BST ekr 500 - User Manual

Questions and Answers

C
christina91Sep 23, 2025
What causes an undefined controller process on my BST Controller?
- R
  Reginald KellySep 23, 2025
  If you are experiencing an undefined controller process with your BST Controller, it may be because the connection cable between the controller and control panel is longer than 20 m, or the controller or control panel has been installed close to a component that uses mains power or power lines. Ensure that the cable length does not exceed 20m and maintain a minimum clearance of 100 mm from power components.
A
Adam PayneAug 23, 2025
How to stop BST ekr 500 Controller actuator from trembling?
- E
  Edward TerrellAug 23, 2025
  If the actuator or guiding device of your BST Controller is trembling, it could be due to guiding system overdrive. Try optimizing the gain and carry out a material setup to resolve this.
T
tamifarleyAug 25, 2025
What to do if BST ekr 500 Controller actuator does not move?
- J
  Jeffrey DanielAug 25, 2025
  If the BST Controller's actuator isn't moving, it could be due to a wrong actuator selection during start-up or the gain being set too low. Check the adjustment of DIL switch S4 in the controller and optimize the gain.
S
smithsandyAug 27, 2025
Why is my BST ekr 500 Controller not responding?
- S
  Stacey TaylorAug 27, 2025
  If the BST Controller isn't responding, a remote control might be connected, locking the control panel keys, or the device address of the controller/control panel might be set incorrectly. Deactivate the remote control and check the setting of the rotary switch S1 in the controller and the control panel.
J
Jordan SnyderAug 27, 2025
Why does my BST ekr 500 actuator stay at the end position in automatic mode?
- M
  Maria ThompsonAug 27, 2025
  If, in automatic mode, the BST Controller's actuator moves to an end position and stays there, it might be because a material setup wasn't run after changing the material, or the actuator guiding direction is set up wrongly. Carry out a material setup and reverse the guiding direction of the actuator.
K
Keith TaylorSep 18, 2025
Why does my BST ekr 500 Controller display a symbol and not respond?
- F
  Felicia FerrellSep 18, 2025
  If the BST Controller isn't responding and the display shows a symbol, there may be a fault in the bus connection between the controller and control panel, the device address of the controller or control panel is set incorrectly, or the internal terminating resistor in the controller and/or in the control panel is not switched on. Check the cable connection between the controller and control panel, ensure cable connections are correct at terminal strip X8, check the setting of the rotary switch S1 in the controller and the control panel, and switch on the internal terminating resistor in the controller and in the control panel.
J
joshua66Sep 15, 2025
Why can't I shift the guiding setpoint on my BST Controller?
- N
  Nathan ValenciaSep 15, 2025
  If shifting the guiding setpoint via the arrow keys isn't possible and the message “EFE“ is displayed, the optional electronic remote precision adjustment EFE 1 is connected. Shift the guiding setpoint via the potentiometer on the electronic remote precision adjustment EFE 1.
J
Jacqueline LinSep 16, 2025
Why is my BST Controller flashing and not switching off?
- J
  Joseph SparksSep 16, 2025
  If the BST Controller's actuator has moved to an end position, the motor switch-off isn't working, and the LEDs are flashing, the supply voltage (24V DC) might have dropped due to the actuator’s increased current consumption. Check the power supply.
R
Robert GonzalezSep 6, 2025
Why can't I activate the guiding mode on my BST ekr 500?
- P
  pmccormickSep 6, 2025
  If the guiding mode cannot be activated on your BST Controller, the corresponding sensor (sensor 1 or sensor 2) might not have been activated during start-up. Check the adjustment of DIL switch S5.
L
lisapriceSep 3, 2025
Why is my BST Controller edge sensor not working?
- R
  Robert ReidSep 4, 2025
  If a connected edge sensor isn't working with the BST Controller, it could be due to wrong settings during start-up or connecting two edge sensors with different signal polarity. Check the adjustment of DIL switch S5 and connect edge sensors with the same signal polarity.

Summary

Product Description and Manual Symbols

Symbols and Indicators

Explains warning signs, key usage, and LED status indications for manual comprehension.

General Operating Guidelines

Covers general information and essential adherence to operating instructions for the controller.

System Description and Components

Details the system structure, functional principle, and connectable components of the web guiding system.

Safety and Compliance Information

Lists essential safety regulations, ESD protection, emissions, and RoHS conformity.

Technical Data

Controller Specifications

Details ambient conditions, protection class, power supply, and I/O for the controller unit.

Control Panel Specifications

Outlines ambient conditions, protection class, power, display, and dimensions for the control panel.

Sensor and Actuator Data

Provides technical details for various infrared, ultrasonic sensors, and electric-motor-driven actuators.

Assembly and Installation

Transport and Storage

Instructions for shipping and storing the web guiding system components safely and correctly.

Installation Site Requirements

Guidelines for selecting an appropriate location for mounting the controller and panel.

Controller and Panel Assembly

Steps for mounting the controller and control panel, including dimensions and options.

Wiring and Connection Fitting

Guidelines for fitting cable connections, EMC wiring, and terminal/plug assignments.

Setup and Configuration

Setting DIL Switches

How to configure the controller using DIL switches for various functions and component selections.

Service Indications (LEDs)

Explains the meaning of various service LEDs on the processor board for status monitoring.

Start-up Procedures

Steps for starting up the actuator, checking motor rotation, guiding direction, and material setup.

Gain Adjustment and Set Point

Procedure for optimizing controller gain and setting the web set point for stable guiding.

Operation and Control

Operation Display and Modes

Explains the control panel display, special displays, and operating mode selection.

Material Setup Procedures

Detailed steps for automatic and manual material setup for web edge and center-line guiding.

Remote Control Functions

Enables remote control via external switches or PLC signals, with truth table.

Default Settings and Troubleshooting

Device Address Configuration

How to set device addresses for the controller and control panel using rotary switches.

Terminating Resistor Setup

Instructions for configuring internal terminating resistors for controller and panel.

Common Faults and Solutions

Lists common issues, their possible causes, and solutions with references to other sections.

Maintenance and Decommissioning

General Maintenance Guidelines

Safety precautions and general procedures for maintaining the controller and panel.

Component Specific Maintenance

Maintenance requirements for the controller, control panel, sensors, and actuators.

System Decommissioning

Procedures for scrapping the guiding system in compliance with legal requirements.

Connecting Plan

Processor Board and Power Supply

Diagram of the processor board, terminal strips, and power supply connection.

Sensor Wiring Connections

Wiring diagrams and DIL switch settings for infrared and ultrasonic sensors.

Actuator Wiring Connections

Wiring diagrams and DIL switch settings for various actuators.

Servo-center Transducer Wiring

Wiring and DIL switch settings for servo-center transducers OMG 8 and OMG 4.

Remote Control & EFE Connections

Wiring for remote control, enable controller, relay contact, and EFE options.

BST ekr 500 Specifications

General

Brand	BST
Model	ekr 500
Category	Controller
Language	English

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