BST eltromat Web Guiding System

EKR 1500
with CCD 30000 or
CCD 5000 from hardware version M

Translation of the
Original Operating Manual

BST eltromat International GmbH

Heidsieker Heide 53
33739 Bielefeld, Germany

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

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

Edition: EDV No.:

05.11.1999 MD.066.01.01
 Definition of the symbols in this manual

Attention

Comments of this type have to be taken into consideration to protect the operator
against mechanical risks

Caution

Comments of this type have to be absolutely considered to protect the

operator against electrical risks

press key

key combination; between the keys means that these keys

have to be actuated simultaneously

LED ‘OFF’

LED constantly lighted = activated phase

LED blinking
 0.0

Table of contents

Table of contents

Chapter 1 Despription
1.1 General
1.2 General plan
1.3 Operating elements
1.4 Signification of the keys on the front panel
1.5 Signification of the LED’s on the front panel
1.6 Safety instructions
1.7 Emissions

Chapter 2 Technical Data

2.1 EKR 1500
2.2 CCD 30000 / CCD 5000M
2.3 Viewing ranges / viewing distances CCD camera

Chapter 3 Transport/Storage

Chapter 4 Mounting/Installation
4.1 Location requirements
4.2 Installation
4.3 Mounting plan
4.4 Installation CCD 30000 / CCD 5000M
4.5 Installation of EMC-wiring

Chapter 5 Start-up
5.1 Start-up requirements
5.2 Start-up
5.3 Basic SET UP
5.4 Determine desired sense of rotation for manual operation
5.5 Adjustment of cameras
5.6 Start-up of automatic operation with sensor 1 (and possibly sensor 2)
5.7 Electric powered actuators
5.8 Hydraulic powered actuators
5.9 Special indications Mastersetup
5.10 Reset to manufacturers settings

Chapter 6 Operation
6.1 Amplifier
6.2 Set point scaling when change over the web edge
6.3 Status indications
6.4 Operation with BST eltromat interface

Chapter 7 Remote control

Chapter 8 Trouble shooting

8.1 Indications on the EKR 1500
8.2 Indications on the CCD 30000 / CCD 5000M

Chapter 9 Maintenance
9.1 Amplifier EKR 1500
9.2 Camera CCD 30000 / CCD 5000M
9.3 Hydraulic powered actuator with plunger coil regulator
9.4 Electric motor powered actuator

Chapter 10 De-commissioning

Enclosure: Annex 1 Connecting plan EKR 1500 with cameras CCD 30000 / CCD 5000M
Annex 2 General plan EKR 1500 with 1x CCD 30000 / CCD 5000M
Annex 3 General plan EKR 1500 with 2x CCD 30000 / CCD 5000M

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 1.0

Please follow the instruction of

start-up, maintenance and installation
as descripted in the operating instruction

1. Description

1.1 General
The EKR 1500 system is a microprocessor-controlled amplifier.
With the CCD-cameras 30000 and 5000M this amplifier could be used for:

- web edge guiding (right or left)

- center line guiding

Please contact the producer for any different application.

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

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

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

1.2 General plan

The general plan (annex 2 and 3) indicates the connectable edge sensors and components to the
amplifier.

1.3 Operating elements

 The amplifier includes all necessary operating elements.

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

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

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

 Connection of components via separated terminal compartment.

Advantage: Quick and easy accessibility to the terminal parts.

 Indication of web edge position by two LED arrays

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

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1.4 Signification of the keys on the front panel

11 13 15 17 18 19 4 5
10 12 14 16

2 7

8 20 21 9
key and/or combination of keys function

AUTO (1) = automatic guiding

MAN (2) = manual positioning

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

MAN (2) +  / + (4) = manual shifting

AUTO (1) +  / + (4) = shifting of guiding point to the left *
AUTO (1) + SET UP +  / + = increase of gain

MAN (2) +  / - (5) = manual shifting

AUTO (1) +  / - (5) = shifting of guiding point to the right *
AUTO (1) + SET UP +  / - = decrease of gain

S-C (3) + SET UP +  / + = increase of S-C transducer gain

S-C (3) + SET UP +  / - = decrease of S-C transducer gain

AUTO (1) + SET UP (6) = release of gain with the keys (4) and (5)

MAN bzw. S-C + SET UP = SET UP when changing the material

ENTER (7) = storing of the adjustment and end of SET UP

functions

„SENSOR LEFT“ (8) = guiding to the left web edge

„SENSOR RIGHT“ (9) = guiding to the right web edge

= center-line guiding = „Sensor left“ + „Sensor right“
* The shifting of set point via the arrows keys can be locked by a DIL-switch
(see also chapter 5, point 5.1).

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key and/or combination of keys function

Line/Printed edge (20) = No function when guiding system is operating with

CCD 30000 / 5000M!

Watchdog (21) = No function when guiding system is operating with

CCD 30000 / 5000M!

1.5 Signification of the LED´s on the front panel

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

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

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

 LED-No. 11, 13, 16 and 18 (green) signalize the admissible measuring band of the sensors.

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

 additional indications of the LED's for gain and shifting of the guiding point see point 6.1.3 and
point 6.3.

10 11 12 13 14 15 16 17 18 19

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1.6 Safety instructions

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

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

machine walls,construction etc.

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

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

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

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

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

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

- Don’t remove any safety devices.

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

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

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

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2. Technical Data
2.1 EKR 1500
Line voltage: 115V/230V +10% / -20% 50-60Hz

Power consumption: 80VA

Fuses: 115V 1A T
230V 0,5A T

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

chapter 5.0, point 5.1)
± 24V, max. 1A or
± 24V, max. 0,33A or
± 300mA short circuit proof, dither amplitude adjustable

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

Status signal (“system OK“)

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

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

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

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

tlow > 30ms

Uin Max acc. to IEC 1,2kV / 50µs

analogue inputs (see also chapter 5, point 5.1 and connecting plan
2x 0...+ 5V or 0...+ 10V, individual adjustable
2x ± 9,75V or 0...+ 9,75V, individual adjustable
2x ± 11,75V
1x NAMUR adaption with output ± 11,75V

tacho input for motor powered actuator

Interface: serial interface RS485 for BST eltromat module bus

Protection class: IP 54

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

atmospheric humidity: 0 - 90%, nicht kondensierend

Dimensions: W = 263mm, D = 214mm without screwed connections, H= 115mm

Weight: approx. 3kgs

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2.2 CCD 30000 / CCD 5000M

Line voltage: 15 to 24V (from EKR 1500)

Power consumption: 3W

Measuring range: depending on the lenses (see point 2.3)

Sensor resolution: 5000 pixels

SUB pixel resolution: max. factor 6 for CCD 30000,
CCD 5000 from hardware version M factor 1 in general

Exposure time: min. 0,6ms

max. 30ms (with interface up to 60ms)

Interface: serial internal BST eltromat module bus interface R485

Protection class: IP54

Ambience conditions: temperature: 0 – 45 deg. C

atmospheric humidity: 5 - 90%, non-condensed

Weight: 0,845 kgs

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2.3 Viewing ranges/ viewing distances CCD camera

Scanning of entire web width Scanning of web width

with one camera with one camera per edge

Minimum necessary camera measuring range M:

M=( ABmax + 2 x J ) x 1,1 M= ABmax - ABmin + 2 x J x 1,1

2

ABmax = maximum web width

ABmin = minimum web width
J = incoming error of web to one side

The definition of measuring distance D occurs in dependence on

the necessary measuring range M and the type of camera.

CCD 5000M/ 50, CCD 30000/ 50: CCD 5000M/ 28, CCD 30000/ 28:
 = 35°  = 60°

M D distance M D distance
setting setting
330 515 0,60 m 220 200 0,20 m
470 715 0,80 m 480 400 0,50 m
600 915 1,00 m 720 600 0,60 m
940 1415 1,50 m 960 800 0,80 m
1960 2915 3,00 m 1190 1000 1,00 m
1800 1500 1,50 m

Important: Layout / positioning of the HF fluorescent lamp:

Keep in reserve additional 50 mm luminous range on
both sides of the camera measuring range!

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3. Transport/storage
Depending upon the order, delivery will be carried out:

 completely built-in and connected with the actuator

 as component parts in standard cardboard boxes with cellular lining material

If the unit is not incorporated immediately, it should be stored in a dry room.

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 4.0

4. Mounting / Installation
4.1 Location requirements
The amplifier has to be installed at dry, vibration-free area.

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

atmospheric humidity: 5 - 90%, non condensed

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 4.0

4.2 Installation
Mounting plan see point 4.3

19
1 - Open terminal
compartment
A U T O Pull the two rear
mounting rails upward

150
S E T E UN P T E R

M A N
S E N S S O E R N S
L EO F R T R I G H T

and screw into the

mounting wall

214
S - BC D R A I G R HK T

25
6 264 115
276
10

2 - Push the housing up-

ward so that the moun-
ting rails stay flush
A U T O

again in respect of the

M A NS E N S S O E R N SL
S

EO F
E

R T
T

R
E

I
UN

G H
P T

T
E R
upper edge of the
housing.
S - BC D R A I G R HK T

3 - Apply the third fixing in

the terminal compart-
ment. Complete wiring
A U T O
and close terminal
S E T E UN P T E R
compartment.
M A N
S E N S S O E R N SL EO F R T R I G H T

S - BC D R A I G R H K T

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 4.0

4.3 Mounting plan

262
180

M4 or Ø 5

housing EKR 1500

212 191

131

4.4 Installation CCD 30000 / CCD 5000M

4.4.1 Connectable components

Up to a maximum of three cameras CCD 30000 / CCD 5000M can be connected to one amplifier.
A combination with a CCD 2004 camera and/or an Analog Interface module is possible.

Attention! The use of a CCD 30000 camera and a CCD 5000 camera within the same
system is forbidden.

4.4.2 Installation

Attention! Includes a guiding system more than one CCD 30000 / CCD 5000M, the connecting
plugs of the cameras must be mounted in the same direction.
Connecting plug of camera 1 must point to the outside.
Switch off line voltage before pin up or pull off the connecting plug.

CCD CCD
camera 1 camera 2

Web
scanning direction
transition bright/dark dark/bright

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 4.0

4.5 Installation of EMC-wiring

disk of the cable - shield remove 90mm of

fitting external insulation

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

nut unsrew nut and

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

figure 1 figure 2

insulated cable leads

remove 60mm of shield, galvanised washer

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

vanished shield

Fan the protective shield, so

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

figure 3 figure 4

only for connecting cable CCD 5000

up to hardware version G
and Interbus-S

ferrite core

Refold and twist the shield Housing

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

figure 5 figure 6

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 5.0

5. Start-up

5.1 Start-up requirements

1) Set DIL-switches according to application.

Lageplan EKR 1000 H

EPROM

Prozessor RAM

TRAFO

S1.1
S1.2
S1.3
S T U V W X S1.4
S1.5
JX12 JX13 JX14 S1.6
I S1.7 H1
H J K L M N Z S1.8 H2
Y S2.1 H3
JX8 JX9 S2.2 H4 A
H11 S2.3 H5 B JX11
115V: F1= 1AT F1 S2.4 H6 C
230V: F1= 0,5AT OK 44454647495051525354555657585960616263646566676869707172737475 S2.5 H7 D
O S2.6 H8 E JX10
P 404142 0 6 7 8 9 1011 0 1314151617182021222425262829313233343536373839 S2.7 H10 H9 F
L N R Relais S2.8

Darstellung nicht maßstäblich! LED +5V

S1.1 = Inverse function Automatic'

S1.2 = OFF = electric motor powered actuator

ON = lifting of zero level and Dither for hydraulic units
(from software version E0030401 see schedule 1)

S1.3 = Inverse function S-C

S1.4 = OFF = normal operation

ON = guiding to sensor 3 and 4 with scaling = 1:1 (e. g. Slave)

S1.5 = OFF = EMS1/plunger coil regulator , EMS 1000/1001 power module

ON = EMS5

S1.6 = ON = chase and follow system with CCD 5000 / CCD 30000

S1.7 = OFF = inverse function CCD camera 3

S1.8 = OFF = EKR 1500

S2.1 = see schedule 2

S2.2 = see schedule 2

S2.3 = OFF = reserved

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

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

S2.5 = from software version E0030401 see schedule 1

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

S2.7 and S2.8 = see schedule 3

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 5.0

Schedule 1 Special functions of the DIL switches S1 and S2

from software version E0030401

S1.2 S2.5 function

OFF OFF electric motor powered actuator

 lifting of zero level OFF
 Dither OFF

OFF ON electric motor powered actuator

 lifting of zero level ON
 Dither OFF

ON OFF hydraulic actuator

 lifting of zero level ON
 Dither ON

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

Schedule 2 Special functions of the DIL switches S2.1 and S2.2

from software version E0030501

The DIL switches S2.1 and S2.2 are used to adjust the fundamental gain of the amplifier according
to the application.

S2.1 S2.2 fundamental gain

OFF OFF 0,125 (manufacturer setting CCD 30000, CCD 5000A)
OFF ON 0,25
ON OFF 0,5
ON ON 1 (manufacturer setting CCD 5000M)

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Schedule 3 Signification of LED´s in the terminal box for service indication

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

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

S2.8 OFF S2.8 OFF S2.8 ON S2.8 ON
H1 CCD1 locking from guiding device
remote control centered
H2 CCD2 locking from external release
CCD 1 of keyboard and
remote control
interlock
H3 CCD3 / Analog-Interface locking from
(recognized) CCD2
H4 INTERCON (1/2) locking from
CCD3
H5 INTERBUS-S Module locking from external
command module
INTERBUS,
INTERCON,
I-O Module
H6 I-O Module (1/2) locking from
FVG 1000 module
H7 FVG 1000 Module internal locking within
the EKR
H8 blinker blinker blinker blinker

The blinker indicates a perfect program flow.

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

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2) Lay jumper according application

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

- jumper O-P equipotential bonding carried out

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

Modification / adjustment is only necessary by a different application.

Socket Jumper Function Comment

JX1 O-P equipotential bonding carry out equipotential bonding

P-R PE / 0V non equipotential bonding

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

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

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

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

JX10 D-E motor tacho + tacho ‘OFF’

E-F motor tacho - tacho ‘ON’

JX11 A servo component A motor ± 24V

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

JX12 S-T signal sensor 1 signal input ± 9,75V

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

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

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

JX14 I-Z reserved

Z-Y reserved

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 5.0

3) Set line voltage

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

Lageplan EKR 1000 H

230V
EPROM

F1 = 0,5AT
Prozessor RAM

TRAFO

S1.1
S1.2
S1.3
S T U V W X S1.4
S1.5
JX12 JX13 JX14 S1.6
I S1.7 H1
H J K L M N Z S1.8 H2
Y S2.1 H3
JX8 JX9 S2.2 H4 A
H11 S2.3 H5 B JX11
115V: F1= 1AT F1 S2.4 H6 C
230V: F1= 0,5AT OK 44454647495051525354555657585960616263646566676869707172737475 S2.5 H7 D
O S2.6 H8 E JX10
P 404142 0 6 7 8 9 1011 0 1314151617182021222425262829313233343536373839 S2.7 H10 H9 F
L N R Relais S2.8

115V Darstellung nicht maßstäblich! LED +5V

F1 = 1AT

4) Connection of components according connection plan

Installation of EMC-wiring see point 4.4

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

6) Switch-on line voltage

7) Check of the camera address

After switching on line voltage (usually “power on“ on the amplifier) the LED array of the CCD
camera is displayed as a running array.
About one second after all LEDs are lit, the camera address given by the connection appears for
a short time.

LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1
running LED array after switching
   on the amplifier
About one second after all LEDs are lit, one of the following combinations of indication appears.
camera 1 with camera 2
          existing in the guiding system
          camera 2
camera 1 without camera 2
          existing in the guiding system
          camera 3
 = LED on  = LED off

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 5.0

5.2 Start-up

Attention: During the start-up the actuator will carry-out

positioning movements!
The machine must be protected against danger of
injury according to the relevant rules and regulations!

Start-up must be carried out by qualified personnel!

The system only admits operation with components actually present.

5.3 Basic SET UP

Only necessary after installation or

change of components connected!

1) Clean the lenses

2) Press simultaneously keys ‘PLUS’ and ‘SET UP’

SET UP

The basic initialization is switched on.

If the guiding device with connected servo-center switch is in center position or if no servo-center
switch is connected, the guiding device will be displaced automatically for a short moment in
order to check whether a servo-center switch is connected.

3) Press key ‘ENTER’

ENTER

The basic initialization is finished.

The CCD 30000 / CCD 5000M cameras are preset on edge scanning by nontransparent material in
processing of transmitted light with a HF fluorescent lamp.

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5.4 Determine desired sense of rotation for manual operation

1) Press key ‘MAN’

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

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

Attention: When actuator EMS 6 will be

employed, interchange the
terminals 65 and 66 in
addition.

5.5 Adjustment of cameras (to be carried out only once at the first start-up)
5.5.1 Basic adjustment of camera 1

Alignment of the camera can be carried out in two different ways:

 Aligning the camera by means of the standard indicators on the display of the camera
 Aligning the camera by means of an oscilloscope connected through the BST eltromat
measuring adapter

5.5.1.1 Alignment by means of the standard displays of the camera

1) Remove the guard ring and clean the lenses

SET UP
2) at the amplifier:

Basic initialization is switched on.

The LED array of the CCD 30000 / CCD 5000M is switched to the indication 'Special
indications Mastersetup' and the first parameter selection 'Indication exposure time' is
activated.

LED 10 LED 1
SET UP

Set the diaphragm of the CCD 30000 / CCD 5000M to the value 11.
The indication of the exposure time occurs by means of the LEDs.
The allocation is shown in the schedule on the next page.
For adjustment of additional parameters, if necessary, see chapter 5.9 'Special indications
Mastersetup'.

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LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1 exposure time in ms

 o o o o o o o o  ≤ 0,6 (possibly overexposed)

 o o o o o o o   ≤1

 o o o o o o o  o ≤2

 o o o o o o   o ≤3

 o o o o o o  o o ≤4

 o o o o o   o o ≤5

 o o o o o  o o o ≤6

 o o o o   o o o ≤7

 o o o o  o o o o ≤8

 o o o   o o o o ≤9

 o o o  o o o o o ≤ 10

 o o   o o o o o ≤ 15

 o o  o o o o o o ≤ 20

 o   o o o o o o ≤ 30

 o  o o o o o o o ≤ 40

   o o o o o o o ≤ 50

  o o o o o o o o ≤ 60

o = LED off
 = LED on
 = LED blinker

standard value

values can only be reached if the camera is parameterized via interface

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3) Adjustment of diaphragm

a) The camera has to adjusted on the HF fluorescent lamp and/or on the lightened band, that if
possible a minimum of LEDs will be lighten

b) If the LEDs indicates no reaction, this procedure has to be repeat again with a larger
diaphragm opening.

c) Does only one LED or no LED lighten, lower diaphragm and repeat adjustment of the camera

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4) Adjust camera parallel to the HF fluorescent lamp (fixing of the viewing range)

a) Push in the cover until the exposure

time increases (position at which the
number of LEDs lighted will increase).
Mark this position.

fluorescent lamp

b) Push in the cover until the exposure

time increases (position at which the
number of LEDs lighted will increase).
Mark this position.

fluorescent lamp

fixed
viewing range

c) Is the viewing range found approx. equal yes no

to the physical viewing range M alignment of the camera has to be
according to table, point 2.3 ? camera ok aligned
 continue with point e)  continue with point d)

d) Alignment of the camera

Screw in or screw out

adjusting screw Y

fluorescent lamp

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e) Centering of the scanning position to the longitudinal axis

of the luminous band / fluorescent lamp

Screw in (-) or
screw out (+) the
adjusting screw X Test of the scanning position compared
to the luminous band / fluorescent lamp

position of the
dark/bright transition alignment correction

correct

Push in the cover to such extent

that the bright/dark transition
will be displayed to adjust

to adjust

Fluorescent lamp

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5.5.1.2 Aligning the camera by means of an oscilloscope

1) Connect the BST eltromat measuring adapter to the camera.

Attention: Only connect and remove connecting cables to the CCD camera that are not live.

2) Connect the standard camera cable to the measuring adapter.

3) Connect the oscilloscope to the measuring adapter.

4) Switch on the voltage again.

5) Remove the guard ring and clean the lens.

SETUP
6) On the amplifier
press the 'SETUP' and 'PLUS' keys.
+
The basic set-up is switched on.

The LED array of the CCD 30000 / CCD 5000M is switched to the display ‘special display
master set-up’’ and the first parameter selection of ‘display exposure period‘ is activated.

LED 10 LED 1
SET UP

Adjust the diaphragm of the CCD 30000 / CCD 5000M to the value 11.

The LED’s show the exposure time. You can see the relationship between exposure time and
the appropriate LED display from the table on page 7

7) Align the camera parallel to the fluorescent lamp / to the luminous field (Y-direction).

Adjustment screw (Y-direction)

a) screw it in or b) screw it out

fluorescent lamp /
luminous field

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a) If the camera is properly aligned to the fluorescent

lamp/luminous field, i.e. parallel, the following
brightness profile appears on the oscilloscope.

b) If the camera is not aligned parallel to the fluorescent

lamp / luminous field, there is a limited visual field
with the following brightness profile.

Align the camera to produce a brightness profile as per (a) by screwing in or screwing out the
adjustment screw (Y-direction).

8) Align the camera to the longitudinal axis (X-direction)

screw the adjustment screw

(X-direction) in (+) or out (-)

a tooth appears on the oscilloscope

at the point where the camera
records the object

insert a long small object

such as a screwdriver

luminous field or
fluorescent lamp

It is necessary to correct it depending upon the position of the transition point.

Position of the transition point Alignment Correction

correct no

should be corrected yes (+)

should be corrected yes (-)

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9) Adjusting the exposure time

The exposure time should be adjusted to 2 – 3 ms. Open or close the diaphragm of the camera
lens accordingly. The oscilloscope shows the following image:

exposure time

5.5.1.3 Alignment of the camera to the scanning plane (web) (Z-direction)

1) Press ‘PLUS’ and ‘MINUS’ key simultaneously +

LED 1 to 10 at the camera
are blinking.

2) Cover the optics completely and press the key on the camera.
The blinking of the LED’s will be interrupted for some seconds.
Comment:
You may have to press the key on the camera a second time before the LED’s start blinking
again.

SETUP
3) When the LEDs are blinking again
press key ‘ENTER’ at the EKR.

4) Push in nontransparent material (e.g. paper) into the viewing range of the camera.
The web edge will be displayed at the LED array of the camera.

Attention: Only one edge of material may be within the viewing range of the camera,

In the following manner:

 with camera 1 bright/dark transition
 with camera 2 dark/bright transition seen from the connector plug of the camera

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Example: CCD camera connected as camera 1

(if camera 2 should be aligned, please press key ‘SENSOR RIGHT’ first)

5) Press key ‘AUTO’ prepositioning by displacement

AUTO
(the positioning device of the camera on the guide bar
moves into a limit
position)

reference edge e.g. machine frame

6) Adjust the camera (screw in or
screw out the adjusting screw Z)
so that the positioning device
a
don't move into a limit position

material b
fluorescent lamp distance a = distance b

7) The sensitivity of adjustment can be determined by means of the adjustment of gain

(see point 5.6.2). Select a high gain to reach a high accuracy of adjustment

8) Check adjustment of the camera parallel to the fluorescent lamp (Y-direction).

See point 5.5.1.1 respectively 5.5.1.2.
Press keys “Setup“ (6) and “+“(4) at the amplifier simultaneously.
The basic setup is switched on.

9) If an adjustment is necessary, repeat the operation according to point 5.5.1.3 alternately.

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5.5.1.4 Adjustment of focus (the system stays in basic initialization)

Press key 'SET UP' on the camera until the parameter 'Indication focus value' will be shown
(LED 2 is blinking in addition to LED 10).
Push in a well defined contrast into the measuring range of the camera and adjust the focus to a
minimum

LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1 Number of pixels necessary for
contrast threshold

 O O O O O O O O O No contrast within the viewing range!

 O O O O O O O O  ≤1

 O O O O O O O   ≤2

 O O O O O O O  O ≤3

 O O O O O O   O ≤4

 O O O O O O  O O ≤5

 O O O O O   O O ≤6

 O O O O O  O O O ≤7

 O O O O   O O O ≤8

 O O O O  O O O O ≤9

 O O O   O O O O ≤ 10

 O O O  O O O O O ≤ 11

 O O   O O O O O ≤ 12

 O O  O O O O O O ≤ 13

 O   O O O O O O ≤ 14

 O  O O O O O O O ≤ 15

   O O O O O O O ≤ 16

  O O O O O O O O ≤ 17
 = LED blinking O = LED off  = LED on
Place the guard ring again!

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5.5.1.5 Carry out white balance

Attention! - Clean lenses and lamps

- Old modes will be overruled
- If selected by error this compensation, use key

SET UP
for leaving the compensation without change

1) Remove the material out of the viewing range , that the camera only recognize the HF
fluorescent lamp. If working in the vertical illumination, the visible surface has to be covered by
an even white dull material (e.g. poster board).

2) Press the keys ‘SET UP’ and ‘PLUS’ SET UP

simultaneously. +

3) Press the keys ‘PLUS’ and ‘MINUS’

simultaneously. +

At the camera LED 1 to 10 are blinking.

4) Press key ‘SET UP´ on the camera

for a short moment. L E D 1 0 L E D 1

Three LED blocks appear in the display of the camera at short intervals after one another with
three switched on LED´s. The automatic white balance is following!
Afterwards the LED 1 to 10 are blinking again.

5) Press key ‘ENTER’. ENTER

Basic initialization with camera 1 is finished

5.5.2 Basic inizialisation of camera 2

See point 5.5.1 for the adjustment of camera 2.

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

5.6.1 Check and/or determine guiding direction

1) Press key ‘edge left’ (8).

2) Press key ‘AUTO’.

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

Setting is required only for the first start-up.

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

5.6.2 Adjustment of gain for sensor 1 and sensor 2

Condition: - material web is pulled in

- actuator is not in a stop position

1) Press key ‘AUTO’.

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

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

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

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

ENTER

5) Press key ‘ENTER’. Gain has been stored.

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5.6.3 Start-up of servo-center operation

Press key ‘S-C’. The servo component must move towards the center
and stop there. If the servo component is moving into
the final position, exchange the connections 25 and 26.

Attention: If using an analog servo-center transducer (CK 37, BI 5 G....) preselect their
adjustment of gain.

Procedure:

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

SE T U P
LED indication at EKR 1500 switch over
and indicate the value of gain.

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

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

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

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

ENTER
4) Press key ‘ENTER’.

The adjustment is finished.

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5.7 Electric powered actuators

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

5.7.1 Use of limit switches

Limit switches for limitation of the regulating distance (stroke) can be used only with electric
motor powered actuators.
The motor is switched off when reaching the end of stroke by means of an alarm contact of the limit
switch. The output will be switched off by a software program.
The motor will be switched off without cutout.

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

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

function terminal 71 terminal 73

limit switch 1 1 0
limit switch 2 0 1
thermal protection (output OFF) 1 1

5.7.2 Positions of the DIL switches and jumpers

Actuator EMS 1 and EMS 10 Actuator EMS 5

S1.2 = OFF S1.2 = OFF

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

Actuator EMS 6 POWER-MODUL(EMS 3 und EMS 4)

S1.2 = OFF S1.2 = OFF

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

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5.8 Hydraulic powered actuators

5.8.1 Zero point adjustment

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

Procedure:

1) Switch on electrical-hydraulic guiding unit and EKR 1500.

2) Press key ‘MAN’ at EKR 1500.
3) Press key ‘SET UP’ at EKR 1500.
4) Bring actuating cylinder by means of arrows keys (4) and/or (5) into center position.
5) Remove metal cover of the plunger coil regulator and unlock the knurled wheel arranged in the
upper area.
6) Turn knurled wheel into one direction - at maximum 5 rotations - until the actuating cylinder
starts moving. Record position.
7) Turn knurled wheel into the opposite direction - at maximum 10 rotations - until the actuating
cylinder starts moving into the opposite direction. Record position.
8) Turn knurled wheel into the center of the a/m two positions and lock it.
Close again the cover of the plunger coil regulator.

From software version E00304-01 dither amplitude

and zero point adjustment can be varied.

5.8.2 Adjustment of Dither amplitude

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

Software Software version from E00304-01

version up to S1.2 has to be set to ON
E00303-01
operation mode terminal 71=X terminal 71=0 terminal 71=1 terminal 71=0 terminal 71=1
EKR ... terminal 73=X terminal 73=0 terminal 73=0 terminal 73=1 terminal 73=1
MAN 41Hz 50Hz 50Hz 50Hz 50Hz
without Set up 5mA 5mA 10mA 25mA 50mA
MAN 41Hz 50Hz 50Hz 50Hz 50Hz
with Set up 25mA 25mA 10mA 25mA 50mA
AUTO or 41Hz 50Hz 50Hz 50Hz 50Hz
S-C 25mA 25mA 10mA 25mA 50mA
Aggregate, e.g.: EH-St 9/3 SV 1-10 HR 024

X = not relevant
0 = „low“ Uinlow: min. -30V, max. +4V
1 = „high“ Uinhigh: min. +8V, max. +35V

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5.8.3 Lifting of zero level

Special application of the DIL switches S1.2 and S2.5.
Only significant from software version E00304-01.

S1.2 S2.5
ON OFF lifting of zero level ON
Dither ON
ON ON lifting of zero level OFF
Dither ON

5.8.4 Adjustment of DIL switches and jumper

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

5.9 Special indications Mastersetup

Press SET UP key on the camera for several seconds.
The 'Actual parameter' selection will be indicated by blinking of the
corresponding LED (in addition to the LED 10).

LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1 signification
Signalizes Special indication
 ? ? ? ? ? ? ? ? ? Mastersetup activated

Selection of parameters
Indication exposure time
 O O O O O O O O  (basic adjustment)

 O O O O O O O  O Indication focus value

 O O O O O O  O O Indication actual trigger threshold

O = LED off
 = LED blinking
? = depends on the actual parameter value

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Indication of the actual trigger threshold

The trigger threshold of the first contrast transition will be indicated in general
(gray scale value 0-255).

LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1 Trigger threshold A

 O O O O O O O O  ≤ 25

 O O O O O O O   ≤ 30

 O O O O O O O  O ≤ 35

 O O O O O O   O ≤ 40

 O O O O O O  O O ≤ 45

 O O O O O   O O ≤ 50

 O O O O O  O O O ≤ 60

 O O O O   O O O ≤ 70

 O O O O  O O O O ≤ 80

 O O O   O O O O ≤ 90

 O O O  O O O O O ≤ 100

 O O   O O O O O ≤ 125

 O O  O O O O O O ≤ 150

 O   O O O O O O ≤ 175

 O  O O O O O O O ≤ 200

   O O O O O O O ≤ 255

 = LED blinking O = LED off  = LED on

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 5.0

5.10 Reset to manufacturers settings

Attention: The reset to manufacturers settings may be carried out after start-up and correct
addressing of the cameras (camera 1/2/3).
Any preceding adjustments will be overruled!

configuration edge 1 edge 2 middle between

camera 1 and 2 last bright/dark first dark/bright
(two-camera system) transition transition edge 1 and 2
first bright/dark last dark/bright
one-camera system transition transition edge 1 and 2
first bright/dark
camera 3 insignificant for insignificant for transition and last
camera 3 camera 3 dark/bright transition

Parameters Preset by manufacturer

Interpolation factor 6 with CCD 30000; factor 1 with CCD 5000M
Exposure time MIN limit 0,6ms
Exposure time MAX limit 30ms
Automatic exposure timer activated
Adjustment also when no contrast is within the
viewing range
Trigger thresholds 127
Minimum edge width after trigger threshold 69 pixels
Minimum edge width before trigger threshold 0 pixel
Imaginary center-line guiding activated

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 6.0

6. Operation
The system only admits operation with
the components actually present!

6.1 Amplifier
Function key and control symbols on the front panel

Operating functions = green coloured area

Preset functions = red coloured area

Setting and control functions = blue coloured area

6.1.1 Operating functions

Select the desired operating functions as follows:

Automatic

- Press key ’AUTO’

Manual positioning

- Press key ‘MAN’

Manuel positioning of the actuator

1) Press key ‘MAN’

2) or Adjust positioning with key ‘PLUS’ or

‘MINUS’

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Servo Center S-C

- Press key ‘S-C’

6.1.2 Preset functions

Web edge guiding, left web edge*

Web edge guiding, right web edge*

* in running direction of the material

Web center-line guiding

6.1.3 Setting and control functions

Adjustment of gain

* optimization: during operation see point 5.6.2

* with analog servo-center device see point 5.6.3

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shifting of guiding point

In operation mode 'AUTO' with switched off SET UP a shifting of the guiding point for the
activated sensing mode is possible via arrow keys (4) and (5).

Attention: SET UP must be switched off. After each SET Up the set value will
be deleted automatically.

1) Press key ‘AUTO’

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

‘MINUS’. The indication of shifting occured
or via EKR display.
The actual position of the et point will be
displayed.

set point
center range

set point
limit 1

set point
limit 2

LED ON
LED OFF

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

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

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 6.0

6.2 Set point scaling when change over the web edge
The actual position of web edge or web center-line can be taken over as set point for guiding by
means of scaling the set point before switch on the guiding to edge 1, edge 2 or center-line guiding.
That means, the web will be guided accurate at this position.
So it is possible to switch over from center-line guiding to web edge guiding without displacement of
the web.

Condition: This function is only available with one or two cameras CCD 5000 guiding to edge 1,
edge2 or center-line guiding.
This function can't be activated when camera CCD 5000 is sensor 3. It is only possible
to take over a position within the range F.
Is the position outside of range F, the nearest position possible is taken over.

sensor measuring range

center
40% 40%

F = 80%

sensor measuring range

Attention: This function can not be used with connected EFE 1!

Procedure:

The set point scaling can be carried out for 'guiding to edge 1', 'guiding to edge 2' and 'center line
guiding'. A separate adjustment has to be done for the different guiding modes.
You can continue to change the set point by hand after set point scaling.

1) Press key “MAN“ or “S-C“

or

2) Bring web in the desired position

3) Select the desired sensing mode

or or

4) Press key ‘SET UP’ SET UP

LED of the key is lighting

5) Press key ‘ENTER’

ENTER

Set point scaling will be finished automatically.

LED of the key 'SET UP' extinguishes.

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6.3 Status indications

The following typical indications can appear during normal operation.
Please pay attention that the bright / dark transition indicates the position of the contrast referred to
the measuring range.

LED 10 LED 1
SET UP

scanning direction

LED
10 9 8 7 6 5 4 3 2 1 signification

O O O O O O     bright / dark transition

    O O O O O O dark / bright transition

    O O O O   dark line (web center)

O O O     O O O bright line
(e.g. web center with incident light)

    O      narrow dark line

(narrow web center)

O O       O O wide bright line

(wide web center)

          no contrast; guiding stopped

(interlocked)

O O O O O      No function for the time being

O = LED off
 = LED on
 = LED blinking

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6.4 Operation with BST eltromat interface

Parameters of the camera can set and/or changed via a corresponding BST eltromat interface.
Programming and procedure see manual of the used interface.

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7. Remote control
Truth table for the remote control inputs EKR 1500 (e.g. activation by PLC):

Terminal 31 = +24V non regulated supply

Terminal 38 = GND (0V)
Terminal:

32 33 34 35 36 37 72 70 71 73

Function

Automatic X 1 0 X X 0 X X X X

Manual X 0 0 X X 1 X X X X

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

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

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

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

Guiding to a printed line / edge

without watchdog X X X 0 0 X 1 X X X

Guiding to a printed line / edge

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

Guiding to a printed line / edge

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

Guiding to a printed line / edge

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

X 1 0 X X 1 X X X X

X X 1 X X 1 X X X X

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

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

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

Interface conditions:

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

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

tlow, thigh : min. 30ms

U in Max.: acc. IEC 1.2kV/50µs

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

Web Guiding System EDV No.: MD.066.01.01 Chapter: 7.0

EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99 Page: 1/1
 8.0

8. Trouble shooting
8.1 Indications on the EKR 1500
When an error is detected, the relay „System OK“ falls off. When pressing

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

Error Responsible Remedy

Actuator / guiding device Guiding system overdrive  Optimize gain

‘trembles’  Possibly new ‘basic SET UP’

Actuator too slow Gain was decreased  Optimize gain

and/or guiding operates  Possibly new ‘basic SET UP’
not correctly

 Guiding device has reached  Activate into the opposite direction.

MAN or the end of stroke or is stuck. Error message is cleared
 Limit switch was actuated automatically.
(if present).
or  The guiding device was
activated continuously in one
direction for a long time
(approx. 50 sec).

With power module connected

The working temperature of the  Check servomotor.

servomotor is too high. Error message can be cleared by
Motor was switched off. pressing the key 'ENTER'.

After basic SET UP Faulty ‘Basic SET UP’ was Repeat ‘Basic SET UP’ according
all LED`s are blinking carried. to point 5.3.

The sensor has to be cleaned soon.

SETUP Message of contamination The error message will be switched
off automatically then.
The guiding is further working

LEDs at the EKR 1500 are During set point scaling the web Bring web edge back into the
blinking as follows: edge was recognized outside permissible measuring range.
the valid measuring range (appr. Error message will be cleared
or 80% of the measuring range). automatically.

(Actual position of the web edge

or is not taken over but the next
valid position).

Web Guiding System EDV No.: MD.066.01.01 Chapter: 8.0

EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99 Page: 1/2
 8.0

8.2 Indications on the CCD 30000 / CCD 5000M

Error messages will be indicated by fast blinking of the LEDs.
Error messages can be deleted by pressing the 'SET UP’ key of the CCD camera.

LED 10 LED 1
SET UP

LED
10 9 8 7 6 5 4 3 2 1 message
lighting error during white
O O   O O   O O
balance (without contrast)
lighting error during white
O    O O    O
balance (overexposed)
O O O O O O O O  O EEPROM error

O = LED off  = LED blinking

Error Responsible Remedy

Lighting error during white Maximum exposure time is reached.  Check alignment camera /
balance (without contrast) (black balance was carried out). fluorescent lamp.
 Check fluorescent lamp.
 Check diaphragm.
 Remove protection cap.
 Repeat start-up of the camera.

Lighting error during white Minimum exposure time is reached.  Check fluorescent lamp.
balance (overexposed)  Check diaphragm.
 Repeat start-up of the camera.

EEPROM error EEPROM values are not correct.  Carry out white balance and
Camera is not ready for operation. Setup.
 Carry out parameterization again
if the camera has been
parameterized via interface.

Web Guiding System EDV No.: MD.066.01.01 Chapter: 8.0

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 9.0

9. Maintenance
9.1 Amplifier EKR 1500
The amplifier is maintainance-free.
The cleaning of the keyboard should be carry out with a dry, clean and smooth cloth.
By high contamination, use for cleaning a usual liquid cleaner, benzine or spirit.

The amplifier has to be switched off!

9.2 Camera CCD 30000 / CCD 5000M

For optimum guiding results, the lenses of the CCD cameras have to be kept clean.
Therefore, clean the lenses and the lighting equipment regularly.

9.3 Hydraulic powered actuator with plunger coil regulator

See separate manual.

9.4 Electric motor powered actuator

The electric motor powered actuator is maintenance-free.

Web Guiding System EDV No.: MD.066.01.01 Chapter: 9.0

EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99 Page: 1/1
 10.0

10. De-commissioning
De-commissioning (scrapping) of the guiding system must carry out only together with the complete
unit. The procedure used has to be defined by the OEM.
Regarding the guiding equipment, please bear in mind that mainly electric/electronic components
are involved. The disposal of which is subject to the relevant legal rules and regulations.
A taking back of the equipment by BST eltromat International GmbH is possible.
Please reach the necessary agreements.

Web Guiding System EDV No.: MD.066.01.01 Chapter: 10

EKR 1500 with CCD 30000 / CCD 5000M Date: 05.11.99 Page: 1/1
Annex A1: Connecting plan EKR 1500 with CCD 30000/CCD 5000M

Power supply Actuators Components External keyboard EKR 3000 Commander

Remote electronic precision adjusting Operation with connecting box

EMS1
EMS5
EMS 10
EMS 16 EFE 1

Limit switch 2

Remote control (PLC inputs) acc. to chap. 7

EFE 1000
Stationary operation

EMS6
Limit switch 1
If the functional direction of the EFE 1 External keyboard
remote control (right/left) shall be reversed, EKR 3000
remote the connections at the terminals 20 and 21
Commander
control have to be interchanged.
The signal direction of the tachometer generator has to be adapted
to the direction of rotation of the motor. Therefore switch over the Servo center components
amplifier to mode “MAN“. Press one of the arrow keys. Additional
If the actuator is moving to the end of the guiding device, interchange module bus
the terminals 65 and 66. subscriber’s
station
OMG 4
Sensors

rotation of the motor by interchanging

the terminals 71 and 73 if necessary.
The allocation of the limit switches
can be adapted to the sense of
isolated
isolated
OMG 6
CCD
OMG 7
camera
OMG 8
sensor 3
CK 37
Bi5G
Wiring colours:
EMS 16P rt = red rs = pink
Oscillation
br = brown gr = grey
isolated gn = green bl = blue
CCD ws = white ge = yellow
camera metal plate sw = black
sensor 2
Attention: Both limit switches must be OZ 3
Sensor 2 could be drop off, covered by the metal plate
during normal operation - Not required components will fall away!
sensor 1 could also be
used for web center (limit switches are carried The corresponding terminals stay free!
guiding. out as break contacts). - Shields are pinched in the screwing
isolated
(see installation of EMC-wiring).
limit switches
CCD
camera Connection of BST eltromat module bus with
sensor 1 cable Twisted Pair Unitronic-Bus LD 3x2x0,22.

Plunger Please contact the manufacturer for setting of

coil cross-bonding boxes.
regulator
Modules Setting of DIL switches and position of the
R2 = 2,7 kΩ / 0,3 W jumpers see chapter „Start-up“.

Servo valve SV 1-10

FVG 1000 module
IO module
Interbus-S module
Intercon module
CAN module

R1 = 680 Ω / 0,3 W
MD.066.01.A02 / 19.09.2002
Annex 2 General plan EKR 1500 with 1x CCD 30000 / CCD 5000M

Remote control Interface (see

separate manual)

Commander EKR 1500

Set point shifting
EFE 1

Servo-center component

OMG 4 EFE 1000

CCD 30000 / CCD 5000M
sensor 1

CK 37 Oscillation

BI5G OZ 3

HF fluorescent lamp

Actuators
EMS 1 / EMS 10 / EMS 16

EMS 6

EMS 5

Plunger coil regulator

EH-St 9/3

EMS 1000 power module

~3

MD.066.01.01 / 05.11.99
Annex 3 General plan EKR 1500 with 2x CCD 30000 / CCD 5000M

Interface
Remote control (see separate manual)

Commander EKR 1500

Set point shifting
EFE 1

Servo-center component

OMG 4 EFE 1000

CCD 30000/ CCD 5000M

sensor 1 sensor 2 Oscillation

CK 37

BI5G OZ 3

HF fluorescent lamp

Actuators
EMS 1 / EMS 10 / EMS 16

EMS 6

EMS 5

Plunger coil regulator

EH-St 9/3

EMS 1000 power module

~3

MD.066.01.01 / 05.11.99
Start-up of the Actuator EMS 17 / EMS18
Connected to EKR 1500 / EKR 1000 / CCD Line Guider

1. Requirements for Start-up

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

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

1.1 Set DIL Switches

 S1.2 = OFF
 S1.5 = OFF

1.2. Lay Jumpers

 Socket JX11: Set jumper "A"

 Socket JX10: Set jumper "DE"

2. Setup

2.1 Activate Manual Stroke Setup

 Press key "MAN" and hold it.

SET UP

 Press key "SETUP" in addition.

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

2.2 Determine Sense of Motor Rotation

Stroke setup is active.

or  Press one arrow key.

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

2.3 Setting of Stroke Limitation

Stroke setup is active.

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

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

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

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

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

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

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

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

key "SETUP" gets extinguished.

The settings are not overwritten during basic

setup.

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

Attention! Do not press any arrow key between

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

2. Press key "SETUP" in addition.

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

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

3. Electrical Connection

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

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

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

Date: 23.08.11 Page: 2/2