front of the
device in the factory.

Fig. 1: Controller with ekr commander control panel fitted

Controller with control panel detached

If necessary (e.g. if the controller is installed in a position difficult
to access on the machine) the ekr commander control panel can
be detached and installed in a central operator panel or a cus-
tomer-supplied control station. In this case the connection
between the controller and the control panel is completed using a
cable extension that is available as an optional extra.

Fig. 2: Controller with ekr commander control panel detached

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 3 Design and Function

Controller with additional control panel

Depending on the conditions in the production machine or the pro-
duction demands, it may be necessary to operate the controller
from a remote location on the machine.
In this case an additional ekr commander control panel can be
connected to the bus interface (socket X101) of the controller.
The connection between the controller and the additional control
panel is completed using a cable extension that is available as an
optional extra.

Fig. 3: Controller with additional ekr commander control panel

3.2 Function
With web edge guiding or web center-line guiding in automatic
mode, one or two edge sensors connected to the controller detect
the current position (ACTUAL position) of the material web and
transmit the respective information to the integrated position
controller.
With line, contrast or feature guiding, a line, contrast or object
sensor detects the current position (ACTUAL position) of a line,
contrast transition or print feature on the material web and trans-
mits the respective information to the position controller.
The position controller compares the ACTUAL recorded position
against the predetermined SETPOINT position. The controller will
send a relevant correction signal to the actuator if a deviation is
found to exist between the two values. The actuator will move the
guiding device (rotating frame guide or swivel roll guide) until the
material web returns to its SETPOINT position.

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3.3 Guiding Modes

The controller permits the following web guiding modes:
■ Web edge guiding
(guiding to the right or the left web edge)
■ Web center-line guiding
■ Guiding on continuous or interrupted printed lines
(in conjunction with the CLS Pro 600 line and contrast sensor or
the CLS CAM 100 object sensor from firmware version 1.4.x.x)
■ Guiding on continuous or interrupted contrast edges
(in conjunction with the CLS Pro 600 line and contrast sensor or
the CLS CAM 100 object sensor from firmware version 1.4.x.x)
■ Guiding on print features
(in conjunction with the CLS CAM 100 object sensor)
■ Watchdog
Guiding to a printed line, contrast edge or print feature with
automatic switching to web edge guiding when the printed
line, contrast edge or print feature is interrupted or lost

3.4 Special Guiding and Monitoring Functions

For applications with special requirements on the web guiding
system the ekr 500 digital Unit Touch controller offers a range of
special guiding and monitoring functions.

3.4.1 Watchdog
The Watchdog function is used to prevent the web from wander-
ing after the total loss of the guiding criterion (printed line, con-
trast transition or print feature) during line, contrast or feature
guiding. If the guiding criterion disappears from the scanning area
of the line, contrast or object sensor (e.g. if the print is not carried
out, a poor splice or similar), the current web position is detected
by the edge sensor (capture sensor) and saved by the controller.
Then the controller will switch over from the line, contrast or ob-
ject sensor to the edge sensor used. Switching back to the line,
contrast or object sensor is carried out automatically immediately
after re-detecting the guiding criterion.
For a detailed description of this function, see chapter Watchdog,
page 79.

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 3 Design and Function

3.4.2 Overlaid Web Edge/Web Center-Line Guiding with CLS CAM 100 Object Sensor
The overlaid web edge/web center-line guiding is a combination
of a web edge or web center-line guiding and an overlaid feature
guiding with the CLS CAM 100 object sensor.
This special guiding function is used for feature guiding with the
CLS CAM 100 object sensor when guiding on a print feature where
the individual recurring features on the material web have a large
distance to each other.
For a detailed description of this function, see chapter Overlaid
Web Edge/Web Center-Line Guiding with CLS CAM 100 Object
Sensor, page 82.

3.4.3 Speed Dependent Guiding

In automatic operating mode, the speed-dependent guiding
ensures for an optimum guiding behaviour even at low machine
speeds. For this purpose the control of the actuator is limited
automatically below an adjustable speed range. This prevents
overloading of the controller and oscillation of the guiding device.
For a detailed description of this function, see chapter Speed-
Dependent Guiding, page 85.

3.4.4 Oscillation
The oscillation is used, for example, for the rewinding of tubular
films or for materials with an irregular thickness profile in order to
avoid poor winding. The function enables the controlled transverse
displacement of the web of material with an adjustable amplitude
(size of the displacement) and frequency (speed of the displace-
ment). You can choose from a triangular or sinus oscillation curve.
For a detailed description of this function, see chapter Oscillation,
page 91.

3.4.5 Speed-Dependent Oscillation

In this special type of oscillation the oscillation frequency is auto-
matically adjusted to the web speed. This means that the oscilla-
tion frequency rises with the increasing web speed. This ensures
that the ratio between oscillation frequency and web feed rate re-
mains constant.
For a detailed description of this function, see chapter Speed-
Dependent Oscillation, page 97.

3.4.6 Master-Slave Guiding

The Master-Slave guiding is used when two material webs have to
be guided together precisely to the edge (laminating control). In
doing so, the positions of both material webs are detected by two
edge sensors or two CCD cameras.
For a detailed description of this function, see chapter Master-
Slave Guiding, page 86.

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3.4.7 Tear-Off Detection

The Tear-Off Detection is used for the web edge guiding with CCD
camera if, during operation of the web guiding system, material
defects (tear-off) are to be expected on the web edges to be
scanned. When a tear-off is detected, the web guiding system is
blocked automatically for the pre-selected blocking time. The
function detects both tears into the material web (inward tear) as
well as projecting material (outward tear).
For a detailed description of this function, see chapter Tear-Off
Detection, page 89.

3.4.8 Web Width Measurement

The web width measurement enables a continuous monitoring of
the material width during the production process. In this manner,
tendency toward deviation in the material width can be detected
early.
The function continuously measures the width of the web of
material and compares the calculated value to the preset target
width. The web width measured is shown in the display of the
control panel. If the web width measured is less or more than the
warning or error limit set by the operator, it is displayed. The
controller provides digital message outputs for the warning and
error limits.
For a detailed description of this function, see chapter Web Width
Measurement, page 100.

3.4.9 Line Width Measurement

The line width measurement enables a continuous monitoring of
the width of a printed line during the production process. In doing
so, the line is scanned by a BST CLS Pro 600 line and contrast
sensor or a CLS CAM 100 object sensor.
The function continuously measures the width of the printed line
and compares the calculated value to the preset target width. The
line width measured is shown in the display of the control panel. If
the line width measured is less or more than the warning or error
limit set by the operator, it is displayed. The controller provides
digital message outputs for the warning and error limits.
For a detailed description of this function, see chapter Line Width
Measurement, page 108.

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 3 Design and Function

3.5 Motorized Sensor Positioning

3.5.1 Sensor Positioner

The ekr 500 digital Unit Touch controller has a connection for a
motorized FVG POS 100 sensor positioner. The sensor positioner
enables the motorized positioning of the edge sensors connected
(Sensor 1, Sensor 2).
If the installation position of the sensor is hard to access or the
position of the sensor has to be changed frequently due to chan-
ging web widths, the sensor positioner is used to position the
sensor across the web running direction. In Automatic mode, the
sensor slide runs towards the web of material until the sensor has
detected a web edge (automatic edge detection).
For a detailed description of the sensor positioner, see the install-
ation and operating manual FVG POS 100, document number
MD.476.

3.5.2 Positioning Unit

The ekr 500 digital Unit Touch controller has connections for two
positioning units. The positioning units enable the motorized
positioning of sensors or tools. The main field of application of the
positioning unit is the motorized positioning of a BST CLS Pro 600
line and contrast sensor (Sensor 3) across the web running
direction in slitter-winders.
If the installation position of the sensor is hard to access or the
position of the sensor has to be changed frequently due to chan-
ging web widths, the motorized positioning unit is used to position
the sensor across the web running direction. The sensor slide of
the positioning unit is moved to the desired position using the ar-
row keys of the ekr commander control panel of the controller.
There are two speed levels to choose from for the rough and fine
positioning of the sensor.
For a detailed description of the positioning unit, see chapter
Positioning Unit, page 115.

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3.6 Control and Display Elements

On the ekr commander control panel you will find all control and
display elements that you need for the operation of the web
guiding system.

Fig. 4: ekr commander control panel

3.6.1 Touchscreen Display

The ekr commander control panel is equipped with a display with
touchscreen function. This means that the selection of all buttons
and input fields can be carried out directly on the touchscreen
using your fingers.
The touchscreen display of the ekr commander control panel dis-
plays the different operating statuses and all relevant control
parameters during operation. Using the touchscreen you call up
the different setup menus of the controller and change parameter
settings.
For the meanings of the symbols, see Operation Display, page 35.

3.6.2 Keys
Four different groups of keys are located on the control panel
with the following functions:
Green keys: Select the operating mode
Grey keys: Select the guiding mode
Blue keys: Call up / quit setup mode
White keys: Move the guiding device manually,
Set the guiding setpoint,
Adjust the controller gain,
Edit the parameter values
For the meanings of the individual keys, see ekr commander
Control Panel, page 31.

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 3 Design and Function

3.7 Designation of the Sensors

You can connect two edge sensors or CCD cameras and one line
and contrast sensor or one object sensor to the controller. In this
manual, the sensors are designated with Sensor 1, Sensor 2 and
Sensor 3. In accordance with the BST definition, the following
assignment applies between the sensors and the selector keys for
the guiding mode:
Key Sensor assigned Guiding mode

Sensor 1 Left web edge

Sensor 2 Right web edge

Sensor 3 Line / contrast / feature guiding

3.7.1 Edge Sensors (Sensor 1/2)

For the installation position of the edge sensors (Sensor 1/2), the
following applies:
The sensor that is located on the left of the web in the web
running direction (viewed from the top of the material) is Sensor 1.
The top of the material is also the side of the web that has no
direct contact with the deflection pulleys of the guiding device.

Fig. 5: Examples for the definition of Sensor ① and Sensor ②

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3.7.2 Line, Contrast and Object Sensor (Sensor 3)

In conjunction with the CLS Pro 600 line and contrast sensor or the
CLS CAM 100 object sensor, the controller permits guiding on
continuous or interrupted printed lines or contrast edges or
guiding on print features. In this case, the line and contrast sensor
or object sensor is connected to the controller as Sensor 3.
The following applies for the installation position of the line and
contrast sensor:
The connecting cable of the line and contrast sensor points in the
direction of Sensor 2.

Fig. 6: Installation position Sensor 3

① Outfeed roll ④ Sensor 3

② Sensor 1 ⑤ Connecting cable Sensor 3
③ Sensor 2 ⑥ Printed line

In order to achieve optimum guiding results, the distance

between the sensors and the outfeed roll ① of the guiding
device must be kept as small as possible.

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 3 Design and Function

3.7.3 CCD Cameras (Sensor 1/2)

The assignment of the web edges to the selector keys for the
guiding mode can be obtained from the following figures.
One-camera system

CAN address = 21

Left
edge

Fig. 7: Web edge guiding with one CCD camera

CAN address = 21

Left Right
edge edge

Fig. 8: Web edge or web center-line guiding with one CCD camera

Dual-camera system

CAN address = 21 CAN address = 31

Left Right
edge edge

Fig. 9: Web center-line guiding with two CCD cameras

Adjustment of the CAN address of the CCD camera(s), see separate

instruction manual.
CCD Camera Instruction Manual
(Document Number)
CCDPro 30000/5000 MD.167
CCD CAM 100 MD.465

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3.8 Nameplates
The nameplates are located on the top of the controller and on
the rear of the control panel.
The nameplate displayed is only an example. Please obtain the
current data from the nameplate attached to the product.

Fig. 10: Example of a nameplate

Pos. Field Meaning

① Address Manufacturer address
② RoHS designation
Certificates
③ CE designation
④ IDC Serial number
⑤ Type Type designation
⑥ Ver Hardware version
⑦ U Operating voltage
Date of manufacture
⑧ PC
(Calendar week / Year)
⑨ IP Protection type
⑩ I Nominal current consumption
Data matrix code,
⑪ Code
Content = 30 digit serial number (IDC)

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 4 Technical Specifications

4 Technical Specifications
For the technical specifications of the ekr 500 digital Unit Touch
controller and the connectable web guiding components please
refer to the installation and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.

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5 Operation

5.1 Safety Instructions

WARNING
Severe injuries and material damage due to faulty operation!
► Ensure that operating is carried out by qualified and adequately
instructed personnel only.

NOTICE
Damage to the touchscreen due to faulty operation!
Use of sharp, strong or coarse objects (e.g. pens, gloves) may dam-
age the surface of the touchscreen.
► Touch the touchscreen only using bare fingers or a special input
pen (touchpen).

5.2 ekr commander Control Panel

Fig. 11: ekr commander control panel

On the control panel you will find all control and display elements
that you need for the operation of the web guiding system.

Signals that are located on the remote control inputs of

the controller block the keys on the control panel with
counter functions.

You can find the function of the individual keys in the following
table.

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 5 Operation

Function Key Designation Description

Automatic Automatic web guiding

Operating mode Manual

Manual positioning of the guiding device
selection mode

Center
Center positioning of the guiding device
positioning

Sensor 1 Guiding to the left web edge

Sensor 2 Guiding to the right web edge

Web center-line guiding

Guiding mode
selection
Sensor 3 Line / contrast / feature guiding

Watchdog
Watchdog with sensor 1
Sensor 1

Watchdog
Watchdog with sensor 2
Sensor 2
Manual positioning
Arrow keys In manual operating mode:
of the guiding
left / right Position the guiding device to the left / right
device
Shifting the guiding Arrow keys In automatic operating mode:
setpoint left / right Shift the guiding setpoint to the left / right
In manual operating mode:
Call up the setup menu
SETUP
In automatic operating mode:
Activate the gain setting
Setup mode
ENTER Accept the set value (gain setting)

Arrow keys Reduce / increase the parameter value of

left / right the gain setting.

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5.3 Touchscreen Operation

The control panel is equipped with a display with touchscreen
function. This means that the selection of all buttons and input
fields can be carried out directly on the touchscreen using your
fingers. Changing to a menu on the same level is carried out by
swiping the touchscreen. Slide bars and scroll buttons can be
moved by pulling them on the touchscreen. This changes the
value allocated to the slide bar or it can be scrolled from a menu
list. Functions are switched on and off by pressing the respective
buttons on the touchscreen. Buttons for switched on functions are
displayed with a blue background.

5.3.1 Switching Functions On / Off

A button whose function is switched off appears with a white
background.
► To switch the function of the respective button on (here, e.g.
oscillation), press on the touchscreen.
The button appears with a blue background.

5.3.2 Editing Numerical Values

5.3.2.1 Entering the numerical values via the input keyboard

Input fields for numerical values can be edited via the touch-
screen. For this purpose, tap on the input field on the touch-
screen. A numeric keypad appears that can also be operated using
your fingers. After entering the desired numerical value and con-
firming with the button, you return to the original menu. The
numeric value entered appears in the respective input field.

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 5 Operation

5.3.2.2 Editing the numerical values via the slide bar

Fig. 12: Example of a display with slide bar switched on

›› A menu is displayed that permits the numerical value to be

edited via a slide bar.
1. Activate the slide bar by pressing the respective function button.
The function button is displayed with a blue background.
By pressing the function button, the swiping function is deactiv-
ated to allow the slide bar to be operated via the touchscreen.
2. Pull the slider on the touchscreen to the left or right until the
desired numeric value is displayed above the slide bar.
3. To adopt the numerical value set, press the function button
again.
The function button is displayed with a blue background again.
The swiping function is activated.

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5.4 Access to the Online Documentation

This function allows you quick and direct access to the online
documentation of the controller. All you need is a smartphone or
tablet with camera and internet access where a QR Code scanner
software is installed. Free apps with QR code scanners can be
found on the internet.

Displaying the online documentation

1. Press and hold the desired symbol on the touch screen for at
least 3 seconds.

A window appears in the display showing a QR code.

2. Scan the QR code with your smartphone or tablet.

The generated link leads you directly to the corresponding
chapter of the online documentation.

3. Press the button to hide the QR code.

5.5 Operation Display

5.5.1 Overview
The operation display in the display of the control panel shows the
different operating states and all relevant control parameters as
graphical symbols and numeric values. You will find the meanings
for the individual symbols in the following illustration.

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 5 Operation

Application with edge sensors

Fig. 13: Operation display for application with edge sensors

Pos. Symbol Display function

Operation display edge sensor

①
(Sensor 1)

Operation display edge sensor

②
(Sensor 2)

Displays the setpoint of the

③
web edge

Status display System OK

④
(heart beats)

⑤ Displays the controller gain

⑥ Actuator operation display

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Application with CLS Pro 600 line and contrast sensor

Fig. 14: Operation display for application with CLS Pro 600 line and contrast sensor

Pos. Symbol Display function

Operation display CLS Pro 600

① line / contrast sensor
(Sensor 3)

Displays the setpoint of the

②
web edge

Status display System OK

③
(heart beats)

④ Displays the controller gain

⑤ Actuator operation display

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 5 Operation

Application with CLS CAM 100 object sensor

Fig. 15: Operation display for application with CLS CAM 100 object sensor

Pos. Symbol Display function

Operation display
① CLS CAM 100 object sensor
(Sensor 3)

Displays the setpoint of the

②
web edge

Status display System OK

③
(heart beats)
Displays the controller gain for
proportional control mode*
④
Displays the controller gain
for offset control mode*

⑤ Actuator operation display

* A description of the different control modes of the CLS CAM 100

object sensor can be found in the separate installation and operat-
ing manual CLS CAM 100, document number MD.577.

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Application with CCD cameras

Fig. 16: Operation display for application with CCD cameras

Pos. Symbol Display function

Operation display CCD camera

①
(left edge)

Operation display CCD camera

②
(right edge)

Displays the setpoint of the

③
web edge

Status display System OK

④
(heart beats)

⑤ Displays the controller gain

⑥ Actuator operation display

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 5 Operation

Application with sensor positioner

Fig. 17: Operation display for application with sensor positioner

Pos. Symbol Display function

Operation display edge sensor

①
(Sensor 1)

Operation display edge sensor

②
(Sensor 2)

Displays the setpoint of the

③
web edge

Status display System OK

④
(heart beats)

⑤ Displays the controller gain

⑥ Actuator operation display

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If the function Automatic setpoint acceptance is activated, the

display of the controller gain in the bottom left corner of the
operation display is cross-faded by an additional button. To activate
the function, see Automatic Setpoint Acceptance, page 112.

Fig. 18: Operation display with activated automatic setpoint acceptance

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 5 Operation

5.5.2 Edge Sensors Operation Display (Sensor 1/2)

The operation displays for sensor 1 and sensor 2 appear only if the
respective edge sensors are connected to the controller.

Fig. 19: Edge sensors operation display

Edge sensor operation display

Symbol meanings
The white triangle marks the set position of the web edge in
①
the sensor scanning area.
The numeric value indicates the current web edge position.
Connection via CAN bus:
②
Position of the web edge in the sensor scanning area
(unit [mm] or [inch])

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Displaying the web edge position (example)

Edge position = 0 Edge position = - 6 mm

The web edge is located in the The web edge is displaced by

center of the sensor scanning -6 mm from the center of the
area. sensor scanning area.

5.5.3 CLS Pro 600 Line and Contrast Sensor Operation Display (Sensor 3)
The operation display for the CLS Pro 600 line and contrast sensor
only appears if a corresponding sensor is connected to the con-
troller as sensor 3.

Fig. 20: CLS Pro 600 line and contrast sensor operation display

The appearance of the operation display depends on the guiding

mode that is selected on the line and contrast sensor.
Line guiding Contrast guiding

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 5 Operation

Symbol meanings
① The triangle marks the guiding setpoint set.
Line guiding:
The white bar marks the current position of the line.
② Contrast guiding:
The black bar marks the current position of the contrast
transition.
The value specifies the relative position of the line or
③
contrast transition in relation to the sensor scanning area.

Display of the position of the line to be scanned (example)

Position of the line = 50% Position of the line = 25%

The line is located in the center The line is located at 25% of the
of the sensor scanning area. sensor scanning area.

Display of the position of the contrast transition to be scanned

(example)
Position of the contrast Position of the contrast
transition = 50% transition = 75%

The contrast transition is The contrast transition is

located in the center of the located at 75% of the sensor
sensor scanning area. scanning area.

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5.5.4 CLS CAM 100 Object Sensor Operation Display (Sensor 3)

The operation display for the CLS CAM 100 object sensor only
appears if a corresponding sensor is connected to the controller as
sensor 3.

Fig. 21: CLS CAM 100 object sensor operation display

CLS CAM 100 object sensor operation display

Symbol meanings
① The triangle marks the guiding setpoint set.
The light blue bar marks the current position of the line,
②
contrast transition or print feature.
The value specifies the position of the line, contrast transition
③
or print feature within the sensor scanning area.

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 5 Operation

Display of the position of the print feature (example)

Position of the print feature = 0 Position of the print feature = -19.8

The print feature is located in The distance of the print feature

the center of the sensor to the center of the sensor
scanning area. scanning area is -19.8 mm.

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5.5.5 CCD Cameras Operation Display

The operation display for the CCD cameras appear only when the
respective CCD cameras with the correct CAN address are connected
to the controller.

One-camera system

Fig. 22: One-camera system operation display

CAN address camera 1 = 21

Dual-camera system

Fig. 23: Two-camera system operation display

CAN address camera 1 = 21

CAN address camera 2 = 31

Adjustment of the CAN address of the CCD camera(s), see separate

instruction manual.
CCD Camera Instruction Manual
(Document Number)
CCDPro 30000/5000 MD.167
CCD CAM 100 MD.465

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 5 Operation

CCD camera operation display

Symbol meanings
CAN address of the assigned CCD camera
One-camera system: 21
①
Dual-camera system: camera 1 = 21, camera 2 = 31
(see CCD Cameras (Sensor 1/2), page 28)
② The triangle marks the guiding setpoint.
The value specifies the web edge position as a percentage or
③ absolute value (see Display of the Web Edge Position, page
49).
The contrast transition (white / black) marks the actual
④
position of the web edge.

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5.5.5.1 Display of the Web Edge Position

The web edge position is displayed as a percentage or absolute
value dependent on the type (CCDPro5000/30000 or CCD CAM 100)
and the operating mode of the CCD camera connected.

CCD camera CCDPro 5000/30000

On this type of CCD camera the web edge position is always dis-
played as a percentage value.
Display of the web edge position as percentage value

Relative position of the web edge

with regard to the camera measuring range
Examples:
Edge position = 0% Edge position = -46%

The web edge is located in the The web edge is located at -46%
center of the camera measuring of the camera measuring range.
range.

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 5 Operation

CCD camera CCD CAM 100

On this type of CCD camera the web edge position is displayed as
a percentage or absolute value dependent on the operating mode
set.
Operating Mode DIL Switch Display of the Edge Position
S1.1 S1.2 S1.4
CCDPro 30000 OFF ON — Percentage value
CCDPro 5000 ON OFF —

OFF OFF OFF

Relative position of the web
edge with regard to the
camera measuring range
Absolute value
CCD CAM 100

OFF OFF ON

Absolute position of the web

edge within the camera
measuring range
Examples:
Edge position = 0 Edge position = +148,3

The web edge is located in the The distance from the web edge
center of the camera measuring to the center of the camera
range. measuring range is 148.3 mm.

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5.5.6 Actuator Operation Display

The operation display for the actuator appears only if an actuator
with position feedback or a servo centre transducer (OMG 4, OMG 8,
CK 37) is connected to the controller.

Fig. 24: Actuator Operation Display

Actuator Operation Display

The tachometer symbol indicates that the speed-dependent

①
guiding is activated.
② The black line marks the zero position of the actuator.
The symbol indicates that the position control for the
③
actuator is switched on.
The value specifies the relative position of the actuator in
④
relation to the end positions.
⑤ The grey bar marks the current position of the actuator.

Normalized display of the actuator position

For actuators with position feedback, you can activate a normal-
ized display for the actuator position in the Actuator setting menu
of the setup menu. When the normalized display is active, the po-
sition of the actuator is shown in the operation display as an abso-
lute value in the units [mm] or [inch].

Fig. 25: Normalized display of the actuator position

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 5 Operation

When operating the ekr 500 digital Unit Touch controller

with the CLS CAM 100 object sensor, the normalized dis-
play of the actuator position must always be activated.

The procedure for commissioning the normalized display is

described in the installation and commissioning manual ekr 500
digital Unit Touch, document number MD.497 .

5.6 Configurable Displays and Setting Menus

You may reach the configurable displays and setting menus from
the operation display by horizontally swiping on the touchscreen.

Fig. 26: Swiping function

You can select the pages that are displayed using the swiping
function. This means that the display is configurable. The selection
of the displays and setting menus that are displayed using the
swiping function is done in a special setup menu (see Switching
the Configurable Displays and Setting Menus On/Off, page 123).

Fig. 27: Setup menu for selecting the displays and setting menus

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Configurable displays and setting menus

Symbol Function Description

Displaying the web/ See Displaying the Web

line width Width, page 100

Adjusting the See Adjusting the Oscillation

oscillation amplitude Amplitude, page 92

Adjusting the See Adjusting the Oscillation

oscillation frequency Frequency, page 95

See Adjusting the Guiding

Setting the guiding
Setpoint with the Setting
setpoint
Menu, page 70

Operating the See Positioning Unit, page

positioning unit 115

When swiping on the touchscreen the displays and setting menus

selected are displayed one after the other.
The indicator in the upper left corner of the display serves as a
navigation aid.

Fig. 28: Navigation aid of the swiping function

① Navigation aid

The number of circles indicates how many displays or menus are

activated (five in the example). The black filled circle shows the
position of the currently displayed menu within the menu
sequence (in the example menu 2 of 5).

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5.7 Performing the Material Setup

5.7.1 Overview

WARNING
Danger of cutting on sharp edges of the material web!
Severe cutting injuries caused by the edges of the moving material
web.
► Never touch the edges of moving material webs.

► Carry out the material setup only when the production machine
is stationary.
During the material setup the controller is automatically adjusted
to the properties of the material to be scanned.

If a FVG POS 100 sensor positioner is connected to the

controller, the calibration of the optical edge sensors is
carried out using the Automatic edge sensor standardization
function (see Automatic Edge Sensor Standardization,
page 113)

5.7.1.1 When does a material setup have to be carried out?

In order to be able to achieve optimum guiding results, a material
setup must be carried out during / after the following work:
■ During the initial commissioning of the web guiding system
■ With optical edge sensor (IR 2011, IR 2012): After changing
over to a material with other contrast characteristics (e.g. film
with a different material transparency)
■ With ultrasonic edge sensors (US 2010): After changing over to
a material with different sound absorption properties
■ After cleaning a dirty sensor

5.7.1.2 Manual or automatic material setup?

The material setup can be run automatically or manually.
■ The automatic material setup describes the normal procedure
for saving the bright / dark values of the sensors.
■ The manual material setup should always be used if the con-
trast that has to be scanned is critical.

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5.7.1.3 Generating bright / dark values

The illustrations show the procedure for generating the bright /
dark values.

Bright value
► Completely clear the sensor's scanning area (no material in the
scanning area).

Dark value
► Completely cover the sensor’s scanning area with the material
to be scanned.

If using highly transparent material, when covering the

measurement window you must ensure that there are no
folds in the material in the sensor scanning area. The
material must be tensioned.

5.7.1.4 Displaying the determined bright / dark values

The bright / dark value determined is displayed graphically (bar
indicator) and as a numeric value in the display under the sensor
symbol.

Fig. 29: Screen display with the connection of the sensor via CAN bus

① Bright / dark value (numeric display)

100.0% = scanning area is completely free
0.0% = scanning area is completely covered
② Bright / dark value (graphical display)

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Fig. 30: Screen display with analogue connection of the sensor

① Dark value (graphical display)

② Current value (graphical display)
③ Bright value (graphical display)

Each screen display for the connection of the sensor via CAN bus
is shown in the following chapters.

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5.7.2 Activating the Material Setup

You activate the material setup (manual or automatic) in the
setup menu.

Fig. 31: Setup menu

① Automatic material setup

② Manual material setup

Activating the material setup

1. Press the Manual mode key.
The LED of the key will illuminate.
The controller switches to manual mode.
2. Press the SETUP key.
The controller changes to setup mode.

The first page of the setup menu will be displayed on the

screen.
3. Press the button for the desired setup type (automatic ① or
manual ②).
The material setup is active.
The bright or dark value determined for the selected sensor is
shown in the display under the sensor symbol.

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5.7.3 Cancelling Material Setup

You can cancel the material setup at any time as follows:
► Press the SETUP key.
The material setup is cancelled.
The bright / dark values determined are not saved.
ð The screen display changes to the operation display.

5.7.4 Automatic Material Setup

This chapter describes the normal procedure for saving the
bright / dark values.

You have to perform the material setup for each edge

sensor (sensor 1, sensor 2) separately.

1. Remove any material that may be present from the connected

edge sensors and clean the sensor scanning areas.
2. Select the desired sensor by pressing the respective key Sensor 1
or Sensor 2.
The LED of the key will illuminate.
3. Activate the automatic material setup (see Activating the
Material Setup, page 57).

The adjacent screen appears in the display (here with Sensor 1

selected). The animation shows the operating steps necessary
for generating the bright / dark values:
The hand moves the material into the sensor scanning area
(dark value) and back out again (bright value).

4. Completely clear the selected sensor's scanning area (no

material in the scanning area).
The bright value measured is displayed.

5. Completely cover the selected sensor's scanning area with the

material to be scanned for at least 2 seconds.
The dark value measured is displayed.

6. Press the button.

The material setup for the selected sensor is completed.
The bright / dark values determined are saved.
ð The setup menu is displayed.

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5.7.5 Manual Material Setup

This chapter describes the procedure for saving the bright / dark
values with critical contrasts.
You have to perform the material setup for each edge
sensor (sensor 1, sensor 2) separately.

1. Remove any material that may be present from the connected

edge sensors and clean the sensor scanning areas.
2. Select the desired sensor by pressing the respective key Sensor 1
or Sensor 2.
The LED of the key will illuminate.
3. Activate the manual material setup (see Activating the Material
Setup, page 57).

The screen display shows the operating step necessary for gen-
erating the bright value for the selected sensor (Sensor 1 here).

4. Completely clear the selected sensor's scanning area (no

material in the scanning area).
The bright value measured is displayed.

5. Press the button.

The bright value will be saved.

The screen display shows the operating step necessary for gen-
erating the dark value for the selected sensor (Sensor 1 here).

6. Completely cover the scanning area of the selected sensor with

the material to be scanned and keep it covered.
The dark value measured is displayed.

7. Press the button.

The dark value will be saved.
The material setup for the selected sensor is completed.
ð The setup menu is displayed.

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

5.8.1 Function
If you use an IR 2011/40 optical edge sensor to detect the web
edge position, you can choose between six different sensor oper-
ating modes. The operating modes allow optimum adaptation of
the sensor's scanning behaviour to different material properties.
A description of the six operating modes can be found in chapter
IR 2011/40 Operating Modes, page 60.
The desired operating mode is selected in the setup menu using a
special setting menu (see Operating Mode Selection, page 62).

5.8.2 Requirements
The following requirements must be fulfilled for using the selection
function for the IR 2011/40 optical edge sensor operating mode:
■ An optical edge sensor type IR 2011/40 is connected to the
ekr 500 digital Unit Touch controller.
■ Firmware version of the IR 2011/40 edge sensor ≥ 3.2.6
■ Firmware version of the ekr commander control panel ≥ 1.9.2

5.8.3 IR 2011/40 Operating Modes

The desired operating mode is selected in the setup menu using a
special setting menu.

Fig. 32: Setting menu for selecting the IR 2011/40 edge sensor operating mode

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IR 2011/40 operating modes

Operating Field of Application Features Measuring
Mode Range
Standard
Scanning of different
24 mm
homogeneous materials ■ Material setup by user
(± 12 mm)
(opaque or transparent)

Narrow
Scanning of different
7 mm
homogeneous materials ■ Material setup by user
(± 3,5 mm)
(opaque or transparent)

Auto Setup
Scanning of different
■ Continuous sensor calibration due to 20 mm
homogeneous materials
permanent automatic material setup (± 10 mm)
(opaque or transparent)

Scanning of material webs

■ Reliable compensation of interfering
with marginal perforation
influences of the marginal perforation on
(e.g. continuous forms)
Marginal the web guiding control
Geometry of the marginal
Perforation ■ Suitable for materials with circular or
perforation: 7 mm
rectangular tractor feed perforation
(± 3,5 mm)
circular rectangular ■ Scanning of the web edge is independent
of the shape and size of the holes.
Requirement: The edge distance D of the
tractor feed perforation is at least 4 mm.

Nonwoven Scanning of fleece materials ■ Continuous sensor calibration due to

(Nonwoven) with inhomogen- permanent automatic material setup 24 mm
eous material structure and ■ Automatic compensation of interfering (± 12 mm)
strongly varying transparency influences from gaps in the material
Dynamic Scanning of material webs ■ Very sensitive guiding behaviour with
with highly dynamic web extremely short response times 24 mm
position errors and high web ■ Sensor measuring value follows any web (± 12 mm)
speeds edge position change without delay

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5.8.4 Operating Mode Selection

If two edge sensors of the IR 2011/40 type are connected

to the controller, you must select the operating mode for
Sensor 1 and Sensor 2 separately. In this way you can
also set different operating modes for the two sensors.

Procedure
1. Press the Manual mode key.
The LED of the key will illuminate.
The controller switches to manual mode.
2. Activate the edge sensor (Sensor 1 or Sensor 2) whose operating
mode is to be changed.
The LED of the key will illuminate.
3. Press the SETUP key.
The controller changes to setup mode.

The first page of the setup menu appears in the display.

4. Tap the symbol of the IR 2011/40 operating mode setting

menu on the touchscreen.

The symbol for the setting menu for the IR 2011/40 op-
tical edge sensor operating mode is only displayed in the
Setup menu if the items listed in chapter Requirements,
page 60 are fulfilled.

The setting menu for the operating mode selection is displayed.

The button of the currently selected operating mode is dis-
played with a blue background.
5. Select the desired operating mode by tapping the corresponding
button.

6. Confirm your selection by pressing the button in the setting

menu.
The setting menu is closed.
The setup menu is displayed.
7. Press the SETUP key, to return to the operation display.
8. Repeat the process for the second edge sensor if desired.

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5.9 Selecting the Guiding Mode

You can select between the following guiding modes.

Guiding to the left web edge (Sensor 1)

›› An edge sensor or a CCD camera is connected to the controller
as sensor 1.
► Press the Sensor 1 key.
ð The LED of the key will illuminate.

Guiding to the right web edge (Sensor 2)

›› An edge sensor or a CCD camera is connected to the controller
as sensor 2.
► Press the Sensor 2 key.
ð The LED of the key will illuminate.

Web center-line guiding (Sensor 1 and Sensor 2)

›› Two edge sensors or one or two CCD cameras are connected to
the controller.
► Press the Sensor 1 and Sensor 2 keys at the same time.
ð The LEDs of both keys will illuminate.

Line / contrast / feature guiding (Sensor 3)

›› A CLS Pro 600 line and contrast sensor or a CLS CAM 100 object
sensor is connected to the controller as Sensor 3.
► Press the Sensor 3 key.
ð The LED of the key will illuminate.

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5.10 Selecting the Operating Mode

5.10.1 Manual Mode

In this operating mode, you can change the position of the guiding
device.

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

1. Press the Manual mode key.

The LED of the key will illuminate.
The controller switches to manual mode.
2. Using the arrow keys, move the guiding device to the desired
position.

Position control

WARNING
Danger to life caused by movements of the setting drive!
If position control is active, the setting drive may execute auto-
matic movements in manual mode . Body parts could be crushed,
sheared or impacted.
► Ensure that no persons remain in the swivel or positioning
range of machine components positioned by the actuator.

The position control is only available for actuators with position

feedback (EMS 17 … 23). With position control switched on, the
actuator stops in the traversed to position when in manual mode,
independently of any external forces acting on the drive.
To switch the position control on / off, see installation and com-
missioning manual ekr 500 digital Unit Touch, document number
MD.497.

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5.10.2 Automatic
In this operating mode, automatic web guiding is carried out
depending on the guiding mode selected (guiding to the left or
right web edge, web center-line guiding, line or contrast guiding).

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

›› The desired guiding mode is selected (see Selecting the Guiding

Mode, page 63).
► Press the Automatic key.
The LED of the key will illuminate.
ð The controller switches to automatic mode.

5.10.3 Center Positioning

In this operating mode the guiding device automatically moves to
its central position.

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

► Press the Center Positioning key.

The LED of the key will illuminate.
ð The guiding device moves to its central position.

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5.11 Setting the Guiding Setpoint

The guiding setpoint is the desired position of the web edge, prin-
ted line, contrast transition or print feature in the sensor scanning
area. It is displayed in the operation display.

Display for edge sensors (Sensor 1, Sensor 2)

Display for CLS Pro 600 line and contrast sensor (Sensor 3)

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Display for CLS CAM 100 object sensor (Sensor 3)

Display for CCD cameras

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Display for sensor positioner

Symbol meanings
① The triangle marks the set guiding setpoint during operation.
② Numeric display of the set guiding setpoint
③ The black line marks the set guiding setpoint
You can select the following two methods to adjust the guiding
setpoint:
■ Adjusting the guiding setpoint using the arrow keys of the
control panel
■ Adjusting the guiding setpoint using a special setting menu
The two methods are described in the following chapters.

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5.11.1 Adjusting the Guiding Setpoint with the Arrow Keys

In Automatic mode you adjust the guiding setpoint using the
arrow keys of the control panel.

The guiding setpoint is saved separately for each guiding

mode.

If the optional electronic remote precision adjustment

EFE 1 is connected to the controller, adjust the guiding
setpoint using only the potentiometer of the EFE 1. The
function of the arrow keys on the control panel of the
controller is then blocked in Automatic mode.

1. Select the desired guiding mode (see Selecting the Guiding

Mode, page 63).
2. Press the Automatic key.
The LED of the key illuminates.
The controller switches to automatic mode.
3. Set the desired guiding setpoint of the web using both arrow
keys.

The guiding setpoint set is shown graphically (bar indicator)

and as a numeric value at the lower right corner of the display.
The new guiding setpoint will have an immediate effect on the
controller. If both arrow keys are pressed at the same time
then the guiding setpoint is reset to 0.

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5.11.2 Adjusting the Guiding Setpoint with the Setting Menu

Using the swiping function, you can call up a special setting menu
for the guiding setpoint.

Fig. 33: Setting menu for the guiding setpoint

Adjusting the guiding setpoint

The guiding setpoint is saved separately for each guiding

mode.

›› The setting menu for the guiding setpoint has been activated in
the setup menu for the configurable displays and setting
menus (see Switching the Configurable Displays and Setting
Menus On/Off, page 123).
›› The display shows the operation display.
1. Select the desired guiding mode (see Selecting the Guiding
Mode, page 63).
2. Call up the setting menu for the guiding setpoint using the
swiping function (see Configurable Displays and Setting Menus,
page 52).
The set guiding setpoint is shown in the display as a numeric
value and using a ruler display with slider.
3. Set the desired guiding setpoint by entering the corresponding
numeric value (see Entering the numerical values via the input
keyboard, page 33) or using the slide bar (see Editing the
numerical values via the slide bar, page 34).
The new setting will have an immediate effect on the guiding.

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5.11.3 Accepting Current Position of a Web Edge as Guiding Setpoint

This accept function allows you to use the current position of the
web edge in the sensor measuring range as the new guiding set-
point for the web guiding system.

5.11.3.1 Function
In Manual or Center Positioning mode, you can move the material
web into the desired position for guiding (e.g. by moving the
guiding device manually using the arrow keys or by moving the
edge sensor acrossy to the web running direction). Then accept
the current position of the web edge as the guiding setpoint for
web guiding. Depending on the acceptance mode, the acceptance
is triggered by pressing a key or by a remote control signal (see
Acceptance Modes, page 71).

5.11.3.2 Acceptance Modes

The function supports four acceptance modes. You activate the
different acceptance modes in the public list of parameters of the
controller (see Parameter List 0, page 142).

Acceptance mode 1: Automatic acceptance when changing into

Automatic Mode
›› The acceptance mode is activated (Parameter w-setup man
->auto = ON).
›› The controller is in operating mode Manual or Center Positioning.
›› The material web is located in the desired position.
► Press the Automatic key.
ð The controller regulates according to the position of the web
edge that was found when switching to the Automatic
Mode.

Acceptance mode 2: Manual acceptance in Manual Mode

›› The acceptance mode is activated (Parameter w-setup by
command = ON).
›› The controller is in operating mode Manual.
›› The material web is located in the desired position.
► Press the ENTER key.
ð The controller accepts the current position of the web edge
as the new guiding setpoint for the web guiding.

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Acceptance mode 3: Automatic acceptance with remote control

signal
›› The acceptance mode is activated (Parameter w-setup by input
= ON).
›› Function table 5 (Table 5) or 6 (Table 6) for the allocation of the
digital inputs and outputs is active. For selecting the function
table see installation and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.
›› A respective remote control signal is present at terminal 22 of
the controller.
›› The material web is located in the desired position.
► Switch on the remote control signal.
ð The controller regulates according to the position of the web
edge that was found when switching on the remote control
signal.

Acceptance mode 4: Automatic acceptance with change of the

guiding mode
›› The acceptance mode is activated (Parameter w-setup by edge
change = ON).
›› The controller is in operating mode Automatic.
›› The material web is located in the desired position.
► Press the key(s) for the desired guiding mode.
Key(s) Guiding Mode
Guiding to the left web edge
(Sensor 1)

Guiding to the right web edge

(Sensor 2)

Web center-line guiding

(Sensor 1 and Sensor 2)

Line / contrast / feature guiding

(Sensor 3)

The controller accepts the current position of the web edge as the
new guiding setpoint for the web guiding.

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5.11.4 Saving and Loading the Guiding Setpoint

The memory of the controller allows you to save four different
parameter sets for the guiding setpoint, and to re-load them when
required. In this way, you reduce the setup time for repeat orders.
In each of the four parameter sets, the controller saves the guid-
ing setpoint for the following guiding modes:
■ Web edge guiding with sensor 1
■ Web edge guiding with sensor 2
■ Web center-line guiding with sensor 1 and sensor 2
■ Line / contrast / feature guiding with sensor 3
The number of the current parameter set loaded is shown in the
small sensor symbol at the bottom edge of the display.

Fig. 34: Display of the parameter set loaded for the guiding setpoint

Number of the parameter set loaded

①
(see the following table)

Symbol Meaning Note

Parameter set 1 is loaded Factory setting

Parameter set 2 is loaded

Parameter set 3 is loaded

Parameter set 4 is loaded

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Loading the guiding setpoint

›› Function table 1 (Table 1) or 4 (Table 4) for the allocation of the
digital inputs and outputs is active. For selecting the function
table see installation and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.
► Select desired parameter set.
The selection is carried out using an external switch or via a
respective remote control signal on terminals 22 and 33 of the
controller (see installation and commissioning manual ekr 500
digital Unit Touch, document number MD.497).

Saving the guiding setpoint

1. Select desired parameter set.
The values saved for the guiding setpoint for the guiding mode
currently selected are shown in the display.
2. Select the desired guiding mode (see Selecting the Guiding
Mode, page 63).
3. Set the guiding setpoint to the new value using the keys of the
control panel (see Setting the Guiding Setpoint, page 66).
ð The new value for the guiding setpoint is automatically
saved in the parameter set selected.

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5.11.5 Entering an Offset Value for the Guiding Setpoint

The offset value for the guiding setpoint is used for web center-
line-guiding with CCD camera when the CCD camera is mounted in
the machine off-center, but the material web should be guided
through the machine in the middle.

Center
camera measuring range

CCD camera

Machine frame Offset

Material web

Machine center

Fig. 35: Off-center assembly of the CCD camera

Problem If the value "0" is set on the controller for the guiding setpoint,
the material web will be guided to the center of the camera
measuring range. Due to the off-center assembly of the CCD
camera, a difference (offset) results between the center of the
camera measuring range and the machine center. This difference
results in that with the set guiding setpoint "0", the material web
does not run in the middle of the machine.

Objective If the guiding setpoint on the controller is set to the value "0", the
material web should run exactly in the middle of the machine.

Solution On the controller, an offset value is entered that corresponds with

the difference between the center of the camera measuring range
and the machine center.

Procedure
›› The material web is pulled into the machine.
1. Activate the Web center-line guiding mode.

2. Activate Automatic operating mode.

3. Move the guiding setpoint of the material web using both

arrow keys in such a manner that the web runs exactly in the
middle of the machine.
A value unequal "0" (in the example "-500") is shown for the
guiding setpoint in the display of the controller.

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Application example

Offset

Controller display screen

Fig. 36: Determining the offset value for the guiding setpoint

① Position of the machine center

② Position of the center of the camera measuring range
③ Set guiding setpoint (≙ offset value)

The value ③ displayed corresponds with the offset between

the center of the camera measuring range and the machine
center.
4. Enter the displayed value for the guiding setpoint (in the
example "-500") as offset value on the controller (parameter
setpoint offs. Cam M12 of the public parameter list 0, see
Parameter List 0, page 142). Note the prefix sign!
5. Activate the offset value on the controller (parameter setp-offs.
Cam M12 act. = 1).
After activating the offset value, the controller uses the value
entered to compensate the deviation between the center of the
camera measuring range and the machine center. If the guiding
setpoint is set to the value "0", the material web runs exactly
through the middle of the machine.

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5.12 Optimizing the Controller Gain

You use this function to set the gain for the different guiding
modes. The controller gain is normally set once during commis-
sioning. If control oscillations occur during operation (the guiding
device trembles), the controller gain has to be optimized.

You have to set the gain for each guiding mode separately.

Fig. 37: Display of the controller gain (standard application with proportional
control mode)

Fig. 38: Display of the controller gain (application with CLS CAM 100 object sensor
in “offset” control mode (mode 4))*

* A description of the different control modes of the CLS CAM 100

object sensor can be found in the separate installation and operat-
ing manual CLS CAM 100, document number MD.577.
You can set the controller gain either using the arrow keys or by
entering a specific value using the touchscreen function.

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5.12.1 Adjusting the Controller Gain with the Arrow Keys

›› The material web is pulled in and is tensioned.
›› The guiding device is not in an end position.
1. Select the desired guiding mode (see Selecting the Guiding
Mode, page 63).
2. Press the Automatic key.
The LED of the key will illuminate.
The controller switches to automatic mode.
3. Press the SETUP key.
The set gain is displayed at the bottom edge of the display
using a bar indicator ① and as a numeric value ②. If the
numeric value is displayed in blue colour, it can be adjusted
using the arrow keys.
4. Keep increasing the gain using the right arrow key until control
oscillations occur (the guiding device starts to tremble).

5. Keep reducing the gain using the left arrow key until the
oscillation ceases (stable guiding operation).
If you desire a slower reaction of the guiding, you can reduce
the gain even further.
Pressing both arrow keys at the same time will reset the gain to
a value of 5.0.
6. Press the ENTER key.
ð The gain setting is complete.

If control oscillations do not occur we recommend setting

the maximum gain.

5.12.2 Adjusting the Controller Gain via the Touchscreen

›› The material web is pulled in and is tensioned.
›› The guiding device is not in an end position.
›› If the display of the controller gain is covered by the button for
the setpoint acceptance, you must at first hide this button by
pressing the SETUP key.
1. Select the desired guiding mode (see Selecting the Guiding
Mode, page 63).
2. Tap on the displayed gain value on the touchscreen.

A numeric input keypad appears in the display.

3. Enter the desired value for the controller gain.
4. Confirm the entry with the button.
ð The gain setting is complete.

If control oscillations do not occur we recommend setting

the maximum gain.

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5.13 Special Guiding and Monitoring Functions

5.13.1 Watchdog

5.13.1.1 Function
The Watchdog function is used to prevent the web from wander-
ing after the total loss of the guiding criterion (printed line, con-
trast transition or print feature) during line, contrast or feature
guiding. If the guiding criterion disappears from the scanning area
of the line, contrast or object sensor (e.g. if the print is not carried
out, a poor splice or similar), the current web position is detected
by the edge sensor (capture sensor) and saved by the controller.
Then the controller will switch over from the line, contrast or ob-
ject sensor (Sensor 3) to the edge sensor (Sensor 1 or Sensor 2)
used. Switching back to the line, contrast or object sensor is car-
ried out automatically immediately after re-detecting the guiding
criterion. When the Watchdog function is activated, the scanning
area of the capture sensor is limited to 80%.

5.13.1.2 Requirements
The following requirements must be fulfilled for operating the
Watchdog function:
■ A CLS Pro 600 line and contrast sensor or a CLS CAM 100 object
sensor is connected to the controller.
■ If a CLS CAM 100 object sensor is used, the proportional control
mode is set on the sensor. For setting the control mode, see the
installation and operating manual Object sensor CLS CAM 100,
document number MD.577.
■ At least one edge sensor is connected to the controller.
■ The edge sensor (capture sensor) is arranged at the same
height or behind the line and contrast or object sensor in the
web running direction (see Figure).

Fig. 39: Correct arrangement of the capture sensor and the line / contrast / object sensor

① Capture sensor
② Line / contrast / object sensor (CLS Pro 600 in this case)
③ Capture sensor scanning area
④ Line and contrast sensor scanning area

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5.13.1.3 Before Switching On

Before switching on the Watchdog function for the first time, the
following preparation measures must be carried out:
► Carry out separate commissioning for the guiding with the
CLS Pro 600 line and contrast sensor or the CLS CAM 100 object
sensor and the guiding with the edge sensor (capture sensor).
► Carry out the material setup for the edge sensor.
► Carry out the setup for the CLS Pro 600 line and contrast sensor
or the CLS CAM 100 object sensor (see separate operating
instructions Line and contrast sensor CLS Pro 600, EDP no.
MD.323 or installation and operating manual Object sensor
CLS CAM 100, EDP no. MD.577).
► Optimize the controller gain for both sensors.

When the Watchdog function is active, changes to the

controller gain are only effective on the CLS Pro 600 line
and contrast sensor or the CLS CAM 100 object sensor.

► Set the guiding setpoint of the CLS Pro 600 line and contrast
sensor or the CLS CAM 100 object sensor to the value 0 (see
Switching On the Watchdog, page 80, Step 4).

If the optional electronic remote precision adjustment

EFE 1 is connected to the controller then the guiding set-
point must be set to the value 0 using the potentiometer
of the EFE 1 (see Electronic Remote Precision Adjust-
ment (Option), page 139).

5.13.1.4 Switching On the Watchdog

The Watchdog function is only available in conjunction

with the web edge guiding. The Watchdog cannot be
switched on if the web center-line guiding is active.

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

›› The web edge guiding is selected as guiding mode (guiding to

the left or right web edge).
1. Position the CLS Pro 600 line and contact sensor or the
CLS CAM 100 object sensor on the printed line, contrast trans-
ition or print feature.
2. Press the Sensor 3 key on the controller.
The LED of the key illuminates.
The line / contrast / feature guiding is activated.

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3. Press the Automatic key on the controller.

The LED of the key illuminates.
The controller switches to automatic mode.

4. Press both arrow keys on the controller at the same time.

The guiding setpoint for sensor 3 is reset to the value 0.
If the optional electronic remote precision adjustment EFE 1 is
connected to the controller then the guiding setpoint must be set
to the value 0 using the potentiometer of the EFE 1 (see EFE 1,
page 139).
5. Move the web to the desired guiding setpoint (by moving the
CLS Pro 600 line and contrast sensor or the CLS CAM 100 object
sensor mechanically across the web running direction).
6. Position the capture sensor so that the web edge is located in
the centre of the sensor scanning area.
The current position of the web edge in the sensor scanning area
is shown in the display of the controller under the respective
sensor symbol.

7. Press the Sensor 3 key on the controller and keep it pressed.

The LED of the key illuminates.

8. Press the key for the capture sensor used (Sensor 1 or Sensor 2).
9. First release the Sensor 3 key and then the key for the capture
sensor used (Sensor 1 or Sensor 2).
Caution! Observe the order in all cases!
The LED of the capture sensor key illuminates.
ð The Watchdog function is switched on.
If the capture sensor takes over the guiding in event of losing the
printed line, contrast transition or print feature then the LED of
the respective key (Sensor 1 or Sensor 2) flashes.

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

5.13.2.1 Function
The overlaid web edge/web center-line guiding is a combination
of a web edge or web center-line guiding and an overlaid feature
guiding with the CLS CAM 100 object sensor.
This special guiding function is used for feature guiding with the
CLS CAM 100 object sensor when guiding on a print feature where
the individual recurring features on the material web have a large
distance to each other.
The position of the material web is controlled either by a web
edge or web center-line guiding with one or two edge sensors. At
the same time, a CLS CAM 100 object sensor in the offset control
mode detects the position of the recurring print feature on the
web across the web running direction. If the object sensor detects
a deviation between the current position (actual position) and the
specified target position of the print feature, the setpoint value
for the web edge or web center-line guiding is automatically
adjusted according to the detected position deviation. In this way,
the position of the material web is controlled so that the print
feature is held in its specified setpoint position.

5.13.2.2 Requirements
The following requirements must be fulfilled for operating the
overlaid web edge/web center-line guiding with the CLS CAM 100
object sensor:
■ Firmware version of the controller ≥ 2.3.2
■ Firmware version of the ekr commander control panel ≥ 1.8.1
■ A CLS CAM 100 object sensor is connected to the controller.
■ The offset control mode is set on the CLS CAM 100 object
sensor. For setting the control mode, see installation and oper-
ating manual Object sensor CLS CAM 100, document number
MD.577.
■ One or two edge sensors for web edge or web center-line guid-
ing are connected to the controller.
■ The edge sensors are arranged at the same height or behind
the object sensor in the web running direction.

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5.13.2.3 Before Switching On

Before switching on the overlaid web edge/web center-line guiding,
the following preparation measures must be carried out:
► Carry out separate commissioning for the feature guiding with
the CLS CAM 100 object sensor and the web edge/web center-
line guiding with the edge sensors.
► Carry out the material setup for the edge sensors.
► Carry out the setup for the CLS CAM 100 object sensor (see
separate installation and operating manual Object sensor
CLS CAM 100, document number MD.577).
► Optimize the controller gain for the web edge/web center-line
guiding and the feature guiding with the CLS CAM 100 object
sensor.

5.13.2.4 Switching On the Overlaid Web Edge/Web Center-Line Guiding

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

›› The web edge guiding or web center-line guiding is selected as

guiding mode.
1. Position the CLS CAM 100 object sensor on the print feature.
2. Press the Sensor 3 key on the controller.
The LED of the key illuminates.
The feature guiding is activated.
3. Press the Automatic key on the controller.
The LED of the key illuminates.
The controller switches to automatic mode.
4. Move the web to the desired guiding setpoint (by moving the
CLS CAM 100 object sensor mechanically across the web running
direction).
5. Position the edge sensors so that the web edges are located in
the centre of the sensor scanning areas.
The current position of the web edge in the sensor scanning area
is shown in the display of the controller under the respective
sensor symbol.

6. Press the Sensor 3 key on the controller and keep it pressed.

The LED of the key illuminates.

7. When using the web edge guiding mode, press the key of the
edge sensor used (Sensor 1 or Sensor 2).

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When using the web center-line guiding mode, press the

Sensor 1 and Sensor 2 keys at the same time.
8. First release the Sensor 3 key and then the keys of the edge
sensors used (with web edge guiding key Sensor 1 or Sensor 2,
with web center-line guiding keys Sensor 1 and Sensor 2).
Caution! Observe the order in all cases!
The LEDs of the edge sensors used illuminate.
ð The overlaid web edge/web center-line guiding is switched on.

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5.13.3 Speed-Dependent Guiding

In automatic operating mode, the speed-dependent guiding
ensures for an optimum guiding behaviour even at low machine
speeds.
If the speed-dependent guiding is activated, a tachometer symbol
appears in the operating display of the actuator. The control of
the actuator is limited automatically below an adjustable speed
range. This prevents overloading of the controller and oscillation
of the guiding device.

Vel. Start % 0..99

Limitation of actuator control [%] 100

20

5,000 10,000 Vel. mV max speed

Speed signal [mV]

Fig. 40: Characteristic curve of the control limitation (example)

① Characteristic curve for Vel. mV max speed = 10,000

② Characteristic curve for Vel. mV max speed = 5,000
With the following parameters of the public parameter list (Para-
meter list 0), you can adapt the speed-dependent guiding to your
individual application.
Function Parameter Parameter value Description
Activating the speed-dependent 0 (OFF) Function deactivated
vel. gain
guiding 1 (ON) Function activated
Analogue input 0 … 10 V
0
Selecting the source of the speed (terminal 56 and 57)
vel. gain by var
signal Take over a value from an
1
internal variable
Determining the starting value of the
Vel. Start % 0..99 0 … 99 % Factory setting: 20%
actuator control limitation
Determining the speed signal at
Vel. mV max speed 0 … 10,000 mV Factory setting: 10,000 mV
maximum machine speed
To select the public parameter list (Parameter list 0), see Extended
Device Settings, page 140.

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5.13.4 Master-Slave Guiding

5.13.4.1 Function
The Master-Slave guiding is used when two material webs have to
be guided together precisely to the edge (laminating control). In
doing so, the positions of both material webs are detected by two
edge sensors or two CCD cameras.

Slave web

Guiding
device

Sensor 2

Master web

Distance
web edges

Sensor 1

Fig. 41: Functional principle Master-Slave guiding (with edge sensors)

Sensor 1 detects the position of the unguided Master web (guide

web) and sensor 2 the position of the guided Slave web (following
web). If the Master web moves laterally to the web running
direction during production, the control simultaneously guides the
Slave web by the respective adjusting movement of the guiding
device. In this way, the control keeps the distance (offset) of both
web edges constant or ensures that both web edges are positioned
precisely over one another (distance of the web edges = 0).

5.13.4.2 Requirements
The following requirements must be fulfilled for operating the
Master-Slave guiding:
■ Two edge sensors or CCD cameras are connected to the controller.
■ Sensor 1 detects the position of the Master web.
■ Sensor 2 detects the position of the Slave web.
■ A guiding device (e.g. rotating frame guide) guides the Slave web.

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5.13.4.3 Guiding Modes

The Master-Slave guiding permits the following guiding modes.
Master-Slave guiding
with edge sensors with CCD cameras
Guiding Guiding Guiding Web center-line guiding
to the left web edge to the left web edge to the right web edge

Slave Slave Slave Slave

Master Master Master Master

5.13.4.4 Before Switching On

Before switching the Master-Slave guiding on for the first time,
you have to carry out the following preparatory measures:
1. Perform the material setup for Sensor 1 and Sensor 2.
2. Activate the Master-Slave guiding (DIL switch S6.6 = ON).
For adjusting the DIL switch see installation and commissioning
manual ekr 500 digital Unit Touch, document number MD.497.

5.13.4.5 Switching On the Master-Slave Guiding

WARNING
Danger of death from actuator movements!
Parts of your body could be crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

1. Select the desired guiding mode (see Guiding Modes, page

87).

2. Activate Automatic operating mode.

3. Set the Slave web guiding setpoint as follows:
Move sensor 2 across the web running direction or adjust the
guiding setpoint using the arrow keys.

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5.13.4.6 Operation Display

If the Master-Slave guiding is active, the text MASTER appears in
the sensor symbol for sensor 1. It indicates that sensor 1 detects
the position of the Master web.
The text SLAVE appears in the sensor symbol for sensor 2. It indicates
that sensor 2 detects the position of the Slave web. The operating
display for sensor 2 is displayed mirrored.

Operation display with edge sensors

Fig. 42: Operation display Master-Slave guiding with edge sensors

① Text MASTER
② Operation display Sensor 2 (mirrored)
③ Text SLAVE

Operation display with CCD cameras

Fig. 43: Operation display Master-Slave guiding with CCD cameras

① Text MASTER
② Text SLAVE

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5.13.5 Tear-Off Detection

5.13.5.1 Use
The Tear-Off Detection is used for the web edge guiding with CCD
camera if, during operation of the web guiding system, material
defects (tear-off) are to be expected on the web edges to be
scanned. The function detects both tears into the material web
(inward tear) as well as projecting material (outward tear).

Inward
tear
CCD camera

Outward
tear

Fig. 44: Tear-off detection with CCD camera

5.13.5.2 Function
With tear-off detection activated, in automatic mode the sensor
value of the CCD camera is read-in at a pre-set time interval
(scanning cycle). If a tear on the web edge occurs in the measuring
range of the CCD camera, the sensor value read in jumps
suddenly. If the change of the sensor value exceeds from one
scanning cycle to the next by a determined minimum value, the
change is detected as tear-off and the web guiding system is
blocked automatically for the pre-selected blocking time. It is
possible to deactivate the tear-off detection after the detection of
a tear-off for a pre-selected period (blocking hold time).

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 5 Operation

Material web Tear Tear Tear Tear

Tear

Sensor signal
Minimum
change of the
sensor value

Tear-off detection

Start End Start End

of tear of tear of tear of tear
detected detected detected detected

Actuator
correction signal

Blocking time Blocking time

Tear-off detection Tear-off detection
deactivation deactivation

Fig. 45: Function principle of the tear-off detection

With the following parameters of the public parameter list (para-

meter list 0), you can activate the tear-off detection and adapt the
function to your individual application.
Function Parameter Parameter Description
value
0 (OFF) Function deactivated
Activate tear-off detection tear off active
1 (ON) Function activated
Min. change of the sensor value per
depending on
scanning cycle so that a tear-off is tear off value digits Factory setting: 0 pixel
the sensor
detected
Scanning cycle
(time interval for reading in the tear off probe time ms ≥ 5 ms Factory setting: 5 ms
sensor values)
Blocking time
tear off lock ms Factory settings: 0 ms
(blocking period)
Blocking hold time
(time from detecting the end of a tear off inhibit ms Factory settings: 0 ms
tear until a new tear can be detected)
To select the public parameter list (parameter list 0) see Extended
Device Settings, page 140.

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5.13.6 Oscillation

5.13.6.1 Function
The oscillation enables the controlled transverse displacement of
the web of material with an adjustable amplitude (size of the dis-
placement) and frequency (speed of the displacement). It is used
for rewinding of tubular films or for materials with an irregular
thickness profile in order to avoid poor winding. You can choose
from a triangular ( ) or sinus ( ) oscillation curve.

5.13.6.2 Defining the Basic Settings

Using the Oscillation setting menu you set the basic oscillation
settings (oscillation form and range of values for the oscillation
frequency).

Fig. 46: Setting menu for the oscillation

Meaning of the buttons

Basic Setting Button Meaning

Triangular curve

Oscillation form

Sinus curve

Range of values
Range of values 0.1 … 50.0 [1/min]
for the oscillation
frequency Range of values
1 … 500 [1/min]

Speed-dependent See Switching On the Speed-

oscillation Dependent Oscillation, page 98.

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Making basic settings

1. Activate the Oscillation setting menu in the setup menu (see
Calling up the Setup Menu, page 120).

The setting menu for the oscillation is displayed.

2. Select the desired oscillation form and the desired range of val-
ues for the oscillation frequency by tapping the corresponding
button.
The selected buttons are displayed with a blue background.

3. Confirm the settings by pressing the button.

The setting menu is closed.
The setup menu is displayed.

5.13.6.3 Adjusting the Oscillation Amplitude

Using the Oscillation Amplitude setting menu you set the amp-
litude of the oscillation (size of the transverse web displacement)
and switch the oscillation on or off.

Fig. 47: Setting menu for the oscillation amplitude

Adjustment range
The adjustment range for the oscillation amplitude depends on
the guiding mode selected and on the sensor used.
Guiding mode Sensor Adjustment range
IR 2011 0 … 19.2 mm * (± 9.6 mm)
Web edge guiding/
IR 2012 0 … 12 mm * (± 6 mm)
web center-line guiding
US 2010 0 … 9.6 mm * (± 4.8 mm)
Line/contrast guiding CLS Pro 600 0 … 12.5 mm (± 6.25 mm)
* The specified maximum values for the oscillation amplitude
apply for a sensor coverage of 50% and guiding setpoint = 0. In the
case of a smaller or larger sensor coverage the oscillation
amplitude will automatically be restricted, to ensure that the web
edge does not leave the sensor scanning area during oscillation.

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Sensor coverage = 50% Sensor coverage ≠ 50%

maximum automatic
oscillation restriction of the
amplitude oscillation amplitude

Oscillation
(triangular
wave)

Material web

Material web
Sensor
scanning
area

Center Center
sensor scanning area sensor scanning area

Fig. 48: Automatic restriction of the oscillation amplitude

Oscillation in the Center position operating mode

In the Center position operating mode of the controller, the oscil-
lation is achieved by the actuator carrying out cyclic actuating
movements in both directions originating from its central position
(depending on the amplitude and frequency set).

In order to prevent the actuator from reaching its end

position during the oscillation, the amplitude of the
oscillation must be smaller than the maximum available
actuating path of the actuator.

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Adjusting the oscillation amplitude

WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

›› The Oscillation Amplitude setting menu is activated in the

setup menu for the configurable displays and setting menus
(see Switching the Configurable Displays and Setting Menus
On/Off, page 123).
›› The display shows the operation display.
1. Call up the Oscillation Amplitude setting menu using the
swiping function (see Switching the Configurable Displays and
Setting Menus On/Off, page 123).
The set oscillation amplitude is shown in the display as a numeric
value and using a ruler display with slider.
2. Set the desired amplitude by entering the corresponding
numeric value (see Entering the numerical values via the input
keyboard, page 33) or using the slide bar (see Editing the
numerical values via the slide bar, page 34).
When the oscillation is switched on, the new setting will have
an immediate effect on the function.
3. Switch the oscillation on or off by tapping the adjacent button.
When the oscillation is switched on, the button is displayed
with a blue background.

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5.13.6.4 Adjusting the Oscillation Frequency

Using the Oscillation Frequency setting menu you set the fre-
quency of the oscillation (speed of the transverse web displace-
ment) and switch the oscillation on or off.

Fig. 49: Setting menu for the oscillation frequency

Adjustment range
1 … 500 [1/min] *
* The maximum possible oscillation frequency is restricted by
■ the maximum actuating speed of the actuator used
■ the actuating path of the actuator used
■ the set amplitude of the oscillation

Adjusting the oscillation frequency

WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

›› The Oscillation Frequency setting menu is activated and the

setup menu for the configurable displays and setting menus
(see Switching the Configurable Displays and Setting Menus
On/Off, page 123).
›› The display shows the operation display.
1. Call up the Oscillation Frequency setting menu using the
swiping function.
The set oscillation frequency is shown in the display as a
numeric value and using a ruler display with slider.

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2. Set the desired frequency by entering the corresponding

numeric value (see Entering the numerical values via the input
keyboard, page 33) or using the slide bar (see Editing the
numerical values via the slide bar, page 34).
When the oscillation is switched on, the new setting will have
an immediate effect on the function.
3. Switch the oscillation on or off by tapping the adjacent button.
When the oscillation is switched on, the button is displayed
with a blue background.

5.13.6.5 Link Between Oscillation Amplitude and Guiding Setpoint

If the oscillation is switched on, the symbol ① ( ) appears
above the sensor symbol for the display of the guiding setpoint in
the operation display. It indicates that the current position of the
web edge differs from the adjusted guiding setpoint (+2.5 in the
example) due to the lateral displacement (oscillation).
For determining the current edge position an offset value must be
added to the adjusted guiding setpoint.

Oscillation amplitude
Guiding setpoint

Fig. 50: Connection between oscillation amplitude and guiding setpoint

The example illustrated shows the deviation between the current

web edge position and the adjusted guiding setpoint. At the
moment T of the oscillation, the web edge is in position +5.0
although the display continues to show the value +2.5 for the
guiding setpoint.
If the operating mode is changed from Automatic to Manual
mode during the oscillation, the current web position is detected
by the edge sensors and is saved in the controller. After reactiva-
tion of the Automatic mode, the oscillation continues from the
edge position where it was stopped before.

The oscillation can be initialized by switching to the

Center Positioning operating mode. The symbol ①
disappears and the oscillation will be restarted at the
adjusted guiding setpoint (+2.5 in the example).

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5.13.7 Speed-Dependent Oscillation

5.13.7.1 Function
In this special type of oscillation the oscillation frequency is auto-
matically adjusted to the web speed. This means that the oscilla-
tion frequency rises with the increasing web speed. This ensures
that the ratio between oscillation frequency and web feed rate
remains constant.

5.13.7.2 Requirements
The following requirements must be fulfilled for operating the
speed-dependent oscillation:
■ A tacho generator that supplies a speed-dependent analogue
signal (0 … 10 V) is connected to the terminals 56 and 57 of the
controller.

5.13.7.3 Selecting the Speed Signal Source

With the following parameters of the public parameter list 2, you
can adapt the speed-dependent oscillation to your individual
application.
Function Parameter Parameter value Description
Analogue input 0 … 10 V
0
Selecting the source of the (terminal 56 and 57)
osc sp. source 0=analog
speed signal Take over a value from an
1
internal variable
Determining the speed signal
osc. mV at 100% speed 0 … 10,000 mV Factory setting: 10,000 mV
at maximum machine speed
To select the public parameter list 2 see Extended Device Settings,
page 140.

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5.13.7.4 Switching On the Speed-Dependent Oscillation

Switching on the speed-dependent oscillation and determining
the starting threshold is carried out in the setting menu for the
oscillation.

Fig. 51: Oscillation setting menu

① Switching on the speed-dependent oscillation

② Determining the starting threshold
With the percentage value in the editing field ② you determine
the speed signal level (starting threshold) where the oscillation is
started. If the speed signal level is less than the preset percentage,
there is no oscillation. This prevents the oscillation from being
carried out even at low machine speeds. When using a tacho
generator that supplies a speed signal even if the machine is
stopped (web speed = 0) for technical reasons (in case of an offset
error for example), the starting threshold can be used to prevent
the oscillation from being started even when the production
machine is at standstill. The starting threshold is entered as a
percentage of the signal level at maximum machine speed.
Example
Speed signal at maximum machine speed 10,000 mV
Set starting threshold > 2%
Speed signal that the oscillation is started > 10,000 mV x 0.02
from = 200 mV

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Determining the starting threshold and switching the speed-

dependent oscillation on

WARNING
Danger of death from actuator movements!
When the oscillation is switched on, the actuator automatically
carries out actuating movements. Parts of your body could be
crushed, cut or hit.
► Make sure that no persons remain in the vicinity of the pivot /
traversing area of machine components that are positioned by
the actuator.

1. Activate the Oscillation setting menu in the setup menu (see

Calling up the Setup Menu, page 120).

The setting menu for the oscillation is displayed.

2. Enter the desired percentage value for the starting threshold in

the editing field (>2% in the example).

3. Switch on the speed-dependent oscillation by tapping on the

adjacent button.
If switched on, the button is displayed with a blue background.

4. Confirm the setting by pressing the button.

The setting menu is closed.
The setup menu is displayed.

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5.13.8 Web Width Measurement

5.13.8.1 Function
The web width measurement with edge sensors or CCD camera(s)
enables a continuous monitoring of the web width during the pro-
duction process.
The function calculates the width of the web of material from the
positions of the two material edges detected by the edge sensors
or CCD cameras of the web guiding system. The material width
calculated is shown in the display of the control panel. If the web
width measured is less or more than the warning or error limit
preset by the operator, it is displayed. The controller provides
digital message outputs for the warning and error limits.
For the web width measurement with edge sensors, two sensors
are used for detecting both material edges regardless of the
material width. For the web width measurement with CCD
camera(s), one or two CCD cameras are used depending on the
maximum material width.

5.13.8.2 Displaying the Web Width

You can show the web width measured in the display of the
ekr commander control panel.

Fig. 52: Display of the web width

›› Two edge sensors or one or two CCD cameras are connected to

the controller.
›› The material web is drawn in and the web edges are located in
the measuring range of the edge sensors or CCD camera(s).
›› The width measurement has been calibrated (see Calibrating
the Web Width Measurement, page 107).
›› The display of the web width is activated in the setup menu for
the configurable displays and setting menus (see Switching the
Configurable Displays and Setting Menus On/Off, page 123).
›› The display shows the operation display.

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► Call up the display of the web width using the swiping function
(see Configurable Displays and Setting Menus, page 52).
The width of the material web determined by the web width
measurement is shown in the display (500.5 mm in the example).

The display of the control panel shows five different states.

Display Screen Meaning

No warning or error limit is activated.

The material width is within the tolerance range.

The material width has fallen below the specified warning limit
or has exceeded the specified warning limit.
An orange signal field appears in the lower left corner of the
display. The signal field shows the deviation of the material width
measured with regard to the specified target width (+1.5 mm in
the example).

The material width has fallen below the specified error limit or
has exceeded the specified error limit.
An red signal field appears in the lower left corner of the display.
The signal field shows the deviation of the material width
measured with regard to the specified target width (+3.2 mm in
the example).
The material width could not be determined.
Three dashes are displayed.
Possible causes:
■ The web width measurement was not calibrated.
■ At least one web edge has not been detected as the material
is located outside the measuring range of the sensor or the
material completely covers the sensor measuring range.
For specifying the warning and error limits see Specifying the
Warning and Error Limits, page 102.

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5.13.8.3 Specifying the Warning and Error Limits

You can specify user-defined warning and error limits for the
width measurement using a special setting menu. If the material
width measured falls below or exceeds the specified limits, this is
shown in the display by a coloured signal field (see Displaying the
Web Width, page 100).

Definition of the warning and error limits

The following illustration shows the definition of the warning and
error limits and the resulting tolerance (grey), warning (orange)
and error (red) ranges.

Web of material

upper lower upper

error limit error limit error limit
upper lower upper
warning limit warning limit warning limit
Material target width

Fig. 53: Definition of the warning and error limits

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The width measurement signals five states:

The web of material is much too small.
The width measured is within the lower error range (24 V⎓ at output 3, terminal 28).

Web of material

Material width

The web of material is too small.

The width measured is within the lower warning range (24 V⎓ at output 2, terminal 27).

Web of material

Material width

The material width is correct.

The width measured is within the tolerance range.

Web of material

Material width

The web of material is too wide.

The width measured is within the upper warning range (24 V⎓ at output 2, terminal 27).

The web of material is much too wide.

The width measured is within the upper error range (24 V⎓ at output 3, terminal 28).

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 5 Operation

Example for the specification of the warning and error limits

Material target width = 500 mm

Fig. 54: Example for the specification of the warning and error limits

The following table shows the values for the target width and the
warning and error limits set in the example.
Lower error limit Lower warning limit Target width Upper warning limit Upper error limit

The following tolerance, warning and error limits result from the
values specified in the example:
Lower error range Lower warning range Tolerance Upper warning range Upper error range
(red) (orange) range (orange) (red)
(grey)
< 486 mm 486 … 496 mm 496 … 504 mm 504 … 512 mm > 512 mm

Specifying and activating the warning and error limits

The warning and error limits for the width measurement are
specified using a special setting menu. For the specified limits to
be effective, they need to be activated.

Fig. 55: Setting menu for the warning and error limits

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1. Call up the setting menu for the warning and error limits of the
width measurement in the setup menu (see Calling up the
Setup Menu, page 120).
The setting menu is displayed.

2. For specifying the warning and error limits tap on the editing
field behind the corresponding Minus or Plus button.
A numeric keypad is displayed.
3. Enter the desired value for the warning or error limit.
4. Confirm your entry with the button.
The keypad is closed.

5. Switch the selected warning or error limit on by tapping on the

corresponding Minus or Plus button.
If switched on, the button is displayed with a blue background.

Digital message outputs

The controller has digital message outputs for the warning und
error limits. If the material width measured falls below or exceeds
the specified limits, this is signaled by a 24 V⎓ signal at the
corresponding digital output.
Requirement: The function table 9 for the digital inputs and out-
puts is selected. For selecting the function table see installation
and commissioning manual ekr 500 digital Unit Touch, document
number MD.497.
Function table 9
Output Terminal Width Measurement Message
Warning: Material width has fallen below or
2 27
has exceeded the warning limit
Error: Material width has fallen below or
3 28
has exceeded the error limit

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5.13.8.4 Specifying the Target Width

Using this function, you specify the target width of the web of
material.
›› At least one warning or error limit is activated. For activating
the warning and error limits see Specifying the Warning and
Error Limits, page 102.
›› The web width is displayed. For activating the web width dis-
play see Displaying the Web Width, page 100).

1. Tap on the adjacent button in the lower right corner of the web
width display.

A numeric keypad is displayed.

2. Enter the desired target width.
3. Confirm your entry with the button.
The keypad is closed.
The new target width (500.0 in the example) is displayed on the
button.

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5.13.8.5 Calibrating the Web Width Measurement

Using this function you calibrate the web width measurement.
For the calibration, introduce a piece of material with a known
width (reference material) into the measuring range of the edge
sensors or CCD camera(s) and determine the material width as
reference width.
1. Introduce the reference material into the measuring range of
the edge sensors or CCD camera(s).
2. Position the edge sensors such that the reference material covers
the measuring range of both sensors up to the halfway point.

Fig. 56: Introducing the reference material with edge sensors

① Center of the sensor measuring range ② Reference

material
③ Reference width

3. Call up the Web Width Measurement Calibration menu in the

setup menu (see Calling up the Setup Menu, page 120).

The adjacent window for the input of the reference width is

displayed.
The currently set reference width is displayed in the editing
field in [mm] or [inch] (in this example 285,0 mm).
4. Enter the width of the reference material into the editing field.

5. Confirm your entry with the button.

The set reference width will be accepted.
The calibration of the web width measurement is finished.
The reference width entered is shown as web width in the dis-
play.

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5.13.9 Line Width Measurement

5.13.9.1 Function
The line width measurement enables a continuous monitoring of
the width of a printed line during the production process. In doing
so, the line is scanned by a BST CLS Pro 600 line and contrast sensor
or a CLS CAM 100 object sensor (from firmware version 1.5.x.x).

5.13.9.2 Displaying the Line Width

You can show the line width measured in the display of the
ekr commander control panel.

Fig. 57: Display of the line width

›› A CLS Pro 600 line and contrast sensor or a CLS CAM 100 object
sensor is connected to the controller.
›› The line and contrast sensor or the object sensor is in line mode.
›› The line to be monitored is within the measuring range of the
line and contrast sensor or the object sensor.
›› The line width measurement has been calibrated (see Calibrat-
ing the Line Width Measurement, page 109).
›› The line and contrast guiding mode (Sensor 3) is selected on
the controller. The LED of the key is illuminated.

›› The width display is activated in the setup menu for the

configurable displays and setting menus (see Switching the
Configurable Displays and Setting Menus On/Off, page 123).
›› The display shows the operation display.
► Call up the width display using the swiping function (see
Configurable Displays and Setting Menus, page 52).
The line width deternined by the width measurement is shown
in the display (2.5 mm in the example).

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5.13.9.3 Specifying the Target Width

The procedure for specifying the target width is described in
chapter Specifying the Target Width, page 106.

5.13.9.4 Specifying the Warning and Error Limits

The procedure for specifying the warning and error limits is
described in chapter Specifying the Warning and Error Limits,
page 102.

5.13.9.5 Calibrating the Line Width Measurement

Using this function you calibrate the line width measurement.
For the calibration, introduce a printed line with a known width
(reference line) into the measuring range of the CLS Pro 600 line
and contrast sensor or the CLS CAM 100 object sensor connected
and determine the line width as reference width.
1. Select the line/contrast guiding mode (Sensor 3).
2. Introduce the printed line into the measuring range of the line
and contrast sensor or the object sensor.
3. Carry out a line setup at the line and contrast sensor or the
object sensor (procedure see separate operating manual
CLS Pro 600 line and contrast sensor, document number
MD.323 or operating manual CLS CAM 100 object sensor,
document number MD.577).
4. Call up the Width Measurement Calibration menu in the setup
menu (see Calling up the Setup Menu, page 120).

The adjacent window for the input of the reference width is

displayed.
The currently set reference width is displayed in the editing
field in [mm] or [inch] (2.5 mm in the example).
5. Enter the width of the reference line into the editing field.

6. Confirm your entry with the button.

The set reference width will be accepted.
The calibration of the line width measurement is finnished.
The reference width entered is shown as line width in the dis-
play.

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5.14 Sensor Positioner

5.14.1 Utilization
The ekr 500 digital Unit Touch controller has a connection for a
motorized FVG POS 100 sensor positioner. The sensor positioner
enables the motorized positioning of the edge sensors connected
(Sensor 1, Sensor 2).

Fig. 58: ekr 500 digital Unit Touch controller with FVG POS 100 sensor positioner

If the installation position of the sensor is hard to access or the

position of the sensor has to be changed frequently due to chan-
ging web widths, the sensor positioner is used to position the
sensor across the web running direction. In Automatic mode, the
sensor slide runs towards the web of material until the sensor has
detected a web edge (automatic edge detection).
For a detailed description of the sensor positioner, see the install-
ation and operating manual FVG POS 100, document number
MD.476.

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5.14.2 Operation Display

The operation displays for the sensor positioner appears only if
the FVG POS 100 sensor positioner is connected to the controller.

Fig. 59: Sensor positioner operation display

Sensor positioner operation display

The white triangle marks the set position of the web edge in
①
the sensor scanning area.
The numeric value indicates the current position of the web
②
edge in the sensor scanning area (unit [mm] or [inch])

The number of the displayed sensor slide symbols (one or

two symbols) depends on the type of the sensor positioner
connected.

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5.14.3 Operation

5.14.3.1 Retract Mode

With the retract mode, you specify at which operating mode
changes the sensor positioner sensor slides should run to their
park position (outer end position). The following retract modes
can be selected:
Retract Mode Sensor Slide Behaviour
Upon switching to the Center positioning
Center positioning operating mode, the sensor slides run to the
park position.
Upon switching to the Manual mode
Manual mode operating mode, the sensor slides run to the
park position.
You can activate one of the two retract modes or both retract
modes.
For activating the retract mode see installation and commissioning
manual ekr 500 digital Unit Touch, document number MD.497.
If the sensor positioner is used in combination with a line and
contrast sensor (Sensor 3), the sensor slides automatically run to
their park position if the guiding mode is switched to line/contrast
guiding. The requirement for the retracting of the sensor slides is,
however, that the line or contrast transition which is being used
for guiding lies within the measuring range of Sensor 3.

5.14.3.2 Automatic Setpoint Acceptance

If the Automatic setpoint acceptance function is activated, after
switching to Automatic operating mode, the sensor positioner
carries out an automatic edge detection. In doing so, the sensor
slides of the sensor positioner run towards the web of material
until the sensors have detected a web edge. The position of the
web edge detected is taken over as the setpoint for guiding.
When using a sensor positioner with two sensor slides, the web
detection behaviour depends on the guiding mode selected.
Controller Keys Guiding Mode Sensor Slide Behaviour
Only the sensor slide with the selected sensor
Guiding to the left or
(Sensor 1 or Sensor 2) carries out the edge detection.
right web edge
The other sensor slide runs to its park position.

Web center-line guiding Both sensor slides carry out the edge detection.

If the guiding mode is changed during Automatic operating mode,

e.g. from the left edge (Sensor 1) to the right edge (Sensor 2), the
controller does not switch to the new guiding mode until the
other sensor has completed the edge detection and the automatic
edge sensor norming (if activated).

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For activating the Automatic setpoint acceptance function see

installation and commissioning manual ekr 500 digital Unit Touch,
document number MD.497.

If the function is activated, in the lower left corner of the operation

display, the button Automaticsetpoint acceptance is displayed.

► To switch the function Automatic setpoint acceptance on / off,

press the adjacent button.
When the function is switched on, the button is displayed with
a blue background.

5.14.3.3 Automatic Edge Sensor Standardization

When processing transparent materials, this standardization
mode is used for the calibration of optical edge sensors (IR 2011,
IR 2012).
During automatic edge sensor standardization, the edge sensors
will be adjusted to the optical properties of the material to be
scanned. For the calibration, the device determines the bright
value (no material in the sensor measuring range) and the dark
value (material in the sensor measuring range).
If the Automatic edge sensor standardization function is activated,
after switching to the Automatic operating mode, the sensor
slides automatically run towards the web edge until the sensor
measuring range is completely covered. The dark value is saved.
Then the sensor slides run back until the web edge is located in
the middle of the sensor measuring range.
For activating the Automatic edge sensor standardization function
see installation and commissioning manual ekr 500 digital Unit
Touch, Document number MD.497.

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5.14.3.4 Pre-Positioning
This function is used to carry out material web pre-positioning to a
position determined by the operator.

WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.

Pre-positioning in Manual operating mode

›› The Automatic setpoint acceptance function is deactivated (see
Automatic Setpoint Acceptance, page 112).
›› The controller is in the Manual operating mode. In this operat-
ing mode the sensor slides of the sensor positioner are in the
park position.
›› The display shows the operation display.
1. Tap on the value ① displayed for the guiding setpoint in the
lower right edge of the operation display.

A numeric keypad is displayed.

2. Enter the desired value for the new guiding setpoint for the
web of material.
3. Confirm your entry with the button.
The keypad is closed.

4. Activate the Automatic operating mode.

The sensor slides carry out the automatic edge detection. They
move to the web edges and then slowly shift the web of material
to the pre-determined position immediately.

Pre-positioning in Automatic operating mode

›› The controller is in the Automatic operating mode. In this oper-
ating mode the sensor slides of the sensor positioner are in the
scanning position (at the web edges).
›› The display shows the operation display.
1. Enter the desired value for the new guiding setpoint for the
web of material as described above.
2. Confirm your entry with the button.
The keypad is closed.
The sensor slides slowly shift the web of material to the pre-
determined position.

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5.15 Positioning Unit

5.15.1 Utilization
The ekr 500 digital Unit Touch controller has connections for two
positioning units. The positioning units enable the motorized
positioning of sensors or tools. The main field of application of the
positioning unit is the motorized positioning of a BST CLS Pro 600
line and contrast sensor (Sensor 3) across the web running
direction in slitter-winders.

Control panel
ekr commander

Control panel
CLS Pro 600

Controller
ekr 500 digital Unit Touch

CAN bus distributor

Positio
ning un
it

Line and contrast sensor

CLS Pro 600

Fig. 60: Motorized positioning of a CLS Pro 600 line and contrast sensor (example)

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 5 Operation

If the installation position of the sensor is hard to access or the

position of the sensor has to be changed frequently due to chan-
ging web widths, the motorized positioning unit is used to position
the sensor across the web running direction. The sensor slide of
the positioning unit is moved to the desired position using the ar-
row keys of the ekr commander control panel of the controller.
There are two speed levels to choose from for the rough and fine
positioning of the sensor.
The following chapters describe exclusively the operation of the
positioning unit for Sensor 3.

5.15.2 Requirements
The following requirements must be fulfilled for operating the
positioning unit for Sensor 3 with the ekr 500 digital Unit Touch
controller:
■ A positioning unit with a BST CLS Pro 600 line and contrast
sensor is connected to the socket X101 (Sensor 3) of the con-
troller.

5.15.3 Operation

5.15.3.1 Calling Up the Operating Menu

The motorized positioning unit is operated with a special menu,
which can be reached from the operation display using the swiping
function.
›› The operating menu for the positioning unit is activated in the
setup menu for the configurable displays and setting menus
(see Switching the Configurable Displays and Setting Menus
On/Off, page 123).
›› The display shows the operation display.
► Call up the operating menu for the positioning unit using the
swiping function (see Configurable Displays and Setting Menus,
page 52).

Fig. 61: Operating menu for the positioning unit

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The appearance of the operating menu depends on the

number of positioning units connected to the controller.
The above illustration and the display screens presented
in the following chapters always show the menu for the
version with one positioning unit.

Function of the buttons and editing fields

Button/Editing Field Function
Switching the sensor positioning with the
arrow keys on/off

Selecting the positioning speed

(slow, fast)

Entering a target position

Warning message when calling up the menu

If the controller has detected no motorized positioning unit, the
adjacent warning symbol is displayed instead of the menu.

5.15.3.2 Selecting the Positioning Speed

Using the adjacent button you adjust the positioning speed. You
can choose from two speed levels. The symbol of the speed level
selected (rabbit or turtle) is displayed with a blue background.
Button Symbol Positioning Speed Utilization

Rabbit fast Rough positioning

Turtle slow Fine positioning

5.15.3.3 Positioning the Sensor Slide

You can select two methods to position the sensor slide:
■ Positioning with the arrow keys of the ekr commander control
panel of the controller
■ Positioning by entering a defined target position

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Positioning the sensor slide with the arrow keys

In this method, you use the arrow keys of the controller’s control
panel to move the sensor slide of the positioning unit to the
desired position.

WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.

›› The operation menu for the positioning unit is displayed. For

calling up the menu see Calling Up the Operating Menu, page
116.

1. Activate the positioning with the arrow keys of the control

panel by tapping the adjacent button.
If activated, the button is displayed with a blue background.
2. Activate the fast speed level for the rough positioning of the
sensor slide.
If activated, the rabbit symbol is displayed with a blue back-
ground.
3. Carry out rough positioning of the sensor slide using the arrow
keys of the control panel.

4. Activate the slow speed level for the fine positioning of the
sensor slide.
If activated, the turtle symbol is displayed with a blue back-
ground.
5. Carry out fine positioning of the sensor slide using the arrow
keys of the control panel.

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Entering the target position

Using this method, you move the sensor slide of the positioning
unit to a defined target position.

WARNING
Risk of crushing from motorized traversing of the sensor slides!
Parts of your body could be crushed, cut or hit.
► Never reach into the traversing area of the sensor slides.
► Before setting up / operating, ensure that no other persons are
in the traversing area of the sensor slides.

Before using this method for the first time, three dashes are dis-
played in the editing field for the target position. They indicate
that the sensor slide is in an undefined position.
›› The operation menu for the positioning unit is displayed. For
calling up the menu see Calling Up the Operating Menu, page
116.

1. Tap on the editing field for the target position.

The sensor slide moves to its outer end position (park position)
and remains there.
The current position value (+5.6 in the example) is displayed in
the editing field for the target position.

2. Tap on the editing field for the target position again.

A numeric keypad is displayed.
3. Enter the desired target position.
4. Confirm your entry with the button.
The keypad is closed.

The sensor slide moves to the defined target position (+200.0

in the example).

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5.16 Calling up the Setup Menu

In the setup menu, activate the different setting functions and
service displays of the controller. The setup menu comprises
several pages.

Fig. 62: Setup menu

In the setup menu only symbols are displayed for setting

functions used for components that are connected to the
controller.

Calling up the setup menu

1. Press the Manual mode key.
The LED of the key illuminates.
The controller switches to manual mode.
2. Press the SETUP key.
The controller changes to setup mode.

The first page of the setup menu appears in the display.

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3. To call up the next page of the setup menu, keep pressing the
right arrow button until the desired menu page is shown in the
display.
4. Tap the symbol of the desired setting function or service dis-
play on the touchscreen.
The setting menu or service display selected appears in the dis-
play.

Setting functions and service displays

For the meaning of the different symbols please refer to the fol-
lowing table.

Symbol Component/Function Setting/Display Function Description

Performing the automatic See Automatic Material

material setup Setup, page 58

Performing the manual See Manual Material

Edge sensor material setup Setup, page 59

Selecting the IR 2011/40 See Selecting the Operating

edge sensor operating Mode for the IR 2011/40
mode Edge Sensor, page 60

Actuator with Setting the stroke limitation See installation and

position feedback and servo-center position commissioning manual*

See installation and

Digital inputs / outputs Selecting a function table
commissioning manual*

Setting See Defining the Basic

Oscillation Defining the basic settings
functions Settings, page 91

See Calibrating the Web

Calibrating the width
Width Measurement, page
measurement
107
Width measurement
Setting the warning and See Specifying the Warning
error limits and Error Limits, page 102

See installation and

Calibrating the CCD camera
commissioning manual*

Carrying out the material See installation and

CCD camera
thickness compensation commissioning manual*

See installation and

Entering the position offsets
commissioning manual*

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 5 Operation

Symbol Component/Function Setting/Display Function Description

Selecting the displays and
Configurable displays See Configurable Displays
setting menus that can be
and setting menus and Setting Menus, page
displayed using the swiping
(swiping function) 52
function

Commissioning the See installation and

Positioning unit
positioning unit for Sensor 3 commissioning manual*

Commissioning the sensor See installation and

Sensor positioner
positioner commissioning manual*

Setting the dimension unit

See installation and
Dimension unit for the display and entry of
commissioning manual*
values (mm or inch)
Showing the installed
Controller, See Displaying System
hardware, firmware and
control panel Information, page 125
boot loader versions

Showing the system See Displaying System

System components
components connected Components, page 126

See Displaying a Link to the

Link to the company Calling up the BST
Service Company Website, page
website homepage
displays 129
Showing service
information and See Displaying Service QR
Service QR code
transmitting it to BST Code, page 130
service
See installation and operat-
C2E Coupler (CAN-To- Showing the network
ing manual C2E Coupler,
Ethernet coupler) settings of the C2E Coupler
document number MD.420
* Installation and commissioning manual ekr 500 digital Unit Touch,
document number MD.497

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5.17 Switching the Configurable Displays and Setting Menus On/Off

The selection of the configurable displays and setting menus that
can be called up using the swiping function (see Configurable
Displays and Setting Menus, page 52) is done in a special setup
menu.

Fig. 63: Setup menu for the configurable displays and setting menus

Symbol Function Description

Displaying the web

See Displaying the Web Width
width

Adjusting the See Adjusting the Oscillation

oscillation amplitude Amplitude, page 92

Adjusting the See Adjusting the Oscillation

oscillation frequency Frequency, page 95

See Adjusting the Guiding

Setting the guiding
Setpoint with the Setting
setpoint
Menu, page 70

Operating the
See Positioning Unit, page 115
positioning unit

Switching on the configurable displays and setting menus

›› The setup menu is open (see Calling up the Setup Menu, page
120).
1. Press the Configurable Displays and Setting Menus button.
The setup menu for the configurable displays and setting
menus is displayed.
2. Select the desired display or setting functions that can be called
up using the swiping function by tapping the corresponding
button.

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 5 Operation

The buttons selected are displayed with a blue background.

3. Press the button to confirm the selection.
ð The setup menu is displayed.
When swiping on the touchscreen the displays and setting menus
selected are displayed one after the other.

5.18 Service Displays

The service displays can be used to show a range of useful
information regarding the components of the web guiding system.
Button Service display Information displayed Description
Hardware, firmware and boot loader
versions of the ekr 500 digital Unit Touch See Displaying System
System information
controller and the ekr commander Information, page 125
control panel

See Displaying System

System components Web guiding components connected
Components, page 126

Positions of the internal switches of the See Displaying Switch

— Switch positions
system components Positions, page 128
See Displaying a Link to
Company website Link to the BST homepage the Company Website,
page 129

See Displaying Service

Service QR code Service information
QR Code, page 130

The different service displays are described in the following

chapters.

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5.18.1 Displaying System Information

This service display shows the hardware, firmware and bootloader
versions installed in the ekr 500 digital Unit Touch controller and
the ekr commander control panel.

Fig. 64: Display of the system information (example)

① ekr 500 digital Unit Touch controller ④ Bootloader version

② ekr commander control panel ⑤ Hardware version
③ Enter button ⑥ Firmware version

If you have a service query for our customer services,

please have the installed hardware and firmware versions
to hand.

Calling up the service display

1. Activate the service display System information in the setup
menu (see Calling up the Setup Menu).
The hardware, firmware and bootloader versions installed for
the controller and control panel are shown in the display.

2. Press the button to quit the service display.

The setup menu is displayed.

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 5 Operation

5.18.2 Displaying System Components

This service display indicates the system components that are
connected to the controller.

Fig. 65: Display of the system components connected (example)

Pos. Meaning
① Symbol of the system component
② Type designation of the system component
For system components, whose type designation is placed in a black frame, you can call up the
③ Switch Position service display by tapping the frame on the touchscreen (see Displaying Switch
Positions, page 128).
④ The internal terminating resistor of the system component is activated.
The above illustration shows the system components of a standard
web guiding system. The following table lists possible other system
components.
Symbol System component Designation Type
Controller ekr500d ekr 500 digital Unit Touch controller
comndr1 ekr commander control panel of the controller
Control panel Additional ekr commander control panel
comndr2
(remote control)
IR2011 Optical sensor IR 2011
IR2012 Optical sensor IR 2012
US2010 Ultrasonic sensor US 2010
Edge sensor 1/2
Infrared wide array edge sensor IR SEN …,
WideAr
Ultrasonic wide array edge sensor US SEN …
FvgPos FVG POS 100 sensor positioner
CCD camera 1/2 ccd 1, ccd 2 CCDPro or CCD CAM 100 CCD camera

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Symbol System component Designation Type

Line/contrast/ cls600 CLS Pro 600 line and contrast sensor

object sensor (Sensor 3) cls100 CLS CAM 100 object sensor
Actuator ems… Electric motor powered actuator EMS…
sc-s OMG 4, OMG 8, CK 37 servo center transducer
Servo center transducer
sc-p Actuator with position feedback
Positioning unit fvgSp 1, fvgSP 2 Positioning unit for Sensor 3
C2E coupler c2e CAN-To-Ethernet coupler
External IO module ext-IO

Calling up the service display

1. Activate the System components service display in the setup
menu (see Calling up the Setup Menu).
A list including all system components connected is displayed.
2. Use the scroll bar on the right side to scroll the list up or down.

3. Press the button at the end of the list to quit the service
display.
The setup menu is displayed.

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5.18.3 Displaying Switch Positions

This service display indicates the settings of the internal switches
of selected system components. As such, you can check the switch
positions without having to open the device housing.

Fig. 66: Display of the switch positions (here for the ekr 500 digital Unit Touch controller)

Calling up the service display

1. Activate the System Components service display in the setup
menu (see Calling up the Setup Menu, page 120).

A list including all system components connected is displayed.

For system components, for which the Switch Positions service
display is available, the type designation is placed in a black
frame (in the example ekr500d).
2. Tap the type designation in the black frame on the touchscreen.
The settings of the internal switches of the selected system
component are displayed.

3. Press the button to quit the service display.

The display changes back to the System Components service
display.

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5.18.4 Displaying a Link to the Company Website

This service display shows a QR code leading you directly to the
BST homepage.

Fig. 67: Service display with link to the company website

You can read the content of the QR code using your Smartphone
or Tablet with camera and a QR code scanner software. You can
find free Apps with QR code scanners on the internet.

Calling up the service display

1. Activate the Link to the Company Website service display in
the setup menu (see Calling up the Setup Menu, page 120).
The QR code is displayed.

2. Press the button to quit the service display.

The setup menu is displayed.

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 5 Operation

5.18.5 Displaying Service QR Code

This function is used to send an e-mail to BST customer services
with a list of all relevant information about your web guiding sys-
tem to simplify troubleshooting for the service personnel. For this
purpose, when the service display is called up the web guiding
controller generates a QR code, which enables access to the col-
lected service information.

Fig. 68: Display of the QR code for access to the service information

The itemized service information includes, for example, informa-

tion about the system topology and communication interfaces,
and about firmware and hardware versions of the web guiding
components. In addition, the current statuses of terminating res-
istors and DIL switches, as well as settings for the guiding para-
meters and the control of relevant components are listed.

Requirements
■ Firmware version of the ekr commander control panel ≥ 1.9.3
■ To access the service information and send it to BST customer
services, you need a smartphone or tablet with a camera, Inter-
net and e-mail access, on which a QR code scanning software is
installed. You can find apps with QR code scanners free of
charge on the Internet.

Display service information

1. Activate the Service QR code service display in the setup menu
(see Calling up the Setup Menu, page 120).

The controller starts to collect all relevant service information

for the available web guiding system. During this process, an
hourglass symbol is displayed.

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A QR code is shown in the display after several seconds.

2. Scan the QR code with the smartphone or tablet.

An e-mail to BST customer services is automatically generated

on the smartphone or tablet.
Preset e-mail address: [email protected]
The generated e-mail contains a list of all relevant service in-
formation.
3. To send the e-mail to BST customer services press the SEND
button in the e-mail program.

4. Press the button on the controller to exit the service display.

The setup menu is displayed.

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 5 Operation

5.19 Fault Displays

If a fault or an extraordinary operating state occurs during opera-
tion of the web guiding system, this is shown by a symbol in the
display. The meaning of the different symbols is described in the
following chapters.
For troubleshooting, see Troubleshooting, page 152.

5.19.1 Limit Switch Active

This display appears only if an actuator with position feedback is
connected to the controller. If the actuator has reached a soft-
ware limit switch, the driving of the actuator is automatically
switched off in the respective direction. The symbol Limit switch
active appears in the display above the operation display of the
actuator.

Fig. 69: Screen display with active software limit switch

After driving the actuator in the opposite direction, the symbol is

automatically deleted.

5.19.2 Actuator Blocked (Motor Overcurrent)

If the actuator is blocked, the warning symbol Actuator blocked
appears in the display.

Fig. 70: Screen display with blocked actuator

After driving the actuator in the opposite direction, the symbol is

automatically deleted.

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5.19.3 Supply Voltage Outside the Permissible Range

If the supply voltage of the controller is outside the permissible
range then the warning symbol Supply voltage appears in the dis-
play.

Fig. 71: Screen display with impermissible supply voltage

If the supply voltage lies inside the permissible voltage range

again then the symbol is automatically deleted.

5.19.4 Motor Control Timeout

If the actuator is run uninterrupted in the same direction for more
than 50 seconds during operation of the web guiding system, the
motor output stage is automatically switched off. The warning
symbol Motor control timeout appears in the display.

Fig. 72: Screen display during the motor control timeout

After driving the actuator in the opposite direction, the symbol is

automatically deleted.

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 5 Operation

5.19.5 Controller Interlock Active

When the controller interlock is active, the warning symbol
Controller interlock active appears in the display.

Fig. 73: Screen display with active controller interlock

A controller interlock (e.g. when the machine is stopped) can be

triggered via the digital inputs, by an external switch or a PLC
signal. If the controller interlock is active, the output of the output
stage for the actuator is switched off. The actuator will not
undertake any guiding movements.
Controller interlock Activation
For all operating modes
See terminal strip X10, terminal 1
(Automatic, Manual mode,
and 2*
Center positioning)
Only for operating mode
See truth table*
Automatic
* For activating the controller interlock see installation and com-
missioning manual ekr 500 digital Unit Touch, document number
MD.497.

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5.19.6 Keyboard Interlock Active

When the keyboard interlock is active, the Keyboard interlock
active symbol appears in the display.

Fig. 74: Screen display with active keyboard interlock

With active keyboard interlock all keys of the control panel are
blocked. The keyboard interlock is activated by a 24 V⎓ signal at
terminal 9 (see truth table, installation and commissioning manual
ekr 500 digital Unit Touch, document number MD.497).

5.19.7 Setup Lock Active

With active setup lock, the Setup lock active symbol appears in
the display if the SETUP button is pressed.

Fig. 75: Screen display with active setup lock

With active setup lock, the SETUP button of the control panel is
blocked. The setup lock is activated by a 24 V⎓ signal at terminal
22 (see truth table, installation and commissioning manual ekr
500 digital Unit Touch, document number MD.497).

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 5 Operation

5.19.8 Bus Connection Fault

If a fault occurs in the bus connection between the controller and
the control panel or the EMS 23 actuator then the warning symbol
Bus connection fault appears in the display.

Fig. 76: Screen display with an active fault in the bus connection

5.19.9 Edge Sensor Malfunction

If brief malfunctions occur several times in the communication
between the controller and a digital edge sensor, an explanation
mark appears in the respective sensor symbol.

Fig. 77: Display indicator with the malfunction of a digital edge sensor

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5.19.10 Loss of the Line / Contrast Transition (Sensor CLS Pro 600)
With line / contrast guiding using the CLS Pro 600 line and con-
trast sensor (sensor 3), an explanation mark appears in the display
behind the symbol for sensor 3 in the event of an interruption of
the print or loss of the printed line / contrast transition to be
scanned.

Fig. 78: Screen display with the loss of the line / contrast transition to be scanned

If the line or the contrast transition to be scanned is lost, the

control is blocked until the line / contrast transition is detected by
sensor CLS Pro 600 again.
When the Watchdog function is switched on, if the line or con-
trast transition to be scanned is lost, the controller automatically
switches over to the activated edge sensor (capture sensor).

5.19.11 Loss of the Guiding Criterion (Object Sensor CLS CAM 100)
With line, contrast or feature guiding using the CLS CAM 100 ob-
ject sensor (sensor 3), an explanation mark appears in the display
behind the symbol for sensor 3 in the event of an interruption of
the guiding criterion (line, contrast transition or print feature).

Fig. 79: Screen display with the loss of the guiding criterion to be scanned

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 5 Operation

5.19.12 Loss of the Web Edge (CCD Camera)

If there is no web edge in the camera measuring range with the
web edge or web center-line guiding with a CCD camera, an
exclamation mark appears in the display behind the symbol of the
CCD camera.

Fig. 80: Screen display with loss of the web edge

5.19.13 External Motor Output Stage Fault (Drive Module 160)

This display appears only if an electric motor powered actuator of
type EMS 23 is connected to the controller. If the hardware power
monitoring of the external motor output stage (Drive Module 160)
reports a fault, the warning symbol External motor output stage
fault appears in the display of the controller next to the operation
display of the actuator.

Fig. 81: Screen display with an active fault in the external motor output stage for
the EMS 23 actuator

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 Operation 5

5.20 Electronic Remote Precision Adjustment (Option)

As a result of the machine properties or the requirements of the
production, it may be necessary to correct the position of the web
away from the guiding device. The optional electronic remote
precision adjustment devices EFE 1 (analogue) and EFE 1000
(digital) allow corrections to be made to the web position from
any location on the machine.

5.20.1 EFE 1
With the electronic remote precision adjustment EFE 1, you set
the guiding setpoint of the web in the automatic operating mode.

If the optional electronic remote precision adjustment

EFE 1 is connected to the controller, adjust the guiding
setpoint using only the potentiometer of the EFE 1. The
function of the arrow keys on the control panel of the
controller is then blocked in automatic mode.

Setting the guiding setpoint

1. Press the Automatic key.
The LED of the key illuminates.
The controller switches to automatic mode.

2. Turn the Potentiometer of EFE 1 until the desired guiding set-

point is reached.
ð The current guiding setpoint is shown in the operating dis-
play in the display of the control panel (see Overview, page
35). The value is briefly displayed inverse after changing
each time.

5.20.2 EFE 1000

Using the electronic remote precision adjustment EFE 1000, you
change the position of the guiding device in manual operating
mode.

Changing the position of the guiding device

1. Press the Manual mode key.
The LED of the key illuminates.
The controller switches to manual mode.

2. Using the arrow keys of the EFE 1000, move the guiding device
to the desired position.

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 5 Operation

5.21 Extended Device Settings

You have access to the extended device settings via the public
parameter lists of the controller. You use the different parameters
to adapt the behaviour of the controller to your individual applica-
tion.

5.21.1 Editing the Parameter Value

›› The controller is in the Manual operating mode.
1. Activate the Switch positions service display (see Displaying
Switch Positions, page 128).

Fig. 82: Switch positions service display

2. Press the Sensor 3 key.

The selection menu for the public parameter lists appears in
the display. The currently selected parameter list is displayed in
the editing field.

Fig. 83: Selecting the parameter list

① Parameter list selected

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3. Select the desired parameter list using the arrow buttons on

the right side of the display.

4. Press the > button.

The first parameter of the parameter list selected appears in
the display.

Fig. 84: Edit the parameter value

① Parameter designation ② Parameter index

③ Parameter value ④ Editing field

5. Select the desired parameter using the arrow buttons.

6. Tap the editing field on the touchscreen to change the parameter
value.
An input keypad appears in the display.
7. Enter the desired parameter value.
8. Press the button to confirm the entry.
The input keypad is closed.
The edited parameter value is entered into the editing field.
9. Press the button to save the edited parameter values.
The Switch positions service display is displayed.

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 5 Operation

5.21.2 Public Parameters Lists

5.21.2.1 Parameter List 0

You can activate the special extra functions of the controller using
the parameters of this parameter list.
Function Parameter Description Parameter Note Factory
value setting
Automatic acceptance 0 Acceptance 0
w-setup when activating the (OFF) deactivated (OFF)
man->auto automatic operating 1 Acceptance
mode (ON) activated
0 Acceptance 0
w-setup Manual acceptance in (OFF) deactivated (OFF)
by command manual operating mode 1 Acceptance
Accept the current (ON) activated
edge position as the
guiding setpoint 0 Acceptance 0
w-setup Automatic acceptance (OFF) deactivated (OFF)
by input with digital input signal 1 Acceptance
(ON) activated
0 Acceptance 0
w-setup Automatic acceptance (OFF) deactivated (OFF)
by edge when changing the
change guiding mode 1 Acceptance
(ON) activated
0 Guiding 0
Activate the speed- (OFF) deactivated (OFF)
vel. gain
dependent guiding 1 Guiding
(ON) activated
Analogue input Analogue
vel. gain Source for the speed 0 0 … 10 V⎓ input
Speed-dependent by var signal (terminal 56/57) 0 … 10 V⎓
guiding 1 reserved
0
Vel. Start % Starting value of the
… 20 %
0..99 control limitation
99 %
0
Vel. mV Speed signal at max-
… 10,000 mV
max speed imum machine speed
10,000 mV
0 Reverse polarity 0
OK-relay Reverse the polarity of (OFF) deactivated (OFF)
OK relay
invert the OK relay 1 Reverse polarity
(ON) activated

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Function Parameter Description Parameter Note Factory

value setting
Line monitoring Automatic acceptance 0 0
(with sensor cls ref width of the line width when (OFF) (OFF)
CLS Pro 600 or by var activating the automatic 1
CLS CAM 100) operating mode (ON)
In automatic operating Adjustment of
0 0
Adjustment of the mode: the guiding set-
(OFF) (OFF)
guiding setpoint via setpoints Adjustment of the point deactivated
remote control by Io active guiding setpoint via the Adjustment of
inputs remote control inputs 1
the guiding set-
for the arrow keys (ON)
point activated
0 Offset value 0
setp-offs. (OFF) deactivated (OFF)
Offset value for the cam M12 act. Activate offset value
1 Offset value
guiding setpoint
(ON) activated
(only with CCD
camera) depending
setpoint offs.
Enter offset value on the 0
cam M12
sensor
0 Tear-off detection 0
tear off Activate tear-off (OFF) deactivated (OFF)
active detection 1 Tear-off detection
(ON) activated
Min. change of the
depending
tear off sensor value per
on the 0 pixel
value digits scanning cycle so that a
sensor
tear-off is detected
Tear-off detection
with CCD camera tear off Scanning cycle
probe time (time interval for reading ≥ 5 ms 5 ms
ms in the sensor values)
tear off lock Blocking time
0 ms
ms (blocking period)
Blocking hold time
tear off (time from detecting the
0 ms
inhibit ms end of a tear until a new
tear can be detected)
CANopen userprotocol Selecting the commu- Standard
0
user gateway xxxx nication protocol protocol = 3100
0 Offset value 0
setp-offs. fvg (OFF) deactivated (OFF)
Activate offset value
act. 1 Offset value
Offset value for (ON) activated
sensor positioner
depending
setpoint offs. on the type
Enter offset value 0
fvg of sensor
positioner

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 5 Operation

5.21.2.2 Parameter List 2

You make the basic settings for the width measurement and the
oscillation using the parameters of this parameter list.
Function Parameter Description Parameter Note Factory
value setting
edge pos.tol.
warning µm
edge pos.tol.
error µm
Special line width ref.
Reserved for special applications
operating mode µm
line width
tol.warn µm
line width
tol.error µm
osc-mode 0 Triangular curve 0
Oscillation Oscillation form
0=tri 1=sin 1 Sinus curve
0 Oscillation 0
osc speed dep Activate the speed- (OFF) deactivated (OFF)
active dependent oscillation 1 Oscillation
(ON) activated
osc speed % Starting threshold of
0 … 99 % 2%
low lock the speed signal
Speed- 0
osc mV at Speed signal at maximum
dependent … 10,000 mV
100% speed machine speed
oscillation 10,000 mV
Analogue input Analogue
osc sp. source Source for the speed 0 0 … 10 V= input
0=analog signal (terminal 56/57) 0 … 10 V=
1 reserved
osc-factor Range of values for the 0 0.1 … 50.0 [1/min] 0
0 or 1 oscillation frequency 1 1 … 500 [1/min]
0 Lower warning 0
ref width Activate lower warning (OFF) limit deactivated (OFF)
w.low active limit 1 Lower warning
Web/line width (ON) limit activated
measurement 0 Upper warning 0
ref width Activate upper warning (OFF) limit deactivated (OFF)
w.up active limit 1 Upper warning
(ON) limit activated

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Function Parameter Description Parameter Note Factory

value setting
0 Lower error limit 0
ref width Activate lower error (OFF) deactivated (OFF)
e.low active limit 1 Lower error limit
(ON) activated
0 Upper error limit 0
ref width Activate upper error (OFF) deactivated (OFF)
e.up active limit 1 Upper error limit
(ON) activated
ref width µm Target width — 1,000 µm
ref width
Lower Warning limit — 1,000 µm
warn low µm
ref width
Upper warning limit — 1,000 µm
warn up µm
ref width
Lower error limit — 1,000 µm
err low µm
ref width
Upper error limit — 1,000 µm
err upp µm
Activation of the
0 0
position control
Automatic activation of (OFF) (OFF)
Controller lock pos. deactivated
the position control
interlock contr. active Activation of the
with controller interlock 1
position control
(ON)
activated
0 Setpoint 0 0
Setpoint for sensor3 setp. The value 0 is always (OFF) deactivated (OFF)
sensor 3 zero used as setpoint 1 Setpoint 0
(ON) activated

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 5 Operation

5.21.2.3 Parameter list WebWidthCalib

The parameters in this parameter list are used to determine the
following basic settings for the operation of the controller with
CCD camera:
■ Definition of the bar and hole width of the calibration template
used

Width of hole) Width of bar)

Fig. 85: Hole and bar width of the calibration template

■ Activation of the linearization function for the camera measuring

range (guiding is carried out with linearized customer data)
Function Parameter Description Parameter Note Factory
value setting
10,000 µm
0 Standard calibration
(Standard
width of bar µm Width of the bar … template:
calibration
Bar / hole width 65,000 µm Bar width = 10 mm
template)
of the calibration
template defined 10,000 µm
0 Standard calibration
(Standard
width of hole µm Width of the hole … template:
calibration
65,000 µm Hole width = 10 mm
template)
0 Use of non- 0
Linearization for (OFF) linearized data (OFF)
Use calibr. CCD1
Sensor 1 1 Use of linearized
Activate the (ON) data*
linearisation of
the camera range 0 Use of non- 0
Linearization for (OFF) linearized data (OFF)
Use calibr. CCD2
ensor 2 1 Use of linearized
(ON) data*
* Prerequisite: The CCD camera has been calibrated (see
installation and commissioning manual ekr 500 digital Unit Touch,
document number MD.497).

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 Operation 5

5.22 Restoring Factory Default Settings

When restoring the factory default settings, the values of
all guiding parameters (e.g. controller gain, guiding set-
point, bright / dark values of the sensors, etc.) are over-
written by the factory default settings.

Fig. 86: Rotary switch S1 on the process board

Restoring factory default settings

NOTICE
Damage to the components from working on live parts.
► Before opening the controller, switch off the power supply.

1. Electrically isolate the controller.

2. Open the controller’s housing cover.
3. Set the rotary switch S1 to position 0 on the processor board.
4. Switch on the power supply.
The current values for the different guiding parameters are
overwritten by the factory default settings.
5. Electrically isolate the controller.
6. Set the rotary switch S1 to position 1.
7. Close the controller’s housing cover.
8. Switch on the power supply.

After restoring factory default settings, it is imperative

that the rotary switch S1 be returned to position 1.

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 6 Maintenance and Cleaning

6 Maintenance and Cleaning

Carry out maintenance and cleaning work as described
below. Otherwise, there is a risk of increased wear and
system failure.

Any claims for warranty or compensation for damage shall be-

come null and void, if maintenance or cleaning work is not carried
out or carried out improperly.

6.1 Safety Instructions

DANGER
Danger of death caused by the machine starting up!
Parts of your body could be crushed, cut, drawn in or hit.
► Switch off the machine completely and secure it against it being
switched back on.

DANGER
Danger of death from electric shock!
Life threatening injuries caused by incomplete switching off or
residual current.
► Electrically isolate the controller.
► Secure the power supply against being switched back on.
► Check that the unit is voltage-free.
► Earth the controller.
► Cover or fence off any adjacent parts that are still live.

WARNING
Risk of injury and material damage caused by incorrect mainten-
ance / cleaning!
► Have the maintenance and cleaning carried out only by
qualified personnel that have been instructed by BST service
personnel or authorized personnel.
► Carry out the maintenance and cleaning as described in the
following chapters.
► With particularly intensive stress / soiling, reduce the specified
maintenance intervals.

NOTICE
Damage to the components caused by solvents!
Cleaning agents containing solvents damage the surfaces of the
system components.
► Never use cleaning agents containing solvents, not even with
intensive soiling, unless the respective cleaning agent is
explicitly listed in the instructions.
► Follow the cleaning instructions.

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 Maintenance and Cleaning 6

6.2 Maintenance Table

The following table gives you an overview of the necessary main-
tenance tasks and intervals.
The maintenance intervals specified are reference values. With
particularly intensive stress / soiling, the intervals must be reduced.
Carry out the respective maintenance and cleaning as described in
the following chapters.

Maintenance Interval Maintenance tasks to be carried out

Check the entire system and the rolls for cleanliness and clean if
Weekly
necessary.
Weekly Clean the controller housing.
Weekly Cleaning the control panel housing.
Weekly Clean the housing of the sensors.
As required Clean the actuator housing.
As required Clean the sensor positioner housing.

6.3 Maintenance and Cleaning work

6.3.1 Cleaning the Controller Housing

The controller is maintenance-free

Cleaning the housing

► Clean using a dry, clean and soft cloth.
► Use a commercially available liquid cleaner in event of intensive
soiling.
► Observe protection class IP 54 of the controller.

6.3.2 Cleaning the Control Panel Housing

The control panel is maintenance-free.

Cleaning the housing

► Clean using a dry, clean and soft cloth.
► Use a commercially available liquid cleaner in event of intensive
soiling.
► Observe protection class IP 50 of the control panel.

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 6 Maintenance and Cleaning

6.3.3 Cleaning the Edge Sensor Housing

The edge sensors are maintenance-free.
Cleaning the housing
► Clean using a dry, clean and soft cloth.
► Use a commercially available liquid cleaner in event of intensive
soiling.

Cleaning the measurement window (optical sensors)

► Clean carefully using a dry, clean and soft cloth (e.g. glasses
wipe).
► Use a commercially available liquid cleaner in event of intensive
soiling.
► Perform the material setup after cleaning.

Cleaning the transmitting and receiving capsule (ultrasonic sensors)

► Clean carefully using a dry, clean and soft cloth (e.g. glasses
wipe).
► Use a commercially available liquid cleaner in event of intensive
soiling.
► Perform the material setup after cleaning.

6.3.4 Cleaning the Housing of the CLS Pro 600 Line and Contrast Sensor
See separate operating instructions Line and contrast sensor
CLS Pro 600, document number MD.323.

6.3.5 Cleaning the Housing of the CLS CAM 100 Object Sensor
See separate installation and operating manual Object sensor
CLS CAM 100, document number MD.577.

6.3.6 Cleaning the Housing of the CCD Camera

See the separate instruction manual.
CCD Camera Instruction Manual
(document number)
CCDPro 30000/5000 MD.167
CCD CAM 100 MD.465

6.3.7 Cleaning the Electric Motor Powered Actuator Housing

The electric motor powered actuator is maintenance-free.

Cleaning the housing

The housing of the actuator must be cleaned if soiling can be seen
on the outside.
► Clean using a dry, clean and soft cloth.
► Use a commercially available liquid cleaner in event of intensive
soiling.

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 Maintenance and Cleaning 6

6.3.8 Cleaning the Sensor Positioner Housing

See separate operating instructions FVG POS 100 sensor positioner,
document number MD.476.

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 7 Troubleshooting

7 Troubleshooting
WARNING
Danger to life and assets caused by incorrect rectification of mal-
functions!
► Only allow qualified personnel instructed by BST service staff or
authorized personnel to rectify malfunctions.
► Only rectify malfunctions using the following measures or
follow the instructions of BST customer service.

► Observe all safety instructions in the chapter Maintenance and

cleaning, see Maintenance and Cleaning.
Typical faults with their possible causes and measures for elimina-
tion are specified in the following.
► For further information, please contact BST Customer Services,
address see Customer Services, page 158.

Fault
Possible causes Measures for eliminating the fault

The actuator / the guiding device trembles.

► Optimize the controller gain. See Optimizing the
Controller Gain, page 77.
Guiding system overdrive.
► Perform material setup. See Performing the
Material Setup, page 54.

The actuator / the guiding device reacts too slowly or the guiding operates incorrectly.
► Optimize the controller gain. See Optimizing the
Controller Gain, page 77.
The controller gain has been set too low.
► Perform material setup. See Performing the
Material Setup, page 54.

The actuator / the guiding device does not carry out any guiding movement.
► Check the setting of the DIL switch S4 in the
An incorrect actuator has been selected during controller. See installation and commissioning
commissioning. manual ekr 500 digital Unit Touch, document
number MD.497.
► Optimize the controller gain. See Optimizing the
The controller gain has been set too low.
Controller Gain, page 77.

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 Troubleshooting 7

In operating mode Automatic the actuator / the guiding device moves to an end position and remains
stationary there (with material web threaded in).
A material setup was not run after the material ► Perform material setup. See Performing the
was changed. Material Setup, page 54.
► Reverse the guiding direction of the actuator.
See installation and commissioning manual ekr
The actuator guiding direction is incorrectly set.
500 digital Unit Touch, document number
MD.497.

In operating mode Center positioning the actuator / the guiding device moves to an end position and
remains stationary there.
► Reverse the guiding direction of the actuator.
See installation and commissioning manual
The actuator guiding direction is incorrectly set.
ekr 500 digital Unit Touch, document number
MD.497.
The servo center transducer used (OMG 4, OMG 8, ► Check the installation position of the servo
CK 37) has been installed incorrectly. center transducer.

The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Motor overcurrent is shown in the display.

► Activate the actuator in the opposite direction.

The guiding device has moved into an end position
The warning symbol will be deleted automatic-
or is blocking the electric motor powered actuator.
ally.
The guiding device moves with difficulty. ► Check the ball bearings of the guiding device.
The material setup for the connected sensors has ► Perform material setup. See Performing the
been carried out incorrectly. Material Setup, page 54.

An actuator with position feedback does not carry out any guiding movement.
The symbol Limit switch active is shown in the display.
The actuator has reached a software limit switch.
► Activate the actuator in the opposite direction.
Driving the actuator in the corresponding direction
The symbol is deleted automatically.
is prevented.

The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Controller interlock is shown in the display.

► Deactivate the controller interlock for all

operating modes (bridge terminals 1 and 2).

The controller interlock is active. ► Deactivate the controller interlock for the auto-
matic operating mode. See truth table, installa-
tion and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.

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 7 Troubleshooting

The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Motor control timeout is shown in the display.

The actuator has been activated uninterrupted in ► Activate the actuator in the opposite direction.
the same direction for more than 50 seconds. ► Check the actuator for damage (e.g. broken spindle)
No material web has been threaded in. ► Thread up the material web.
There is no web tension present. ► Check the web tension.

The actuator / the guiding device does not carry out any guiding movement.
The warning symbol Faulty bus connection on the actuator is shown in the display.

Fault in the bus connection between the controller ► Check the cable connection between the
and actuator. controller and actuator (Drive Module 160).

The EMS 23 actuator does not carry out any guiding movement.
The warning symbol External motor output stage fault is shown in the display.

► Check the cable connections between the

controller, external motor output stage
The hardware power monitoring of the external Drive Module 160 and electric motor powered
motor output stage Drive Module 160 has detected actuator EMS 23.
a fault (e.g. overload). ► Read the separate operating instructions of the
external motor output stage Drive Module 160
(document number MD.359).
► Check the external motor output stage
The external motor output stage Drive Module 160 Drive Module 160 and replace it if necessary.
is defective.
► Contact BST customer services.

The actuator / the guiding device has moved to an end position and the motor switch off does not
function. The LEDs of keys or on the control panel and the screen display flash.
As a result of the increased power consumption of
the actuator, the supply voltage (24 V⎓) falls below ► Check the power pack.
the permissible voltage range.

The center position of the guiding device is not approached correctly.

► Check the settings of the DIL switches S4.7 and
When using an actuator with position feedback the
S4.8. See installation and commissioning
servo centre transducer (OMG 4, OMG 8, CK 37) has
manual ekr 500 digital Unit Touch, document
inadvertently been selected during commissioning.
number MD.497.

All the settings for actuator, sensors, servo center transducer, etc. are correct, but the unit does not
control.
The controller gain was inadvertently reduced to
► Set the controller gain. See Optimizing the
the minimum value (0.2). No guiding takes place in
Controller Gain, page 77.
Automatic operating mode.

154/163 ekr 500 digital Unit Touch – Operating Manual

 Troubleshooting 7

A connected edge sensor is not working.

► Check the settings of DIL switch S5. See installa-
During commissioning, the incorrect settings have
tion and commissioning manual ekr 500 digital
been met for the edge sensor connected.
Unit Touch, document number MD.497.

An exclamation mark is shown in the sensor symbol of a digital edge sensor in the display.

► Check the cable connection between the

Malfunctions have occurred several times in the controller and edge sensor.
communication between the controller and a ► To delete the malfunction display switch off the
digital edge sensor. voltage supply of the controller and then switch
it back on.

Web edge guiding with Sensor 1 ( ) or Sensor 2 ( ) cannot be switched on.

► Check the settings of DIL switch S5. See installa-
The respective sensor (Sensor 1 or Sensor 2) was
tion and commissioning manual ekr 500 digital
not activated during commissioning.
Unit Touch, document number MD.497.

The warning symbol Supply voltage is shown in the display.

The supply voltage of the controller is outside the ► Check the power pack.
permissible range. ► Check the mains wiring.

The controller does not react to any operation.

A control panel symbol with a padlock is displayed.

► Deactivate the keyboard interlock (remove the

The keyboard interlock is active.
jumper between terminals 17 and 20).

If the SETUP button is pressed, the SETUP key symbol with a padlock is displayed.

► Deactivate the setup lock. See installation and

The setup lock is active. commissioning manual ekr 500 digital Unit Touch,
document number MD.497.

A shifting of the guiding setpoint of the web using the arrow keys on the control panel is not possible.
► Shift the guiding setpoint using the poten-
The optional electronic remote precision adjust-
tiometer of the electronic remote precision ad-
ment EFE 1 is connected to the controller.
justment EFE 1. See EFE 1, page 139.

ekr 500 digital Unit Touch – Operating Manual 155/163

 7 Troubleshooting

The controller does not react to any operation.

The warning symbol Faulty bus connection is shown in the display.

► Check the cable connection between the

controller and control panel.
Fault in the bus connection between the controller ► Check the correct cable connection on terminal
and control panel. strip X8. See installation and commissioning
manual ekr 500 digital Unit Touch, document
number MD.497.
► Check the setting of rotary switch S1 of the
The device address of the controller or the control controller and the control panel. See installation
panel has not been set correctly. and commissioning manual ekr 500 digital Unit
Touch, document number MD.497.
► Check the setting of the internal terminating
resistor in the controller and in the control
The internal terminating resistor in the controller
panel. See installation and commissioning
and in the control panel is not set correctly.
manual ekr 500 digital Unit Touch, document
number MD.497.

The controller does not respond to any operation.

► Deactivate the remote control (S5.5 = ON). See
A remote control has been connected to the
installation and commissioning manual ekr 500
controller. The keys on the control panel are locked.
digital Unit Touch, document number MD.497.
► Check the setting of rotary switch S1 of the
The device address of the controller or the control controller and the control panel. See installation
panel has not been set correctly. and commissioning manual ekr 500 digital Unit
Touch, document number MD.497.

The controller cannot be switched via the remote control function.

► Check the setting of DIL switch S5.5. See install-
The remote control function is deactivated. ation and commissioning manual ekr 500 digital
Unit Touch, document number MD.497.

Undefined behaviour of the controller.

► The maximum permissible length of the
The length of the connecting cable between the
connecting cable of the control panel must be
controller and the control panel is more than 20 m.
observed.
The controller or the control panel has been
► Maintain a minimum distance of 100 mm to
mounted in the immediate vicinity of high-voltage
high-voltage components or lines.
components or lines.

156/163 ekr 500 digital Unit Touch – Operating Manual

 Troubleshooting 7

During line and contrast scanning using the CLS Pro 600 line and contrast sensor an
exclamation mark is displayed behind the symbol for Sensor 3.

► Check print for missing print.

The printed line / contrast transition to be scanned ► Repeat the setup on sensor CLS Pro 600 (see the
is not detected by the line and contrast sensor. separate operating instructions of the line and
contrast sensor).
► Correct the position of the CLS Pro 600 line and
The printed line / contrast transition to be scanned contrast sensor across the web running direction.
is located outside the scanning area of the ► Read the separate operating instructions of the
CLS Pro 600 line and contrast sensor. CLS Pro 600 line and contrast sensor (document
number MD.323).

During line, contrast or feature scanning using the CLS CAM 100 object sensor an
exclamation mark is permanently displayed behind the symbol for Sensor 3.

► Check print for missing print.

The guiding criterion to be scanned (printed line,
contrast transition or print feature) is not detected ► Repeat the setup on sensor CLS CAM 100 (see
by the object sensor. the separate installation and operating manual
of the object sensor).
► Correct the position of the CLS CAM 100 object
The guiding criterion to be scanned (printed line, sensor across the web running direction.
contrast transition or print feature) is located out-
side the scanning area of the CLS CAM 100 object ► Read the separate installation and operating
sensor. manual of the CLS CAM 100 object sensor
(document number MD.577).
► Increase the web speed.
When scanning a print feature, the web does not
Note: The permanent or long-lasting display of
move or moves very slowly.
the exclamation mark is not an error in this case!

With the web edge or the web center-line guiding with CCD camera, an exclamation
mark is shown in the display behind the symbol of the CCD camera.

► Reconfigure the CCD camera. See separate

The web edge to be scanned is not detected by the instruction manual CCD camera CCDPro
CCD camera. 30000/5000 (document number MD.167) or
CCD CAM 100 (document number MD.465).
► Position of the CCD camera perpendicular to the
web running direction.
The web edge to be scanned is located outside the
► Read the separate instruction manual CCD camera
measuring range of the CCD camera.
CCDPro 30000/5000 (document number MD.167)
or CCD CAM 100 (document number MD.465).

ekr 500 digital Unit Touch – Operating Manual 157/163

 8 Customer Services

8 Customer Services
Do you have any questions about this product? Or for any of the
other products or services of BST?
Then please contact the following address.
In order to be able to reply to your request as soon as possible,
please provide us with the following data (where available):
■ Product name
■ Job number
■ EDP number and software version
■ Serial number and date of manufacture (see name plate)

Customer Services Address

BST GmbH
Service
Remusweg 1
D-33729 Bielefeld
Germany
Tel.: +49 (0) 521 400 70 767
E-Mail: [email protected]
http: www.bst.group

158/163 ekr 500 digital Unit Touch – Operating Manual

 Shutting Down and Disposal 9

9 Shutting Down and Disposal

When shutting down and disposing of the system, the applicable
national laws and guidelines must be observed.
Moreover, the safety concept of the entire system must be ob-
served in which the system is installed. The necessary procedures
must be prepared by the manufacturer of the machine.
To a great extent, the system is made from electric / electronic
components and materials that, depending on the compilation,
can be returned for recycling. Also note the legal regulations as
well as local recycling guidelines for this purpose.
Returning the system to BST GmbH is always possible. About this
and for all other queries, please contact BST Customer Services,
page 158.

ekr 500 digital Unit Touch – Operating Manual 159/163

 Index

Index

A D
Actuator Dark value
Maintenance................................................ 150 Display............................................................ 55
Automatic mode ............................................. 65 Generating ..................................................... 55
Design ............................................................. 19
B Display elements............................................. 25
Disposing of the system................................ 159
Bootloader version
Display.......................................................... 125
Bright value E
Display............................................................ 55 Edge sensor
Generating ..................................................... 55 Malfunction.................................................. 136
BST homepage Edge sensors
Displaying link .............................................. 129 Installation position ....................................... 26
Bus connection fault ..................................... 136 Maintenance................................................ 150
EFE 1000 ....................................................... 139
C EFE 1 ............................................................. 139
ekr commander ........................................ 25, 31
CCD camera
Electricians
Installation position ....................................... 28
Qualification................................................... 14
Loss of the web edge ................................... 138
Maintenance................................................ 150 Electronic remote precision adjustment ...... 139
Center positioning .......................................... 65 Emergency ...................................................... 16
Cleaning ........................................................ 148 Entering a numerical value
Components via the input keyboard ................................... 33
via the slide bar.............................................. 34
Intended use .................................................... 9
Configurable displays...................................... 52 Equipment
Protective....................................................... 17
Switching on/off........................................... 123
Configurable setting menus............................ 52 Error limits
Activating ..................................................... 104
Switching on/off........................................... 123
Definition ..................................................... 102
Contacting BST.............................................. 158 Specifying..................................................... 104
Contrast guiding.............................................. 21 Extended device settings .............................. 140
Loss of the contrast transition to be scanned
External motor output stage fault ................ 138
........................................................ 137, 137
Control elements ............................................ 25
Control panel ............................................ 25, 31 F
Key functions ........................................... 25, 32 Factory default settings
Maintenance................................................ 149 Restoring...................................................... 147
Touchscreen display....................................... 25 Fault
Controller........................................................ 19 Display.......................................................... 132
Maintenance................................................ 149 Feature guiding
with additional control panel......................... 20
Loss of the print feature to be scanned ....... 137
with control panel detached.......................... 19
with control panel fitted ................................ 19 Firewalls.......................................................... 11
Controller gain Firmware version
Adjustment via touchscreen .......................... 78 Display.......................................................... 125
Adjustment with arrow keys.......................... 78 Function .......................................................... 20
Display.............................. 36, 37, 38, 39, 40, 77 FVG POS 100 ................................................... 24
Optimizing...................................................... 77
Controller interlock....................................... 134 G
Customer services......................................... 158
Guiding functions............................................ 21
Guiding mode ................................................. 21

160/163 ekr 500 digital Unit Touch – Operating Manual

 Index

Contrast guiding............................................. 21 M
Guiding to the left web edge ......................... 63
Guiding to the right web edge ....................... 63 Maintenance................................................. 148
Line / contrast / feature guiding .................... 63 Actuator ....................................................... 150
Line guiding.................................................... 21 CCD camera.................................................. 150
Selecting......................................................... 63 Control panel ............................................... 149
Watchdog....................................................... 21 Controller ..................................................... 149
Web center-line guiding........................... 21, 63 Edge sensors ................................................ 150
Web edge guiding .......................................... 21 Line and contrast sensor CLS Pro 600 .......... 150
Guiding setpoint Maintenance interval................................... 149
Accept current position of the web edge as Object sensor CLS CAM 100 ......................... 150
guiding setpoint........................................ 71 Maintenance - Overview .............................. 149
Acceptance mode .......................................... 71 Manual mode.................................................. 64
Display of the parameter set loaded ............. 73 Master-Slave guiding ...................................... 22
Entering an offset value ................................. 75 Function ......................................................... 86
Loading........................................................... 74 Guiding modes ............................................... 87
Saving............................................................. 74 Operation display........................................... 88
Setting............................................................ 66 Preparatory measures ................................... 87
Setting with arrow keys ................................. 69 Requirements................................................. 86
Setting with setting menu.............................. 70 Switching on................................................... 87
Material damage............................................... 9
H Material setup
Activating ....................................................... 57
Hardware version
automatic................................................. 54, 58
Display.......................................................... 125 Cancelling....................................................... 58
Generating bright / dark values ..................... 55
I manual ..................................................... 54, 59
Monitoring functions ...................................... 21
Instructed personnel ...................................... 14
Motor control timeout ................................. 133
IR 2011/40
Operating mode selection ............................. 60 Motor overcurrent........................................ 132

K N
Key functions ............................................ 25, 32 Nameplates..................................................... 29
Keyboard interlock........................................ 135
O
L Object sensor CLS CAM 100
Maintenance................................................ 150
Liability for defects ......................................... 17
Operating company
Limit switch................................................... 132
Duties............................................................. 15
Line / contrast / feature guiding..................... 63 Operating display
Line and contrast sensor CLS Pro 600 Application with CCD cameras....................... 39
Installation position ....................................... 27 Application with CLS CAM 100 object sensor 38
Maintenance................................................ 150 Application with CLS Pro 600 line and contrast
Line guiding..................................................... 21 sensor ....................................................... 37
Loss of the line to be scanned.............. 137, 137 Application with edge sensors ....................... 36
Line width measurement................................ 23 Sensor 1 ................................................... 36, 39
Calibration.................................................... 109 Sensor 2 ................................................... 36, 39
Displaying the line width.............................. 108 Sensor 3 ................................................... 37, 38
Function ....................................................... 108 Symbol meanings........................................... 35
Specifying the target width.......................... 109 Operating manual
Specifying the warning and error limits ....... 109 Distribution ...................................................... 6
Link to the company website Latest version................................................... 8
Displaying..................................................... 129 Storage............................................................. 6
Operating mode
Automatic ...................................................... 65

ekr 500 digital Unit Touch – Operating Manual 161/163

 Index

Center positioning.......................................... 65 Qualified personnel ........................................ 14

Manual mode................................................. 64
Operation display
Actuator ........................... 36, 37, 38, 39, 40, 51 S
Application with sensor positioner ................ 40 Safety instructions .......................................... 12
CCD camera.................................................... 47 Selecting the IR 2011/40 operating mode ...... 60
Edge sensors .................................................. 42 Sensor 1
Line/contrast sensor ...................................... 43 Installation position ....................................... 26
Object sensor ................................................. 45
Sensor 1 ................................................... 40, 42
Sensor 2
Sensor 2 ................................................... 40, 42 Installation position ....................................... 26
Sensor 3 ................................................... 43, 45 Sensor 3
Sensor positioner ......................................... 111 Installation position ....................................... 27
Oscillation Sensor positioner............................................ 24
Adjusting the frequency................................. 95 Automatic edge sensor standardization ...... 113
Function ......................................................... 91 Automatic setpoint acceptance ................... 112
Setting the amplitude .................................... 92 Pre-positioning............................................. 114
Sinus curve ..................................................... 91 Retract mode ............................................... 112
speed-dependent..................................... 22, 97 Utilization..................................................... 110
Switching on/off....................................... 92, 95 Sensors
Triangular curve ............................................. 91 Definition Sensor 1 / Sensor 2 / Sensor 3 ...... 26
Oscillation form Designation .................................................... 26
Selecting......................................................... 91 Service displays............................................. 124
Oscillation frequency Service information
Selecting the range of values ......................... 91 Display.......................................................... 130
Overlaid web edge/web center-line guiding Setpoint
with CLS CAM 100 object sensor ............... 22 Display.......................................... 36, 37, 38, 39
Function ......................................................... 82 Setpoint position
Preparation measures.................................... 83 Display............................................................ 40
Requirements................................................. 82 Setup menu
Calling up ..................................................... 120
Service displays ............................................ 121
P Setting function............................................ 121
Parameter list ............................................... 140 Shutting down the system ............................ 159
Displaying..................................................... 140 Software limit switch .................................... 132
Editing a parameter value............................ 140 Specialists ....................................................... 14
Opening........................................................ 142
Selecting....................................................... 140 Speed-dependent control......................... 22, 85
Parameter list 2 ............................................ 144 Speed-dependent oscillation .................... 22, 97
Requirements................................................. 97
Personnel
Duties............................................................. 16 Supply voltage .............................................. 133
Instructed personnel...................................... 14 Swiping function ............................................. 52
Qualification................................................... 14 Switch positions
Position control............................................... 64 Displaying..................................................... 128
Positioning unit............................................... 24 Switching functions on / off............................ 33
Calling up the operating menu .................... 116 System
Entering the target position......................... 119 Intended use .................................................... 9
Positioning the sensor slide with the arrow keys System components
................................................................ 118 Displaying..................................................... 126
Requirements............................................... 116 System information
Selecting the positioning speed ................... 117 Displaying..................................................... 125
UtilizationFunction....................................... 115
Product - Use .................................................... 9
T
Q Target group ..................................................... 6
Target width
Qualified electricians ...................................... 14 Specifying..................................................... 106

162/163 ekr 500 digital Unit Touch – Operating Manual

 Index

Tear-off detection..................................... 23, 89

Function ......................................................... 89
Use ................................................................. 89
Technical specifications .................................. 30
Touchscreen ................................................... 25
Operation....................................................... 33
Touchscreen display ....................................... 25
Troubleshooting............................................ 152

U
Use
Non-intended................................................. 10

V
Virus Scanners ................................................ 11

W
Warning limits
Activating ..................................................... 104
Definition ..................................................... 102
Specifying..................................................... 104
Warranty terms .............................................. 17
Watchdog ....................................................... 21
Function ................................................... 21, 79
Preparation measures.................................... 80
Requirements................................................. 79
Switching on................................................... 80
Web center-line guiding ........................... 21, 63
Web edge guiding ..................................... 21, 63
Web width
Display.......................................................... 100
Web width measurement............................... 23
Activating the error limits ............................ 104
Activating the warning limits ....................... 104
Calibration.................................................... 107
Digital message outputs............................... 105
Error limits ................................................... 102
Function ....................................................... 100
Specifying the error limits............................ 104
Specifying the warning limits ....................... 104
Warning limits.............................................. 102

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