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BST ekr 500 digital User Manual

BST ekr 500 digital
163 pages
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Web Guiding System
Operating Manual
ekr 500 digital Unit Touch
MD.492.EN.07
Translation of the Original Manual

Table of Contents

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BST ekr 500 digital Specifications

General IconGeneral
BrandBST
Modelekr 500 digital
CategoryControl Unit
LanguageEnglish

Summary

About This Document

What You Need to Know

Essential information for safe and successful operation.

Target Group

Identifies intended users for the manual.

Storage and Distribution

Guidelines for storing and distributing the manual.

Safety Instructions and Symbols

Explains the meanings of safety instructions and symbols used.

Symbols

Defines symbols for essential and easier operation.

Operation Using Keys

Illustrates operations using specific keys on the control panel.

More Detailed Information

Points to additional documents and resources for further information.

About Safety

Intended Use

Specifies the system's intended application for web guiding.

Non-intended Use

Details uses that are not permitted and may cause hazards.

Non-intended Infringement of Guidelines

Lists infringements of operating, maintaining, or installation instructions.

Non-intended Operation

Describes operations considered non-intended or unsafe.

Non-intended Modification of Electronic Data

Prohibits unauthorized modifications to system data or software.

Safety Instructions

Provides essential general safety instructions for system operation.

General Safety Instructions

Covers dangers like explosion, crushing, and electrocution.

Qualification of the Personnel

Defines required qualifications for personnel operating the system.

Duties of Operating Company and Personnel

Outlines responsibilities for safe operation and maintenance.

Duties of the Operating Company

Details the operating company's safety and training responsibilities.

Duties of the Personnel

Specifies duties for individual employees regarding safety.

Conduct in the Event of Danger and Accidents

Provides guidance on actions during emergencies and accidents.

Personal Protective Equipment

Lists personal protective equipment required for certain activities.

Guarantee and Liability

Covers warranty terms and BST's liability.

Disclaimer

Lists conditions under which BST is not liable for damage.

Exceptions to the Disclaimer

Details exceptions where BST may still be liable.

Design and Function

Design

Describes the physical components of the ekr 500 digital Unit Touch.

Controller

Details the controller housing and its connections.

Control Panel

Explains the fitting and detachment of the control panel.

Function

Explains the basic operation of web guiding and position control.

Guiding Modes

Lists the different web guiding modes supported by the controller.

Special Guiding and Monitoring Functions

Introduces special functions for enhanced web guiding.

Watchdog

Prevents web wandering when the primary guiding criterion is lost.

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

Combines edge guiding with feature guiding for specific applications.

Speed Dependent Guiding

Ensures optimal guiding at low machine speeds by limiting actuator control.

Oscillation

Controls transverse displacement for winding and thickness profiles.

Master-Slave Guiding

Guides two material webs precisely together for laminating.

Tear-Off Detection

Detects material defects like tears on web edges and blocks the system.

Web Width Measurement

Monitors web width during production for deviations.

Line Width Measurement

Monitors the width of printed lines during production.

Motorized Sensor Positioning

Describes motorized positioning of sensors for accessibility.

Sensor Positioner

Details the motorized positioning of edge sensors.

Positioning Unit

Enables motorized positioning of sensors or tools.

Control and Display Elements

Identifies control and display elements on the control panel.

Touchscreen Display

Explains the touchscreen interface for selection and input.

Keys

Lists and describes the functions of the control panel keys.

Designation of the Sensors

Assigns sensors (1, 2, 3) and their roles in guiding modes.

Edge Sensors (Sensor 1/2)

Details the installation position and definition of edge sensors.

Line, Contrast and Object Sensor (Sensor 3)

Describes the function and installation of Sensor 3.

CCD Cameras (Sensor 1/2)

Explains CCD camera assignment for guiding modes.

Nameplates

Provides an example of the product nameplate and its fields.

Technical Specifications

Operation

Safety Instructions

Warns about severe injuries and material damage from faulty operation.

ekr commander Control Panel

Introduces the control panel and its elements for operation.

Touchscreen Operation

Details how to use the touchscreen for selections and inputs.

Editing Numerical Values

Describes entering numerical values via keypad or slide bar.

Operation Display

Explains the symbols and values shown on the operation display.

Overview

General explanation of the operation display and its components.

Edge Sensors Operation Display (Sensor 1/2)

Shows the display for edge sensors 1 and 2.

CLS Pro 600 Line and Contrast Sensor Operation Display (Sensor 3)

Details the operation display for the CLS Pro 600 sensor.

CLS CAM 100 Object Sensor Operation Display (Sensor 3)

Explains the operation display for the CLS CAM 100 sensor.

CCD Cameras Operation Display

Shows operation displays for CCD cameras in different configurations.

Actuator Operation Display

Details the operation display for the actuator.

Configurable Displays and Setting Menus

Explains how to configure displays and access setting menus via swiping.

Performing the Material Setup

Guides users through the process of setting up materials.

Overview

Explains the purpose and conditions for material setup.

Activating the Material Setup

Details how to activate automatic or manual material setup.

Automatic Material Setup

Outlines the standard procedure for saving sensor bright/dark values.

Manual Material Setup

Describes manual setup for critical contrast situations.

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

Explains how to select operating modes for the IR 2011/40 sensor.

Selecting the Guiding Mode

Explains how to select guiding modes like edge or center-line.

Selecting the Operating Mode

Describes how to select operational modes like manual or automatic.

Manual Mode

Allows manual adjustment of the guiding device position.

Automatic

Performs automatic web guiding based on selected mode.

Center Positioning

Moves the guiding device to its central position.

Setting the Guiding Setpoint

Explains how to set the desired web edge or feature position.

Adjusting the Guiding Setpoint with the Arrow Keys

Adjusts the setpoint using the control panel's arrow keys.

Adjusting the Guiding Setpoint with the Setting Menu

Adjusts the setpoint via a special setting menu.

Accepting Current Position of a Web Edge as Guiding Setpoint

Uses the current web edge position as the new guiding setpoint.

Saving and Loading the Guiding Setpoint

Allows saving and loading up to four parameter sets for repeat orders.

Entering an Offset Value for the Guiding Setpoint

Enters an offset value for center-line guiding with off-center cameras.

Optimizing the Controller Gain

Adjusts controller gain to prevent oscillations and improve stability.

Adjusting the Controller Gain with the Arrow Keys

Adjusts controller gain using the control panel's arrow keys.

Adjusting the Controller Gain via the Touchscreen

Adjusts controller gain by entering a value via the touchscreen.

Special Guiding and Monitoring Functions

Introduces specialized functions for guiding and monitoring.

Watchdog

Prevents web wandering when the primary guiding criterion is lost.

Speed-Dependent Guiding

Ensures optimal guiding at low machine speeds by limiting actuator control.

Master-Slave Guiding

Guides two material webs precisely together for laminating.

Tear-Off Detection

Detects material defects like tears on web edges and blocks the system.

Oscillation

Controls transverse displacement for winding and thickness profiles.

Web Width Measurement

Monitors web width during production for deviations.

Line Width Measurement

Monitors the width of printed lines during production.

Sensor Positioner

Details the utilization of the motorized sensor positioner.

Operation

Covers retract modes and automatic setpoint acceptance for sensor positioners.

Positioning Unit

Describes the utilization of positioning units for sensors/tools.

Operation

Details operation, speed selection, and positioning methods.

Calling up the Setup Menu

Guides users on how to access the setup menu.

Switching the Configurable Displays and Setting Menus On/Off

Explains how to enable/disable displays and menus via swiping.

Service Displays

Introduces service displays for system information.

Displaying System Information

Shows hardware, firmware, and bootloader versions.

Displaying System Components

Lists system components connected to the controller.

Displaying Service QR Code

Generates a QR code for sending service information to BST.

Fault Displays

Explains symbols indicating faults or extraordinary operating states.

Limit Switch Active

Indicates when a software limit switch is active.

Actuator Blocked (Motor Overcurrent)

Warns when the actuator is blocked due to motor overcurrent.

Supply Voltage Outside the Permissible Range

Alerts if the controller's supply voltage is out of range.

Motor Control Timeout

Indicates motor timeout due to prolonged operation in one direction.

Controller Interlock Active

Shows when the controller interlock is active, stopping actuator movement.

Keyboard Interlock Active

Indicates that all control panel keys are blocked.

Bus Connection Fault

Alerts to faults in the bus connection between components.

Loss of the Line / Contrast Transition (Sensor CLS Pro 600)

Shows loss of guiding criterion for CLS Pro 600 sensor.

Loss of the Guiding Criterion (Object Sensor CLS CAM 100)

Shows loss of guiding criterion for CLS CAM 100 sensor.

Loss of the Web Edge (CCD Camera)

Indicates loss of web edge detection by CCD camera.

External Motor Output Stage Fault (Drive Module 160)

Alerts to faults in the external motor output stage.

Electronic Remote Precision Adjustment (Option)

Describes optional devices for remote web position correction.

EFE 1

Sets guiding setpoint remotely in automatic mode.

EFE 1000

Changes guiding device position remotely in manual mode.

Extended Device Settings

Accesses extended settings via public parameter lists.

Editing the Parameter Value

Guides users on editing parameter values in the lists.

Public Parameters Lists

Details parameters for width measurement and oscillation settings.

Restoring Factory Default Settings

Explains how to restore factory default settings for all parameters.

Maintenance and Cleaning

Safety Instructions

Warns about dangers during maintenance like machine startup or electric shock.

Maintenance Table

Provides an overview of necessary maintenance tasks and intervals.

Maintenance and Cleaning work

Details specific cleaning procedures for system components.

Cleaning the Controller Housing

Instructions for cleaning the controller housing.

Cleaning the Control Panel Housing

Instructions for cleaning the control panel housing.

Cleaning the Edge Sensor Housing

Details cleaning for edge sensor housing and measurement windows.

Cleaning the Housing of the CLS Pro 600 Line and Contrast Sensor

Refers to separate instructions for cleaning CLS Pro 600 sensor.

Cleaning the Housing of the CLS CAM 100 Object Sensor

Refers to separate instructions for cleaning CLS CAM 100 sensor.

Cleaning the Housing of the CCD Camera

Refers to separate instructions for cleaning CCD cameras.

Cleaning the Electric Motor Powered Actuator Housing

Details cleaning for the actuator housing.

Cleaning the Sensor Positioner Housing

Refers to separate instructions for cleaning sensor positioner housing.

Troubleshooting

Actuator Trembles or Overdrives

Addresses issues where the actuator or guiding device trembles.

Slow or Incorrect Actuator/Guiding Device Operation

Troubleshoots slow response or incorrect operation of the actuator.

Actuator/Guiding Device Not Moving

Solves problems where the actuator or guiding device fails to move.

Customer Services

Shutting Down and Disposal

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