BST CLSPro 600 User manual

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 with removable control panel Issued: 07.11.2008

CLS Pro 600 Line and contrast sensor with removable control panel

Operating Manual

BST International GmbH Heidsieker Heide 53 33739 Bielefeld Tel: +49 (0) 5206/999 – 0

Fax: +49 (0) 5206/999 – 999

E-mail: [email protected]

This document may not be copied or accessed by a third party without our specific consent and even then the third party or person to whom the copy is given must not use it improperly in any way whatsoever. BST International GmbH

mailto:[email protected]�

Contents 0

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 with removable control panel Date: 07.11.2008

Table of contents 1. Description 1 1.1 Symbols used in this operating manual 1 1.1.1 Warning signs 1 1.1.2 Using the keys 1 1.1.3 LED operating statuses 1 1.2 General information 2 1.3 Intended use 3 1.4 System description 4 1.4.1 System design 4 1.4.2 Operating principle 5 1.5 Terms used in this manual 7 1.5.1 General information 7 1.5.2 Set position 7 1.5.3 Measuring range 8 1.5.4 Search area 8 1.5.5 Status bar 8 1.5.6 Footnote 8 1.5.7 First edge / second edge 8 1.6 Control panel 9 1.6.1 Graphics display 9 1.6.2 Control panel 9 1.7 Safety information 11 1.8 Laser 12 1.9 Emissions 12 2. Assembly 13 2.1 Installation site requirements 13 2.2 Sensor installation 13 2.2.1 General information 13 2.2.2 Installing the sensor using the holder supplied

in the package 13 2.2.3 Installing the sensor using a holder supplied

by the customer 14 2.2.4 Setting the gap between the sensor and the

sensing roller 15 2.2.5 Turning the control panel 15 2.3 Installing the control panel 17 2.3.1 General information 17 2.3.2 Dismantling the holder 18 2.3.3 Wall mounting 18 2.3.4 Control console installation 21 3. Installation 23 3.1 Fitting the cable connections 23 3.2 Sensor 23 3.2.1 Enclosure socket 23 3.3 Service indicator displays 24 3.3.1 Bus status LEDs 24 3.3.2 Unit status LED 24 3.4 DIL switch settings 25 4. Commissioning 26 4.1 Menus 27 4.1.1 General information 27 4.1.2 Input options 27 4.1.3 Main menu 30

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4.2 Commissioning with a controller … 33 4.2.1 ekrPro Com60 33 4.2.2 ekr 500 Plus 36 4.2.3 EKR 1500 / CCD line guider and CAN - Module bus

coupler 36 4.3 Commissioning as a stand-alone system 37 5. Operation 38 5.1 General information 38 5.2 Operating display 38 5.2.1 Set-up mode display window 38 5.2.2 Scanning mode display window 39 5.2.3 Status bar 40 5.3 Controlling the ekrPro Com60 / ekr 500 Plus controllers remotely 41 5.3.1 Manual mode 41 5.3.2 Automatic 41 5.3.3 Servo-center position 42 5.3.4 Moving the set point position (W-value) 42 5.3.5 Moving the guiding device 42 5.3.6 Adjusting the controller gain. 42 5.4 Operation 43 5.4.1 General information 43 5.4.2 Activating line set-up / edge set-up 43 5.5 Standard operation 43 5.6 Extended operation 48 5.6.1 Change user 48 5.6.2 Job administration 49 5.6.3 Assigning user levels to the parameters 50 5.6.4 Setting up quick menus 51 5.7 Main menu parameter significances 52 5.7.1 Configuration 52 5.7.2 Parameter 60 5.7.3 Remote control ekr 66 5.7.4 Display 67 5.7.5 System Info 68 6. Factory default settings 69 6.1 Device addresses 69 6.1.1 Sensor device address 69 6.1.2 Control panel device address 70 6.2 Terminator resistors 71 6.2.1 Sensor terminator resistors 71 6.2.2 Control panel terminator resistors 72 6.3 Resetting factory default settings 73 7. Troubleshooting / FAQ 74 8. Technical data 75 8.1 Sensor 75 8.1.1 Environmental conditions 75 8.1.2 Power supply 75 8.1.3 Digital inputs 75 8.1.4 Digital outputs 75 8.1.5 Analog output 75 8.1.6 Measuring window cover 75 8.1.7 Control panel interface 76 8.1.8 Weight, dimensions 76

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8.2 Control panel 76 8.2.1 Environmental conditions 76 8.2.2 Power supply 76 8.2.3 Display 76 8.2.4 Weight, dimensions 76 8.2.5 Space requirement 77 8.2.6 Plug pin assignments 79 9. Maintenance 81 9.1 General information 81 9.2 Sensor 81 9.3 Control panel 81 10. Transport / Storage 82 10.1 Transportation 82 10.2 Storage 82 11. Decommissioning 83 I Index A1 Appendix 1; Commissioning example A1 A2 Appendix 2; Saving the parameters and loading the firmware A2 A3 Appendix 3; Factory default settings A3 A4 Appendix 4; BST signal terminal box 1 connections A4 A5 Appendix 5; Teach-in model A5

Description 1 12

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Chapter: 1 with removable control panel Date: 07.11.2008 Page: 1/86

1. Description 1.1 Symbols used in this

operating manual

1.1.1 Warning signs Symbols are used in this operating manual in order to clearly indicate particularly important places.

Warning! You must obey this type of warning, in order to protect yourself, as the operator, from bodily injuries arising from mechanical movements. Beware! You must obey by this type of warning without fail, in order to protect yourself, as the operator, from life threatening injuries caused by electrical voltages. Information This symbol is used to point out additional useful tips, which will help you to make optimum use of all of the functions.

1.1.2 Using the keys Using the keys is represented by the following symbols in this manual:

Press key.

1.1.3 LED operating statuses Some of the keys on the control panel have LEDs (Light Emitting Diodes) built into them. The different LED operating states are represented as follows:

LED off LED constantly lit = activated phase LED flashing

!

Description 1 12


1.2 General information

The start-up, maintenance and installation instructions described in this operating manual must be strictly adhered to!

• You are only permitted to install and commission the CLS Pro 600 line and contrast sensor after you have read the accompanying operating manual. This will help to avoid hazards and prevent the sensors from being damage due to improper installation or operation.

• Everyone working on or with the CLS Pro 600 sensor must abide by this operating manual and the safety instructions in particular.

• You must read, without fail, the safety instructions given in Chapter 1.7 of this operating manual prior to starting the installation and commissioning work!

• Solely BST staff or other persons specifically authorized by BST are permitted to modify or add to the firmware of this sensor. Ignoring this warning might result in the warranty rights being invalidated.

• The settings and details shown in this operating manual (e.g. in the display screens) are given as examples only, unless the text explicitly states otherwise.

• The latest version of the operating manual for the CLS Pro 600 line and contrast sensor can be obtained via the Internet in all available languages under the following address:

http://www.bst-international.com

!

Description 1 12


1.3 Intended use The CLS Pro 600 is a microprocessor controlled line and contrast sensor with a removable control panel. It must only be used for:

• Guiding on continuous or interrupted printed lines

• Guiding over continuous or interrupted printed edges

• Web edges The CLS Pro 600 line and contrast sensor has been designed to be fitted in another machine or to be combined with other machines to form a complete machine in the sense of the Directive 98/37/EC (machine directive). Start-up of the system is forbidden until the user / operator has determined that the machine, in which the system is installed, conforms to the conditions of this directive. The CLS Pro 600 line and contrast sensor is an integral part of our BST web guiding systems. You are only allowed to use BST web guiding systems to correct the position of web-shaped materials (e.g. those made from paper, film, cardboard, rubber, etc.). The sensor and the control panel must never in be installed and used in potentially explosive areas. BST web guiding systems have been designed and built in accordance with state-of-the-art standards and the recognized safety regulations. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties or damage the BST web guiding systems and other equipment. Therefore BST web guiding systems are only to be used if they are working correctly and in a technically safe condition. Any part found to be working incorrectly must be replaced immediately. Only original spare parts are to be used for this. Spare parts obtained from third parties cannot be guaranteed to comply with the design and manufacturing conditions and safety regulations. In this case any guarantee claims made against the BST web guiding system will be invalidated. Only qualified personnel who have been trained on the system are allowed to undertake any work required on the BST web guiding system (i.e. installation, commissioning, operation, maintenance, etc.). Intended use also includes adhering to the instructions given in this operating manual. Use for any purpose other than those mentioned above is considered as contrary to the intended use. BST International GmbH does not accept liability for any damage resulting from this type of use.

Description 1 12


1.4 System description

1.4.1 System design 1.4.1.1 General information

The CLS Pro 600 consists of the sensor and the removable control panel.

The sensor enclosure holds the entire electronics and the control panel and controller connections.

1.4.1.2 Sensor with fitted control panel

The sensor is operated via the control panel, which is fitted to the sensor in the factory. The control panel is pivotable.

Sensor with fitted control panel 1.4.1.3 Sensor with removable

control panel

If necessary (i.e. if the sensor is installed in a difficult to access position on the machine) the control panel can be removed and installed in a central control console or a customer-supplied control station. In this case the connection between the sensor and control panel is completed using a cable extension that is available as an optional extra. Sensor with control panel removed

The length of the connection cable between the sensor and the control panel must never exceed 20 m (maximum).

cable extension (2 m, 5 m, 10 m)

Sensor Control panel

Description 1 12


1.4.2 Operating principle The sensor records the actual position of a line or a contrast transition point on the material web in automatic mode and then transmits the relevant information to the interconnected controller. The controller compares the actual recorded position against the default set point position. A relevant correction signal will be sent to the guiding device’s actuator if a deviation is found to exists between the two values. The actuator will drive the guiding device (rotating frame or swivelling roller guide) until the material web returns to its set point position. The CLS Pro 600 sensor can be used in the following configurations:

1.4.2.1 Stand-alone mode

1.4.2.2 In conjunction with an ekrPro Com60 controller

Customer’s machine controller

Sensor CLS Pro 600 with control panel

BST Signal Terminal Box1

CAN bus connection (optional)

Customer’s machine

controller

BST Signal Terminal Box1 Sensor CLS Pro 600 with control panel

Description 1 12


1.4.2.3 In conjunction with ekr 500 Plus

1.4.2.4 In conjunction with EKR 1500 / CCD line guider as a CCD 2004 replacement

Customer’s machine

controller

BST Signal Terminal Box1(optional)


EKR 1500


CCD Line Guider

CAN – Module bus coupler

CAN bus connection (optional)

Description 1 12


1.5 Terms used in this manual

1.5.1 General information In principle, the windows displayed on the keyboard’s graphics display are laid out as follows:

1.5.2 Set position The set position is the required line / contrast transfer point position in the sensor scanning area. It can be set up in Automatic mode using the control panel’s arrow keys (see Chapter 5.3.2). The set point position will be indicated by a white triangle displayed on the control panel’s screen. The deviation will be faded in as plaintext during displacement of the set position. The deviation can take positive values and negative values as well. The contrast quality will be graphically displayed in the bottom section of the window.

Status bar

Display area

The content shown in this area depends on the mode setting. Detailed descriptions can be found in Section 5.2.1 for the set-up mode and in Section

Footnote

Contrast quality (graphical)

Deviation of the SET POINT position

SET POINT Position without deviation

Center of measuring range

Standard SET-position

Center of measuring range

Standard SET-position

Numeric indication of the deviation

Description 1 12


1.5.3 Measuring range

The sensor’s measuring range is 25 x 3 mm (W x H).

1.5.4 Search area The search area is a section within the measuring area. The line / edge that has to be evaluated and controlled afterwards is located in this section.

1.5.5 Status bar The actual sensor status and the controller’s actual operating status are both displayed in the status bar. See Section 5.2.3 as well regarding this. The controller details are not displayed in the stand-alone version.

1.5.6 Footnote Operating help is integrated in the footnote. This tells you when optimisations can be implemented in the displayed window or what the actual setting of the selected parameter is and how it can be configured.

1.5.7 First edge / second edge The edge that will be controlled afterwards can be defined for the line scanning process. First edge and second edge are both available for use as options.

The edge position on the left of the display must be used for setting up the first edge. The second edge is used for setting up the second edge.

first edge second edge

Description 1 12


1.6 Control panel The control panel contains all of the display and operating controls needed to operate the CLS Pro 600.

1.6.1 Graphics display Different parameters as well as main and quick menus (depending on the mode selected) are displayed on the control panel’s screen during operation. The symbol significances are described in Chapter 5.2.

1.6.2 Control panel Three different groups of keys are integrated in the control panel and they have the following functions: SET-UP keys: Used to select set-up mode Blue keys: Used to access the menu; import the parameters or exit the parameter entering process Arrow keys: Used to enter settings as shown in the operating

help page You will find the separate key significances listed in the table on the following page.

Description 1 12


Function Button Name Description

Edge SET-UP

Calls up the edge guiding set-up mode (only possible in MAN mode)

Line SET-UP

Calls up the line guiding set-up mode (only possible in MAN mode)

Arrow keys

Used to carry out operations as shown in the footnote

ENTER • Imports the mode / parameter

settings • Exit set-up mode

Set-up mode

ESC

• Aborts the parameter entering

process

Menu

MENU

• Calls up or exits the quick menus

The key must be held down for at least 3 seconds to call up the menus

Right arrow key • Used to enters a sub-menu or parameter

Left arrow key • Pages back by one menu level (does not exit the menu)

ENTER • Used to open a sub-menu or select a parameter

ESC • Pages back by one menu level and might also close the menu

Description 1 12


1.7 Safety information The safety relevant information in accordance with DIN EN ISO 13857, DIN EN 349 and the industry specific accident prevention regulations must always be taken into consideration when installing the BST equipment in the production machine, these include: There must always be a safe distance between the BST equipment and the machinery already installed on-site, such as machine panels, building structures, etc. Connection lines between the individual system components must be laid so that nobody can trip over them, not pulled tight and well anchored down. Ensure that there is sufficient free headroom. If the free passage is restricted, the relevant building components causing the restrictions must be padded and a danger warning signs must be affixed to them (yellow / black). In principle, if the cable connections are (e.g. between the sensor and sensors) disengaged then the sensor is no longer connected to the power supply. Any infringements will result in the warranty claim being invalidated. The sensor has not been ATEX certified, i.e. it is not approved for use in potentially explosive areas and must never be used in them! Any transport safety devices that were attached to the guiding device must be removed prior to commissioning.

Only trained specialist personnel are permitted to undertake the assembly, installation and commissioning! Danger of cuts! Never touch the edges of moving material webs! Danger of crushing! Never reach into the area inbetween the fixed lower frame and the guiding device’s moving upper frame (rotating frame or swivelling roller guide). Never reach into the area inbetween moving rollers!

!

!

!

Description 1 12


Ensure the equipment is electrically isolated before starting work. To this end always carry out the following activities: 1. Switch off and disconnect. 2. Protecting against the voltage being switched back

on 3. Determine that the unit is ‘voltage-free’ 4. Earth the unit. 5. Cover or shield any adjacent parts that are still live. Only then can the relevant work be undertaken! Do not use the chassis or machine frame as a climbing aid or a stepladder. Do not remove any of the safety devices. Actuator movements will be run by the drive even during function checks away from the production machine and/or during commissioning. The relevant safety arrangements must implemented during performance checks! Monitor the overall safety concept of the production machine during commissioning!

1.8 Laser A laser is used as a positioning aid when positioning the sensor.

This laser unit has been classified by the manufacturer as a Class 1 laser in compliance with DIN EN 60825-1:2001-11. This laser will not cause eye damage, even after long radiation periods and even if other optical tools (lenses, etc.) are used in the beam’s path.

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

!

!

Assembly 2 10


2. Assembly 2.1 Installation site requirements

The following points must be taken into consideration when choosing the sensor and control panels locations: • The sensor and the control panel must be installed in a dry,

non-vibrating area and be positioned ergonomically. The operator must be able to access the control panel easily. Ensure that sunlight or other external light sources do not cause unwanted reflections on the screen.

• Strong electro-magnetic fields in the immediate vicinity of the sensor, the control panel or the sensors can result in malfunctions.

• Take note of the permitted ambient conditions. Temperature: 0 - +45°C (maximum) Humidity: 5 - 90%, no condensation See chapter 2.1.1 as well regarding this.

• The sensor and the control panel have not been ATEX certified, i.e. they are not approved for use in potentially explosive areas and must never be used in them!

2.2 Sensor installation

2.2.1 General information This chapter describes the procedure for installing the sensors using the holders supplied in the package or the connection options available if using a holder supplied by the customer.

2.2.2 Installing the sensor using the holder supplied in the package A square holder bar has to be used with the holder supplied in the package for the CLS Pro 600 sensor. Two sizes can be used, 25x25 mm and 35x35 mm. The holder consists of a special holding device that enables both sizes to be used.

Fit the holding device onto the square holder bar and slide it into the required position together with the camera.

Now tighten up the securing bolt to clamp the holding device into place on the square bar.

See drawing on the next page.

Assembly 2 10


2.2.3 Installing the sensor using a holder supplied by the customer

If the sensor has been supplied without a holder, then the customer must provide a relevant securing device. Securing threads are available at the sensor enclosure for this purpose. The connection sizes can be found in the following drawing.

Square bar Holder unit

Securing screw

M6 / 7 deep securing threads for securing holder provided by customer

(on both sides)

10,7

6 55

55,5

49,8

20,5 67

1

Assembly 2 10


2.2.4 Setting the gap between the

sensor and the sensing roller The optimum gap between the sensor and the sensing roller can be set up using the measuring window protective packaging. The measuring window protective packaging is an integral part of the overall packaging! In this case you must attach the protective packaging to area around the sensor enclosure’s measuring window. Slide the sensor along in the sensing roller direction until the protective packaging lies up against the sensing roller (see drawing). Pull the protective packaging out to one side afterwards.

2.2.5 Turning the control panel The control panel can be mounted on the sensor in four different positions (each one offset by 90° from the other) (see diagram). The sensor is prepared for installation in Position when delivered from the factory. The control panel mounting position must be altered accordingly if the sensor’s control panel cannot be operated correctly due to the existing installation situation. The relevant procedure is described in the following.

1 2 3 4

1

Sensor enclosure

Sensing roller

Protective packaging

20

Assembly 2 10


1. Unscrew the four control panel securing screws.

2. Carefully pull the control panel upwards and away from the sensor.

3. Turn the control panel into the required position (see illustration above).

4. Take note of the cable guide for the connecting cable. Do not crush or clamp the cable. There is a cut-out in the control panel’s enclosure and the cable should be fed out through it.

5. Use the four securing screws to attach the control panel to the sensor.

Securing screws

Cut-out

Assembly 2 10


2.3 Installing the control panel

2.3.1 General information This Chapter describes the procedure for installing the control panel when using the sensors with control panel removed (see Chapter 1.4.1.3).

Strong electro-magnetic fields in the immediate vicinity of the control panel can result in malfunctions. You must ensure that the control panel is not mounted close to components that use mains power or power lines when installing in a control console or a control station. Always maintain a minimum clearance of 100 mm!

2.3.1.1 Installation versions

The control panel enclosure enables the following installation versions to be used: 1. Wall mounting

The control panel is secured to a level surface. Refer to Chapter 2.3.3 for the procedure.

2. Console mounting

The control panel is installed in an existing on-site control console or a control station. Refer to Chapter 2.3.4 for the procedure.

A CLS Pro 600 securing kit, which is available as an option, is needed to install the control panel in a control console (BST Order-No. 133 459).

2.3.1.2 Cable extension

An optional cable extension is needed to connect the control panel to the sensor. Cable extensions are available in the following lengths:

Cable lengths BST Order-No:

2 m 131 993

5 m 131 994

10 m 131 995

It is also possible to combine different cable lengths. The maximum permitted full length of 20 m between the sensor and the control panel must never be exceeded!

Assembly 2 10


2.3.2 Dismantling the holder

The holder must be removed before the control panel and holder can be removed.

1. Unscrew the holder’s securing screws in the enclosure

2. Pull out the holder. 3. The next procedures depend on the type

of installation. Refer to Section 2.3.3 for a wall mounting or Section 2.3.4 for a console mounting.

2.3.3 Wall mounting

2.3.3.1 Securing hole diagram

Sensor enclosure

Securing screws

Holder

93

105

93105 Control panel

enclosure

4x M3

Assembly 2 10


2.3.3.2 Preparations

1. Unplug the control panel connecting

cable from the sensor (plug X100). 2. Unscrew the holder’s four securing

screws from the sensor enclosure.

3. Pull the holding ring and control panel sideways out of the groove in the sensor enclosure.

Plug X100

Control panel connection cable

Securing screws

Securing screws

Plug

Assembly 2 10


4. Unscrew the four control panel

securing screws and place to one side. These screws will be needed for the wall mounting later on. Pull the control panel out of the control panel enclosure Now pull the connecting cable and the plug carefully through the cut-out in the controller enclosure.

2.3.3.3 Assembly

1. Fit the M3 threads in the holes as

shown in the securing screw hole template (see Chapter 2.3.3.1).

2. Use the four M3 screws to screw

the control panel on. The four hexagon screws that secured the control panel to the sensor when the unit was delivered can be used for this.

3. Use the optional extension cable to

connect up the control panel to the sensor (see Chapter 2.3.1.2).

4. Plug the extension cable connector

into the sensor’s X100 socket.

Securing screws

Don’t crush or clamp the cable!

Assembly 2 10


2.3.4 Control console installation

2.3.4.1 Installation cut-out

2.3.4.2 Preparations

A securing kit, which is available as an option, is needed to install the control panel in a control console (BST Order-No. 133 459).

1. Unplug the control panel

connecting cable from the sensor (plug X100).

101+1

101+1Installation cut-out

Plug X100

Control panel connecting cable

Assembly 2 10


2. Unscrew the four control panel

securing screws and place to one side. These screws will be needed for the console installation later on.

3. Pull the control panel out of the sensor enclosure Pull the connecting cable and the plug carefully through the hole in the sensor’s enclosure.

2.3.4.3 Assembly

1. Cut out the section (see Chapter 2.3.4.1).

2. Carefully push the control panel into the cut-out section.

2. Use two of the securing screws to screw the two securing plates (part of the installation kit) onto the back of the control panel. The four hexagon screws that secured the control panel to the sensor when the unit was delivered can be used for this.

4. Screw the four threaded pins into the securing plates until the control panel is held firmly in place.

5. Use the optional extension cable to connect up the control panel to the sensor (see Chapter 2.3.1.2).

6. Plug the extension cable connector into the sensor’s X100 socket.

Securing screws

Securing screws

Plug

Threaded pins

Securing plates Top view

max

. 15

mm

Control panel

Threaded pin Threaded pin Securing plates

Installation 3 3


3. Installation 3.1 Fitting the cable connections

Warning! All connecting cables must be laid without being tight and you must ensure that there is no danger of anyone tripping over them.

• Cable connections between the specific units

(sensor, sensors, guiding device, etc.) must comply with the connection diagram.

• Tighten up the securing screws in the plugs

• Ensure that the voltage supply has the correct potential equalisation in accordance with the local regulations.

3.2 Sensor

3.2.1 Enclosure socket

Enclosure plug / socket

Function Remark

X100

Control panel connection (plug)

X101

Controller connection (socket)

X80

I/O connection (optional: Terminal Box BST STB 1) connection box with terminal strip for onsite connections; See Appendix 4 for layout

• Analog O/P 0 - 10V • External lighting , trigger

O/P, +12V / 5 mA • External lighting,

switched against +24V • Error O/P,

switched against +24V

!

X80 X101X100

Installation 3 3


3.3 Service indicator displays

There are 3 service LEDs fitted on the sensor enclosure and they have the following significances:

3.3.1 Bus status LEDs

LED Name Status Bus name Meaning

OFF STOPPED The unit is in the initialization phase. No data transfer can take place.

FLASHES PREOPERATIONALThe unit is in PREOPERATIONAL mode. Initialisation is completed. The unit can be started.

H1 RUN

ON OPERATIONAL The unit is in OPERATIONAL mode.

OFF NO ERROR The unit is running ‘OK’. No errors present.

FLASHES 3 x SYNC ERROR No SYNC report has been received. H2 ERR

ON BUS OFF The interface controller is in BUS OFF mode.

3.3.2 Unit status LED

LED Name Status Meaning

OFF The unit is in an undefined state.

FLASHES The unit program is running ‘OK’. H3 PROG

ON The unit is in an undefined state.

H3H1H2

Installation 3 3


3.4 DIL switch settings

The S4 DIL-switch is used for making application specific settings.

DIL switch Meaning

S4.1 Not used at the moment



S4.4 = ON Sets the sensor up as a stand-alone system In this case the sensor is used as the NMT master and bus system sync generator.

S4.4 = OFF Set up the sensor to work with ekrPro Com60 / ekr 500 Plus / EKR 1500 / CCD Line Guider

Commissioning 4 12


4. Commissioning

Warning! Only qualified and trained personnel are permitted to undertake the commissioning! Danger from the power supplies! You are only allowed to open the sensor or other components if the power supplies have been switched off!

Requirements:

• The web guiding system has been fully wired in, i.e. the cable connections between the specific web guiding components have been made.

• The sensor is connected to the power supply. • The sensor switches (see 3.4 and 6.1.1) and the panel

(see 6.1.2) have been set up for the appropriate application.

• The following information window will be superimposed on the screen if the panel cannot make bus contract with the sensor:

The following are displayed: ∗ The panel’s node number on the bus (Commander Node)

∗ The synchronization status (SYNC) ∗ The module status (Modulstate) ∗ Whether the sensor has been detected

on the bus (Sensor at ...) ∗ Whether the terminator resistor has been

set up (Resistor) There must always be one sensor and one panel with corresponding nodes present on the bus (e.g. sensor = 41 and panel = 111) so that the system can work correctly. If the sensor is not detected then this will be indicated, as the bus connection has not been made. Always check the connection cable and the plug in this case. Furthermore, you can also read whether the terminator resistor has been set up correctly or not.

!

Commissioning 4 12


4.1 Menus 4.1.1 General information

Setting up and operating the sensor are menu-controlled processes. The menus differ between:

• Main menu • Quick menu • Set-up mode

All of the parameters that are needed to set up the sensor are included in the main menu. The structure is a hierarchal structure (see menu structure in Section 4.1.3.4). The parameters are user organized, i.e. you can assign any parameter to a user level. In this case only the parameter that the logged-on user has access rights to will be displayed (see Section 5.6 “Expanded operation“ as well).

Parameters that are required for the respective application can be assembled in the quick menu. This gives you direct access. Assigning the quick menu is covered in Section 5.6.4.

Set-up mode enables you to set up the job specific parameters for the material and define the guiding mode (line / edge).

4.1.2 Input options Entries must be made in different sections of the menus; select the entries from the options list or activate the functions. The changes are made as follows:

• Direct via the entry screen. The positions that have to be changed will flash.

or • In the footnote. The selected parameter is displayed

showing the current setting here. The current setting will flash, which is the indication that adaptation is needed here.

Commissioning 4 12


4.1.2.1 Alphanumerical /

numerical entries

Proceed as follows to make direct entries in the input screen: • The positions that have to be changed will flash. • Use the up or down arrow keys to select the required

number / the required letter. The numbers 0 - 9 will be displayed first and then the alphabet from A - Z.

• Press ENTER to confirm the selected number / selected letter.

• If the entry consists of several places then you must use the right arrow key to select the next place. The entry must now be made as described above.

Proceed as follows to make an entry in the footnote: • The positions that have to be changed will flash. • Use the up or down arrow keys to select the required

number / the required letter. The numbers 0 - 9 will be displayed first and then the alphabet from A - Z.

• Press ENTER to confirm the selected number / selected letter.

• If the entry consists of several places then you must use the right arrow key to select the next place. The entry must now be made as described above.

0

Commissioning 4 12


4.1.2.2 Options list

An entry from a default list can be selected from an option list. Example: Select the required parameter. Confirm the selection by pressing ENTER. This will open up the settings window. Use the up / down arrow keys to scroll through the entries displayed in the list. Press ENTER to confirm the selected entry. The entry will be imported.

4.1.2.3 Checkbox

The associated parameter can be activated or deactivated using the checkbox. Example: Select the required parameter. The current status will be displayed in the footnote at the bottom of the setting up window.

Use the up / down arrow keys to activate or deactivate the function.

Commissioning 4 12


4.1.3 Main menu The menu contains all of the parameters needed to run the sensor.

4.1.3.1 Navigating around the main menu

Use the arrow-keys to navigate within the main menu. The selected entry will be displayed with a highlighted background. The entire main menu cannot be displayed in a single window. The window will scroll down automatically when the bottom of the window is reached. The menu displayed in the window will be moved upwards automatically when scrolling downwards and downwards when scrolling upwards. Press ENTER to confirm the parameter or sub-menu selection. Press the ESC key to cancel the entry.

4.1.3.2 General information

The separate menu section descriptions assumes that the menu has already been called up. Opening the menu will only be displayed once. Follow this procedure before you start to edit the specific parameters: 1. Hold the MENU key on the panel down for at least 3 seconds.

2. The main menu will be displayed in the footnote at the bottom of the screen.

3. Select the enter m… entry here (will have a green border around it) and then confirm the selection by pressing ENTER.

4. This menu will be displayed. You can now select and optimize the parameter that you need (see Section 5.7 as well).

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4.1.3.3 Entering the path

The relevant path going to the description of a specific main menu section will be displayed alongside the description. Only the relevant window will be displayed in the actual description. Example: Proceed as follows to set up the sensor parameter:

1. Log on as Admin. 2. Open the main menu first.

3. Now select the configuration sub-menu.

4. Select sensor and then open the setting up window.

The path details will then be displayed in the description \\configuration\sensor.

Commissioning 4 12


4.1.3.4 Menu structure

Access to the different menus and sub-menus depends on the assignment to the password levels. You will find the assignment according to the factory default settings in appendix A3. You can adapt those assignments. The procedure is described in section 5.6.3.

change user (Section 5.6.1)

configuration (Section 5.7.1)

● sensor

● remote control ekr

● save configuration

● commander

● select configuration

● mounting position

● edit menu configuration

● delete configuration

parameter (Section 5.7.2) ● jobs

● illumination

● contrast tracking

● line width tolerance

● splice misalignment

● position averaging

● web stop detection

● recapture factor

● adaption settings

● contrast detection

● gain factor Xp

● signal view type

remote control ekr (Section 5.7.3)

display (Section 5.7.4)

system info (Section 7.5)

Explanations for the specific menu sections can be found in Section 5.7 ‚Signification of the main menu parameters’.

Access password level: administrator System in setup mode

Access password level: operator / maintenance System in setup mode

Access password level: operator

Access password level: maintenance System in setup mode



Commissioning 4 12


4.2 Commissioning with a controller … 4.2.1 ekrPro Com60

ekrPro Com60 firmware > 1.7.6 is needed to run the system! Attention: You must connect the sensor up to the controller and

turn the sensor’s S1 rotary switch to Position 1 (default) and then switch the sensor on before you select the standard system with CLS Pro 600.

Proceed as follows: 1. Wire in and switch on the ekrPro Com60 controller as stipulated

in the operating manual. Start the system, without BUS STATUS; SYNC: Failed will be displayed even if the connection between the controller and the sensor is OK.

2. Configure the ekrPro Com60 controller Select the standard system for use with the CLS Pro 600 as follows.

a) Press the MENU key on the controller. The set-up menu will be displayed on the screen. b) Select Sel. Std. system and then press ENTER. c) The standard system selection window will now be displayed. Now press ENTER. d) The option list opens with the most common standard systems. e) Now select the CLS: EMS 17 entry and then confirm the selection by pressing ENTER. This entry can be used with all applications that use CLS Pro 600. Optimization of the application specific components (e.g. EMS 16) is made afterwards. f) Press the function key F2 (Set). g) Close the set-up menu. h) Now switch the controller’s power supply off for a few seconds and then restart.

Commissioning 4 12


3. Now switch the CLS Pro 600 sensor over to set-up mode.

The controller must be in MAN mode to do this!

Press the set-up line or set-up edge key. A blue background will now be displayed around the window the sensor lighting flashes and the laser is switched on.

4. Open the main menu by pressing down the menu key for approx. 3 seconds. Select the Change User sub-menu from the main menu and then log on as Administrator. The procedure is given in Section 5.6.1.

5. Now open Mounting Position in the Configuration sub-menu and teach-in the sensor’s mounting position. This procedure consists of 4 sub-steps. Teach-in cannot be used in stand-alone mode! Follow the example shown in the operating manual to help you use the teach-in process. You must ensure that this example also moves when you move the material web in step 3. Mounting position A is shown as the example in this procedure: Note that mounting positions B, C and D must first be activated before you can use them.

1. Call up and open the sub-menu configuration.

2. Call up config positon A.

3. Start the teach-in process for this mounting position. Select the teach-in parameter and then confirm your selection by pressing ENTER. The teach-in process has now started.

3a) The first step is to set up manual adjustment. Use the left / right arrow keys to move the guiding device. The settings can be inverted from here if the arrow key assignments are incorrect. This is realized by using the up / down arrow keys. Press ENTER to confirm your settings.

Commissioning 4 12


3b) The window for the second step is now open. Position the teach-in model line in the green field and then press ENTER to confirm the process: The line identification process will now be run. 3c) Move the line to the left in Step 3 afterwards. This is realized by briefly pressing the left arrow key If the teach-in model does not move as well (e.g. when scanning using a fixed roll) you can use your hand to move it slightly to the left. The system will now calculate all of the parameters automatically. 3d) Press key ENTER. Set-up is now complete. You can further optimize the parameters displayed in the Step 4 window whenever necessary. sensor inverted: Determines whether the sensor signal for this mounting position should be read in as inverted or not. The setting should be made so that the image on the screen concurs with the actual conditions. guiding direction inverted: Determines the sensor’s guiding direction so that the system feeds the material web along in the correct direction. This parameter must be checked without fail during the commissioning. manual control inverted: The material web arrow key assignments for manually adjusting the guiding device can be inverted here, e.g. the left arrow key can also be moved to the left. W-Val display inverted: The arrow key assignments for adjusting the set point value can be inverted here.

Laser line

Material to be scanned

Fix teach-in model, e.g. use adhesive tape

Teach-in model. The teach-in model must move when the material is adjusted.

Commissioning 4 12


6. Return to the Change User sub-menu after you have

completed these settings. Now log on as Operator here.

7. This completes the commissioning of the sensor connected to an ekrPro Com60 controller.

8. Press Menu key to leave the set-up menu.

4.2.2 ekr 500 Plus See ekr 500 Plus manual (MD.299.01.xx).

4.2.3 EKR 1500 / CCD line guider and CAN - Module bus coupler

Being prepared

Commissioning 4 12


4.3 Commissioning as a stand-alone system

1. Aligning the sensor for stand-alone mode. Switch the sensor’s S4 DIL-switch to ON for this mode.

2. Now switch the CLS Pro 600 sensor over to set-up mode. Press the set-up line or set-up edge key. A blue background will now be displayed around the window.

3. Open the main menu by pressing down the menu key for approx. 3 seconds. Select the Change User sub-menu from the main menu and then log on as Administrator. The procedure is given in Section 5.6.1.

4. Now open the Select configuration position in the Configuration sub-menu and then select the STAND ALONE setting.

5. Test the controller to ensure that it is working correctly. Sensor orientation and/or the mounting position guiding direction might have to be configured as well.

6. Return to the Change User sub-menu after you have completed these settings. Now log on as Operator here.

7. Commissioning the sensor as a stand-alone system is now complete.

Operation 5 31


5. Operation 5.1 General information

If the sensor will be used an integral part of a projected BST system then the standard configuration has already been completed. However, the onsite set-up (line or edge) still has to be undertaken. If required or if necessary, you can:

a) Create a quick-menu

b) Create and save a job specific configuration.

The procedure for this part is given in Section 5.5 Standard operation. If the sensor is changed onsite (with or without the panel) then a new component optimization is required. Parameter settings might have to be remade. Optimizing the specific parameters and their significances are described in Section 5.6 Expanded operation.

5.2 Operating display The CLS Pro 600 screen display depends on the mode that the sensor will be working in. We differentiate between set-up mode and scanning mode. The menu can be called up from either mode. However, access to the specific sub-menus is differs.

5.2.1 Set-up mode display window The sensor settings are made via the guiding job in set-up mode. The parameters needed for the setting up will be displayed using graphic symbols and numerical values on the control panel screen. You will find the significances for the individual symbols in the following illustration.

Possible contrast Contrast quality of the edges / lines lying in the searched area graphically displayed.

Import the settings by pressing the ENTER key

Sensor details

Runs the settings for the selected function

Measuring area Shows the edges / lines lying in the measuring area and marks the selected edge / line.

Current operating mode (controller) Status bar

Shows you which modes the sensor and the controller are working in. See Section 5.2.3 as well.

Numerical contrast quality details.

Operating help Operating help has been integrated in the footnote. This shows you how the optimization can be run in the displayed window.

Pre-select the setting up functions by using the up / down arrow keys. Activated in the standard settings are:

1. Move search area

2. Change size of search area

3. Other functions are being prepared

Operation 5 31


The background is always blue in set-up mode.

5.2.2 Scanning mode display window

The background will flash red if an error occurs (line or edge not detected), regardless of the mode being used

The background is green in automatic mode (controller).

Current operating mode (controller)

Status bar Shows you which modes the sensor and the controller are working in. See Section 5.2.3 as well Measuring area

Shows the tested edge / line and displays the standard set point.

Numerical contrast quality details. Contrast

Contrast quality of the tested edge / line is graphically displayed.

Operating help Operating help has been integrated in the footnote. This shows you how the optimization can be run in the displayed window. Set point adjustment (W)

in AUTO mode Move guiding device left / right (mot) in MAN mode

Pre-selects the ekrPro Com60 mode and other remote control functions

Operation 5 31


5.2.3 Status bar

The current statuses that the sensor is in are displayed in the status bar as well as the controller’s current operating mode (except for stand-alone mode).

Sensor in edge mode

Sensor in line mode

Sensor in set-up mode

Sensor in stand-alone mode

Sensor transmitting an interlock

Sensor has not detected a valid edge

Controller has activated Watchdog edge 1

Controller has activated Watchdog edge 2

Controller is in manual mode

Controller is in automatic mode

System is in servo-center position (SC mode)

No controller detected on the bus.

Operation 5 31


5.3 Controlling the ekrPro Com60 / ekr 500 Plus controllers remotely

The sensor’s panel enables the controller to be controlled remotely. In this case the remote control function must be activated beforehand. Check this setting. Log on as Admin and call up the main menu afterwards and then select the \\configuration\remote control ekr sub-menu. The enable remote control function must be activated.

5.3.1 Manual mode Set-up and system configuration is carried out in this mode. Use the up or down arrow keys to select manual mode.

The selected mode will be displayed with a green border around it. Press ENTER to confirm your selection The current mode will be displayed in the top right corner of the screen. The sensor will switch over to manual mode.

5.3.2 Automatic Automatic material web controlling is carried out in this mode, depending on the scanning mode that was selected (edge or line). Use the up or down arrow keys to select automatic mode.

The selected mode will be displayed with a green border around it. Press ENTER to confirm your selection The current mode will be displayed in the top right corner of the screen. The sensor will switch over to automatic mode.

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5.3.3 Servo-center position

The material web will always be kept in the servo-center position in this mode. Use the up or down arrow keys to select servo-center

position. The selected mode will be displayed with a green border around it. Press ENTER to confirm your selection The current mode will be displayed in the top right corner of the screen. The sensor will switch over to the mode servo-center position.

5.3.4 Moving the set point position (W-value) Use the left / right arrow keys in automatic mode to adjust the set point.

5.3.5 Moving the guiding device Use the left / right arrow keys in manual mode to move the guiding device to the left or right.

5.3.6 Adjusting the controller gain. The controller gain can be reset via the \\configuration\remote control ekr\gain factor XP parameter. You must be logged on as Admin.

Move set point.

Move guiding device

Operation 5 31


5.4 Operation

5.4.1 General information

Danger of cuts! Never touch the edges of moving material webs! You are only allowed to run set up when the production machine is stopped.

The guiding mode is determined and an automatic equalization to the characteristics of the material that has to be scanned is run during the set-up.

5.4.2 Activating line set-up / edge set-up Use the set-up keys to select the type of set-up (line or edge) that you want to use. Attention: Set-up can only be run when the controller is in MAN

or SC mode. An information window will be opened if you attempt to call up set-up in AUTO mode. This will tell you that this action is not possible in this mode. Press ESC or ENTER to exit the window.

5.5 Standard operation Certain settings, i.e. the so-called jobs, have been set up in the main menu for the current applications (e.g. slitter, etc.). All of the necessary basic settings will be implemented when the required job is selected. You only have to enter the necessary set-up (edge or line) for the work. The system is now ready for operation.

5.5.1.1 Selecting a job

Jobs are loaded via the \\parameter\jobs\load menu. The following selection window will be displayed.

!

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You can select between the jobs entered in the factory here. DEFAULT: Resets the default factory settings

COLORED LINE: These settings are used when a colored line has to be tracked and it lies in a field with changing conditions.

SMALL LINES: This setting must be used if lines with a width of less than 0.5 mm have to be scanned.

STRICT CHECK: Select this setting if very constant measuring and printing conditions are present, regardless of whether there is a lot of noise present in the field. In this case the system will block it relatively quickly, but the danger of latching on to contrast caused by noise is minimal. Use, for example, if there are large breaks in the line (ratio between the broken and usable signal > 20%).

VERY TOLERANT: Select this setting if extremely poor measuring conditions are present (uneven web running, changing print quality, etc.) but no noise spikes. The number of blocking actions undertaken will be kept to a minimum in this case. Use, for example, when the color of the edge being scanned changes frequently or if the print in alignment mode is uneven.

If you are unable to enter any of these settings for your application you can use the relevant settings to create your own jobs. The procedure is described in Section 5.6.2. If you have changed over to set-up mode or if the set-up line or set-up edge keys are pressed again in set-up mode, then the currently loaded job will be displayed on the screen for 2 seconds. If it is not displayed, then the system will be operated using the machine default values or manual modified parameters, which have not been assigned to a job.

Operation 5 31


5.5.1.2 Edge set-up mode

1. Use the arrow keys to select

MAN mode .

The selected mode will be displayed with a green border around it. Confirm the selection by pressing ENTER. The current mode will be displayed in the top right of the screen.

2. Press key SET-UP EDGE .

The LED inside the SET-UP key will illuminate. The LED inside the ENTER key will flash. The camera light will be switched on and it will flash. The laser line will be visible simultaneously.

3. Use the laser line to position the camera on the required edge. Use the mechanical adjustment device to fix it in position. The edge with the best contrast will be selected automatically by the system. In this case it is edge K1.

4. a) If the pre-selected edge is to be used for the controlling, then no other settings have to be entered.

Press the ENTER button. The LEDs inside the ENTER and SET-UP keys will be extinguished. The display will change over from set-up mode to scanning mode. b) If edge K2 has to be used for the guiding then the arrow keys must be used to define the search area. In this case you must select define search area and set up the size of the search area accordingly.

Press the ENTER button. The LEDs inside the ENTER and SET-UP keys will be extinguished. The display will change over from set-up mode to scanning mode.

5. Press the ENTER button. The system will now switch back to AUTO mode (operating mode).

2

1

1

2

K1

K1 K2K2

3 m

m

25 mm

Laser line

or

Operation 5 31


5.5.1.3 Line set-up mode

Standard

1. Use the arrow keys to select

MAN mode .

The selected mode will be displayed with a green border around it. Confirm the selection by pressing ENTER. The current mode will be displayed in the top right of the screen.

2. Press LINE SET-UP.

The LED inside the SET-UP key will illuminate. The LED inside the ENTER key will flash. The camera light will be switched on and it will flash. The laser line will be visible simultaneously.

3. Use the laser line to position the camera on the required line. Use the mechanical adjustment device to fix it in position. The line with the best contrast will be selected automatically by the system. In this case it is line L1.

4. a) If the automatically pre-selected line is to be used for the controlling, then no other settings have to be entered.

Press the ENTER button. The LEDs inside the ENTER and SET-UP keys will be extinguished. The display will change over from set-up mode to scanning mode. b) If line L2 has to be used for the guiding then the arrow keys must be used to define the search area. In this case you must select the search area position and then the search area size functions and then define the search area.

Press the ENTER button. The LEDs inside the ENTER and SET-UP keys will be extinguished. The display will change over from set-up mode to scanning mode.

5. Press the ENTER button. The system will now switch back to AUTO mode (operating mode).

1

2 2

1

Laser line

25 mm

3 m

m

L1 L2

L2 L1

or

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Area-Tracking

If the conditions are present, as shown in the example, then the displayed pre-selection will be used for the standard settings.

This can result in the controller producing unclean web guiding, due to the unevenness of LK1.

The Area-Tracking will have to be used in this case. Only one edge (LK2) will be tracked, but this will be compared by checking the color of an area alongside the edge. This will enable the noise spikes to be suppressed and prevent the system from jumping around. LK1 can no longer be included, as the search area has been reduced. The search area is displayed here. We recommend that the setting is made so that the left edge of the search area lies approx. over half of the smallest point in the line. The area that has to be checked must always lie on the side of the edge on which the crosshairs lie. The panel display will look as follows:

If the search area is enlarged then the are that has to be checked will be enlarged automatically. Normal line tracking using two edges will be resumed automatically as soon as a second edge is detected inside the search area.

LK1 LK2

Left edge

= = Smallest position

in the line

Tested area

42%This edge will be tracked.

Search area limit(left edge)

Operation 5 31


5.6 Extended operation

The system parameters are saved in the main menu. The menu structure is shown in Section 4.1.3.4. You can run the required optimization from here if the pre-configured settings cannot be fully used for a specific type of machine. The settings must be entered in set-up mode. The significances of the specific parameters are described in the following.

5.6.1 Change user Use this parameter to assign or change the user level in a dialog window. Different setting up options are available, but they depend on the user level. Which parameter a user can adapt and which functions he can use are defined in the configuration menu (see Configuration section). Assignments have already been set-up in the factory (see factory default settings). However, the system should be created so that the user only has to log on as the administrator, in order to run a complete commissioning process. Implement any relevant adaptations necessary when you assign user levels to the specific parameters (see Section 5.6.3). The procedure for selecting the user levels is described in the following, e.g. for commissioning or operating.

1. Mark the change user entry and press ENTER to confirm it.

2. Define the user levels in the following dialog window. The following are available for use:

operator (no password) maintenance (password = 00001) administrator (password = 00002)

Use the up or down arrow keys to select the required level and then press ENTER to confirm it.

3. You will be asked to enter a password afterwards. Enter a valid password here and then press ENTER to confirm it.

You are now logged into the selected user level. You can now adapt the parameters that can be accessed from this level.

Operation 5 31


5.6.2 Job administration

It might be necessary to enter different measuring settings due to the variety of materials and print images processed in the different applications. A relevant measuring parameter set, consisting of material and/or job specific parameters can be saved as a Job. These jobs can be called up whenever necessary. This enables you to set up repeat jobs quickly and without any errors. Certain basic jobs have already been pre-configured in the factory and are available under the \\parameter\jobs\load menu (see Section 5.5.1.1 as well).

5.6.2.1 Saving a job

Proceed as follows if you want to create specific jobs for the application:

1. Set up the necessary parameters first. 2. Select the \\parameter\jobs\save job menu afterwards. An

entry screen will be displayed, in which you can use the arrow keys to enter the job name.

3. Press ENTER to confirm your entry. The settings will be saved under this name in the job list.

5.6.2.2 Selecting a job

1. Call up the \\parameter\jobs\choose job menu. The selection list of existing jobs will be displayed on the screen.

2. Use the up / down arrow keys to select the job that you want and then press ENTER to confirm your selection.

3. The selected job will be loaded. A relevant information window will be displayed after the loading has been completed successfully.

5.6.2.3 Deleting a job

A saved job that is no longer wanted can be deleted. Call up the \\parameter\jobs\choose job menu. A selection list of saved jobs will be displayed. Use the up / down arrow keys to select the job that you want to delete and then press ENTER to confirm your selection. The job will be deleted.

Operation 5 31


5.6.3 Assigning user levels

to the parameters Access rights can be assigned to specific parameters via the Configuration sub-menu, i.e. only those holding access rights can access parameters that have been assigned a user level. Attention: The Configuration sub-menu can only be called up in

set-up mode and you have to be logged on as Admin. A relevant information window will be opened up if you try to call it up from scanning mode.

Procedure: 1. Call up the configuration sub-menu. The dialog window is sub-divided into the following sections:

• Parameter display

• Assigned user levels

• Footnote with user help.

Only the parameters that the current user hold access rights to will be displayed in the parameter screen. Assignment: 1. Use the up / down arrow keys to select the parameter that you

want to optimize and then press ENTER to confirm your selection.

2. The associated editing window will be opened. The time [ms] parameter window is used as an example here.

3. Now select access at level. You can now define the user level in the option field on the right that will enable users to view / use this parameter. Confirm the entry by pressing ENTER.

4. The display will return to the configuration screen. The relevant symbol will be displayed in the user level column.

1

2

3

1

2

3

Operation 5 31


Symbol definitions are as follows: Operator

Maintenance

Administrator

BST-Support

5.6.4 Setting up quick menus Parameters that are required for the current application can be assembled in the quick menu. 15 places can be assigned. The displayed sequence is determined by the numbering (no slot). A known weighting can be used here. The entries with the highest numbers (slot places) will be ignored if there are more than 15 entries. Procedure: 1. Call up the configuration sub-menu. The dialog window is sub-divided into the following sections:

• Parameter display

• Entry defining if the parameter will be displayed in the quick menu or not.

• Footnote with user help.

Only the parameters that the current user holds access rights to will be displayed on the screen. Assignment: 2. Use the up / down arrow keys to select the parameter that you

want to optimize and then press ENTER to confirm your selection.

3. The associated editing window will be opened. The illumination parameter window is used as an example here.

4. Now select quickmenuslot. You can now select from the option field on the right if, when and in which place this parameter will be displayed in the quick menu. Confirm the entry by pressing ENTER.

5. The display will return to the configuration screen. The entry will be displayed with the symbol in the quick menu column.

You can easily call up the quick menu whilst working just by pressing the MENU key. However, there must be at least one parameter selected for the quick menu. Otherwise it is virtually deactivated.

1

2

31

2

3

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5.7 Main menu parameter significances

5.7.1 Configuration The sensor, panel and mounting position settings are entered via the Configuration sub-menu. Attention: You can call up this sub-menu with password level Admin and in set-up mode. commander The parameters that apply to the panel are

configured in this sub-menu. display dimtime: This parameter can be used to dim the

panel’s LCD display. The screen’s background illumination brilliance will be dimmed after a set period has expired. The screen will be brightened once again when a key is pressed and the action will also be executed.

Setting range: 0 – 15 min Default setting: 5 min The screen will not be dimmed if ‘0’ min is entered as the setting.

active USB: Activates the memory function.

The panel’s configuration data can also be accessed via the USB interface and this data can also be saved externally if necessary. Furthermore, this also gives you the option of loading firmware updates. Press the ENTER or ESC buttons to shut down the connection.

manual settings: Other setting up options can be activated in

set-up. These are: enable alternative edge: This gives you the option of selecting an alternative contrast. The left edge limit will flash red on the screen. You can select any other edge that is found.

enable alternative 2. edge: This gives you the option of selecting a rear edge for line scanning. The right edge limit will flash red. You can select any other edge that is found.

enable alternative line: This gives you the option of selecting an alternative line. Both edge limits will flash red. You can select any other line that is found.

\\configuration\commander\

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hide menu: If the parameter is active you can call up the

main menu by holding down the menu key for 3 seconds. If the parameter is inactive you can access the main menu via the entry in the quick menu. Note: You must completely exit the menu (quick menu as well) at least once before you can deactivate hide menu. Do not press the ESC key as otherwise the changes will not be imported.

disable operating error dialog:

Warning and information dialogs can be suppressed whilst working if this parameter is activated.

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sensor The parameters that apply to the sensor are

configured in this sub-menu. guiding mode: Use this parameter to define the control

process to be used when exiting set-up.

Setting options: to middle: It will be controlled from the

center of the sensor measuring area.

Attention: With this setting: to setupposition: The edge / line will be stopped in the position entered during set- up. The controller’s set point will be reset. The material will not be moved.

keep value: The setting will not be changed automatically when you exit set- up. The material will not be moved. Pre-adjustment: keep value

active USB: Activates the memory function.

The panel’s configuration data can also be accessed via the USB interface and this data can also be saved externally if necessary. Furthermore, this also gives you the option of loading firmware updates. Press the ENTER or ESC buttons to shut down the connection.

white balance: Use this parameter to run a white balance for

the sensor and to equalize the center of the sensor’s measuring area using the projected laser line. This setting requires a three step dialog for completion.

\\configuration\sensor\

Set-up will be run from this line

The material will be moved into the laser position after switching over to automatic mode

Operation 5 31


1. In the first step you will be asked to place a white material under the sensor.

2. White balance will be run automatically

after you press ENTER. The run will be displayed as an advancement cursor.

3. The successful white balance will be

displayed in an information window. 4. Now press the ENTER key to exit the

white balance process.

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guiding lock delay: Use this parameter to set up how long the last

measured value must be retained for until a blocking signal is sent. This will ensure that a minimum control time is run when scanning a broken line and that the guiding device can react.

Setting range: 0 – 9999 ms Default setting: 20 ms.

dig. out reset delay: Use this parameter to set up the delay time needed for resetting the digital outputs.

Setting range: 0 – 9999 ms Default setting: 0 ms

dig. out set delay: Use this parameter to set up the delay time needed for setting up the digital outputs.


mode digital out: You can define which signal will be transmitted from the digital outputs from here. Only the guiding unlock and guiding lock settings are available for these parameters at the moment.

guiding edge: Use this parameter to define the edge that will

be used for the controlling. This parameter is only available for line scanning applications. Setting options:

median of 1 and 2: Standard setting A median value will be created using both edges of the line and this will be generated as the control position.

first edge: It will be controlled by the left edge as displayed on the screen

second edge: It will be controlled by the second edge.

Int. watchdog: Not used at the moment. Pre-adjustment: median of 1 and 2

Operation 5 31


remote control ekr The parameters for the controller’s remote control are set up in this sub-menu. internal W-Val: Use this parameter to run a W-value internal

simulation. We recommend that the parameter is only activated in stand-alone mode, as a controller is not used in this mode.

Setting options: ON, OFF Pre-adjustment: OFF

enable remote control: Use this parameter to switch the controller’s

remote control option on and off.

Setting options: ON, OFF Pre-adjustment: ON

unit for guiding position: Use this parameter to define the measuring unit

that will be displayed on the screen with the W-value.

Setting options: no mm inch

Pre-adjustment: mm

If parameter no is set then the display will concur with the controller.

step width of guiding position:

Use the left / right arrow keys in automatic mode to set up the W-value. The size of the adjustment made each time a key is pressed is defined by this parameter. If an arrow key is kept held down for 350 ms then a new 150 ms adjustment step will be introduced automatically. If the arrow key is kept held down for longer than the time defined in the time to increase step width parameter it will switch over to the adjustment step width defined in the fast step width of guiding position parameter.

Setting options: 0.01 mm 0.02 mm 0.05 mm 0.10 mm 0.20 mm 0.50 mm 1.00 mm

Pre-adjustment: 0.05 mm

\\configuration\remote control ekr\

Operation 5 31


fast step width of guiding position: You can define the adjustment step width here after which it will switch over from the time to increase step width parameter if the arrow key is kept held down for longer than the defined time. It will reset back to the smallest adjustment step width automatically when the arrow key is released.

Setting options: 0.01 mm 0.02 mm 0.05 mm 0.10 mm 0.20 mm 0.50 mm 1.00 mm

Pre-adjustment: 0.2 mm

time to increase step width: Use this parameter to define the time until it switches over to the biggest step width.

Setting options: off 0.5 s 1.0 s 1.5 s 2.0 s 2.5 s 3.0 s 3.5 s 4.0 s 4.5 s

Pre-adjustment: off

Operation 5 31


mounting position The sensor’s mounting position is

defined in this sub-menu and the different configurations are also set up here.

select: Use the select parameter to select a pre-configured mounting position. You can select from 4 different mounting positions in principle, but mounting position A is the standard setting and mounting positions B – D are optional and these must be activated before you can use them.

configuration: Use the configuration parameter to configure the selected mounting position. The same configuration content and procedure is used for all of the mounting positions.

The procedure is described in detail in Section 4.2.1 when commissioned in conjunction with the ekrPro Com60.

edit menu configuration The menu access rights and the quick menu position are defined in this sub-menu. See Sections 5.6.3 and 5.6.4 for more detailed descriptions.

\\configuration\mounting position

\\configuration\edit menu configuration\

Operation 5 31


5.7.2 Parameter

The parameters that apply to the measuring process are assembled in this section of the main menu. Significances and procedures for the individual settings are described below. jobs The job administration procedure is described in detail in

Section 5.6.2. illumination The parameters that apply to the lighting are set

up in this sub-menu. time [ms]: Use this parameter to set up the CCD line

illumination time. This affects the control measuring cycle time. If a value of > 2 ms is selected, then no more details can be selected, e.g. slightly broken lines.


internal: Use this parameter to configure the bright field illumination. The settings are set up automatically in the standard application. If a reasonable value cannot be set up in automatic mode, e.g. due to the expected different illumination situations (undulating, smooth material), then automatic will be switched off and the required value can be set up using the brightness parameter.

brightness Setting range: 0 – 100 % 0% means that the bright field illumination is switched off. 100% means maximum brightness. automatic Setting options: ON, OFF

Pre-adjustment: ON

The optional and external parameters are not used at the moment.

\\parameter\jobs\

\\parameter\illumination\

Operation 5 31


destination Use this parameter to set up over- or underexposure for the relevant area in automatic mode. These settings can also be used for weak colors inside a light background.

Setting range: 0 – 300%

Pre-adjustment: 100% (i.e. no overexposure)

contrast detection The parameters that apply to the contrast

detection are set up in this sub-menu. quality: Use this parameter to set up the lower contrast

search threshold. This setting is only available when the auto adjustment parameter is switched off. Determining the search threshold can be helpful when, for example, a contrast that varies considerably is present.

Setting range: 10 – 100

Pre-adjustment: Automatic A ‘10’ setting is used to detect weak contrasts and a ‘100’ setting is used for detecting good contrasts

auto adjustment: Switches the automatic determining of the

contrast detection search threshold on and off. Setting options: ON / OFF Pre-adjustment ON

min. line width: This parameter is used to define the minimum

width and it is needed to ensure that the system detects a line as a line. Setting a high value will prevent noise being generated by high-contrast scratches, etc. A smaller value can be set up if very small lines are detected reliably. Settings: 0.1, 0.2, 0.3, 0.4 & 0.5 mm Default setting: 0.3 mm

contrast tracking The tracking conditions for exceptional materials

are optimized in this sub-menu, e.g. poor contrast or print edges with different colors.

\\parameter\destination\

\\parameter\contrast detection\

\\parameter\contrast tracking\

Operation 5 31


plausibility check: This sub-menu includes the parameter that will be

used to check the plausibility. This is described below.

edge color This parameter defines the type of color checks to be used for edge scanning. The details of how the color will be checked always refer to the screen display. Setting options: all off right side only left side only

Pre-adjustment: all

edge intensity This parameter defines the type of intensity checks to be used for edge scanning. The details of how the color will be checked always refer to the screen display.

Setting options: all off right side only left side only

Pre-adjustment: off

line color This parameter defines the type of color checks to be used for line scanning. It describes which color will be checked. Setting options:

all = color checks the right side, the left side and the line off = no color checks only left side = color checks run on the left side only only right side = color checks run on the right side only only line = only the line color will be checked

only not line = color checks the right side and the left side but not the line Default setting: only line

Operation 5 31


line intensity This parameter defines the type of intensity checks to be used for line scanning. The details of how the color will be checked always refer to the screen display.

Setting options: all off only right side only left side only line only not line

Pre-adjustment: only line

edge polarity Use this parameter to define whether a polarity test will be run or not. We recommend that this parameter is always switched on. Switching off is only makes sense if an object with changing colors has to be scanned.

Setting options: ON, OFF

Pre-adjustment: ON

edge sharpness Use this parameter to define whether the contrast transfer point sharpness (slope) has to be checked.


Pre-adjustment: OFF environment The system will check the gap to the next contrast on the left and right alongside the contrast that has to be scanned during edge scanning. If the function is switched then blocking will be released again after an interruption when the gap corresponds to, is larger than or is missing when compared to beforehand. If a contrast that lies closer to the contrast being scanned is detected, blocking will remain in place.


Pre-adjustment: ON

contrast quality Use this parameter to define whether the contrast strength has to be checked or not. This must remain stabile over the measuring process.


Pre-adjustment: OFF

See line color for the significance

Operation 5 31


adaption settings Use this sub-menu to set up how the plausibility

check will be run using the comparable values. general balancing:

Use this parameter to define the weighting that will be applied with the new valid measurements for the marked respective reference. The parameter is only effective when used with an ekrPro Com60 in automatic mode.

Setting options: off = no weighting 2 values 4 values 8 values 16 values 32 values 64 values 128 values 256 values

Pre-adjustment: 256 values A new comparison value must be determined as follows for the default setting of 256 values:

color: This parameter defines whether the color comparison value should be guided.


contrast: This parameter defines whether the search

contrast threshold should be guided. This parameter is only active if contrast detection /auto adjustment is switched on.


Pre-adjustment: ON

edge sharpness: This parameter defines whether the contrast sharpness should be guided.


line width: This parameter defines whether the line width should be guided.


\\parameter\adaption settings\

Sum of the last 256 values – last value + new value

256

Operation 5 31


environment: This parameter defines whether the gap to the next existing contrast alongside the contrast that has to be scanned should be updated.

Parameter ON = the smallest gap between the contrast that has to be scanned and the next existing contrast is used.

Parameter OFF = the value is used that was defined during set-up procedure. There is no update.


splice misalignment Use this parameter to set up the maximum

expected deviation from two subsequent evaluation characteristics when tracking broken edges / lines or a splice. If it proves difficult to check the material and the gap between one evaluation characteristic and the next is big then the parameter must be set up more precisely in order to prevent the system jumping to a wrong edge / line.

Setting range: 1 – 8 mm Pre-adjustment: 2 mm

line width tolerance

Use this parameter to define the tolerance with which the line being checked will be seen as a valid line. The line width can only deviate from the reference by the value set up here. The tolerance value setting is always a ± value.

Setting range: 0.02 – 2.50 mm Pre-adjustment: 0.1 mm

position averaging This parameter can be applied to the measured value output. A new measured value will be imported directly if the setting is set to off. The numerical value describes the new measurement weighting used in the new measured value. This can attenuate the control process, so that, for example, the system will be prevented from overreacting by the torn material present after a splice.

\\parameter\splice misalignment\

\\parameter\line width tolerance\

\\parameter\position averaging\

Operation 5 31


Setting options: off 2 values 4 values 8 values 16 values 32 values 64 values 128 values 256 values

Pre-adjustment: off Example: The new measured value is determined as follows when using a weighting of 64 values:

recapture factor

Use this parameter to define the step width that the system will use for scanning the new edge / line position after the contrast was lost. The following benchmark value applies: Small value – for broken lines Big value – for a splice

Setting range: 0.001 – 10.000

Pre-adjustment: 0.01

web stop detection

Use this parameter to switch the automatic web movement detection on and off. If this function is switched on then web movement will be checked if the edge was lost. The search area will be only be opened if web movement has been detected or if an edge cannot be found. We recommend that the default setting is never changed.


Pre-adjustment: ON

5.7.3 Remote control ekr The remote control ekr sub-menu includes the gain factor Xp parameter. This enables you to enter the controller’s remote gain factor adjustment.

Setting range: 0.00 – 999.99

Sum of the last 64 values – last value + new value

64

\\parameter\recapture factor\

\\parameter\web stop detection\

Operation 5 31


5.7.4 Display

Attention: You can call up this sub-menu with password level Admin and in set-up mode. The sensor signal can be displayed on the panel’s screen in several different ways The display sub-menu is used to configure the signal display. You can select the type of display from here. You can select from the followings display settings:

1. Extended contrast view (default) 2. RGB 3. R 4. G 5. B

This display mode is essentially for service purposes and is used by BST for evaluating the sensor conditions.

Operation 5 31


5.7.5 System Info

General system information is displayed in the System Info sub-menu. You need this information to identify the equipment, e.g. when requesting support from BST service. The following pages will be displayed after you have called up this sub-menu:

Factory default settings 6 5


6. Factory default settings There are four stoppers fitted on the sensor’s connection side and the relevant switches are located behind them. The control panel switch is located on the back behind the stop. Which switches lie behind which stoppers is described below.

6.1 Device addresses The device addresses for the sensor and the control panel are pre-set in the factory. The settings usually do not have to be modified. Check the device address settings if malfunctions or non-defined sensor or operator panel processes occur or re-occur after the devices have been changed.

6.1.1 Sensor device address The sensor device address was preset to "1" in the factory (delivery state).

You are only allowed to modify the device address if authorized to do so by the manufacturer!

The sensor’s device address is set up using the S1 rotary switch. The current setting is displayed in the System info sub-menu as Sensor Node (see Section 5.7.5).

Danger from the power supply! You are only allowed to open the sensor if the power supply has been switched off!

Setting the device address: 1. Switch-off the power to the sensor.

2. Unscrew the stopper in the sensor enclosure

3. Check the S1 rotary switch setting The S1 rotary switch must be set to position “1“.

4. Switch the S1 rotary switch to position “1“ if necessary.

5. Screw the stopper back into the sensor enclosure.

6. Switch the power supply back on.

Switch settings Address 0 Reserved 1 41 2 42 3 43 4 44 5 45 6 46 7 47 8 48 9 Reserved



6.1.2 Control panel device address The control panel’s device address is set up using the S1 rotary switch fitted on the panel board. The S1 rotary switch is mounted behind stopper B on the back of the control panel. The control panel’s device address was preset to "1" in the factory (delivery state). The current setting is displayed in the System info sub-menu as Commander Node (see Section 5.7.5).

You are only allowed to modify the device address if authorized to do so by the manufacturer!

Danger from the power supply! The control panel’s connecting cable plug must be disconnected from the controller before you open the control panel!

Setting the device address: 1. Unplug the control panel connecting cable from the sensor.

2. Carefully remove stopper B from the back of the control panel.

3. Check the S1 rotary switch setting The S1 rotary switch must be set to position “1“.

4. Switch the S1 rotary switch to position “1“ if necessary.

5. Replace the stopper.

6. Reconnect the control panel connecting cable to the sensor.

Rotary switch S1

012345

6 7 8 9

Switch settings Address 0 Reserved 1 111 2 112 3 113 4 114 5 115 6 116 7 117 8 118 9 Reserved



6.2 Terminator resistors The internal terminator resistors for the sensor and the control panel were switched on in the factory. The settings usually do not have to be modified. Check the terminator resistor settings if malfunctions or non-defined sensor or operator panel processes occur or re-occur after the devices have been changed.

6.2.1 Sensor terminator resistors The sensor’s internal terminator resistor is switched on or off using switch S3. The current setting is displayed in the System info sub-menu as Can Resistor Sensor (see Section 5.7.2).

The terminating resistor should only be switched off after first obtaining agreement from the manufacturer!

Switch S3 Function

OFF Internal terminating resistor switched off

ON Internal terminating resistor switched on (default factory setting)

Danger from the power supply! You are only allowed to open the sensor if the power supply has been switched off!

Setting up the terminating resistor: 1. Switch-off the power to the sensor.

2. Unscrew the stopper in the sensor enclosure

3. Check the S3 switch setting. The S3 switch must be set to the “ON“ position.

4. Switch S3 to the “ON“ position if necessary.

5. Screw the stopper back into the sensor enclosure.

6. Switch the power supply back on.

Switch S3



6.2.2 Control panel terminator resistors The control panel’s internal terminator resistor is switched on or off using switch S3. The current setting is displayed in the System info sub-menu as Can Resistor Commander (see Section 5.7.2). The S3 switch is mounted behind stopper C on the back of the control panel.

The terminating resistor should only be switched off after first obtaining agreement from the manufacturer!

Switch S3 Function

OFF Internal terminating resistor switched off

ON Internal terminating resistor switched on (default factory setting)

Danger from the power supply! The control panel’s connecting cable plug must be disconnected from the controller before you open the control panel!

Setting up the terminating resistor: 1. Unplug the control panel connecting cable from the sensor.

2. Carefully remove stop C from the back of the control panel.

3. Check the S3 switch setting. The switch must be set to the “ON“ position.

4. Switch over to the “ON“ position if necessary.

5. Replace the stopper.

6. Reconnect the control panel connecting cable to the sensor.

ON OFF

Switch S3



6.3 Resetting factory default settings The Configuration sub-menu can only be called up in set-up mode and you have to be logged on as Admin.

Warning! All of the settings made during operation will be overwritten when the factory default settings are reset.

1. Open the main menu. 2. Select the select configuration menu option. Press

ENTER to open the menu. The following window will now be displayed:

3. Select the DEFAULT entry and then press ENTER to confirm your selection.

4. An information window will be displayed after the setting has been successfully imported.

5. Press ENTER to exit the menu. .

!

\\configuration\select configuration

Troubleshooting 7 1


7. Troubleshooting / FAQ

Item Error Possible cause Solution

1

• •

2

• •

3

• •

4

• •

5

• •

6

• •

7

• •

Technical data 8 6


8. Technical data 8.1 Sensor

8.1.1 Environmental conditions

Working temperature: 0 to 45°C Storage temperature: -10.3V to 50.00�, 12 bit +

158.00� Working humidity: 5 to 90%, not condensing Protection class: IP 54 Place of installation: In closed buildings

< 2000 m above sea level External light: The sensor and control panel

should be protected from direct sunshine

8.1.2 Power supply Voltage: 24V DC ± 10% (including ripple)

Power consumption: max. 0.5 A (including panel, 2 x lights 100% switched on and 80 mA external outputs)

8.1.3 Digital inputs 2 x digital inputs with metallic separation for path cycle / reset,

Input resistance: 4.7 kOhm each Switching threshold: < 4V (low), > 8V (high) switching sensor can be used for ”+“ only (pnp)

8.1.4 Digital outputs 1x error output, switched against +24V 1x external light switched against +24V 1x external light, trigger output, +12V / 5 mA both external light outputs have a joint load rating of 80 mA

8.1.5 Analog output 1 x analog output 0 - 10V, 5 mA Not protected against external overvoltage / polarity reversals

8.1.6 Measuring window cover Laminated safety glass with PVB film as per EN 1565 and EN 167

Technical data 8 6


8.1.7 Control panel interface

Voltage: 24V DC (corresponds to the power supply)

Current: max. 0.5 A (protected by a polyfuse)

Bus interface: 500k baud, No metallic isolation

Connection: Plugged in from the outside using a 4-pin micro style M8 connector

8.1.8 Weight, dimensions Weight: Approx. 1.18 kgs

(sensor without control panel and holder)

Dimensions: See Chapter 8.2.5

8.2 Control panel

8.2.1 Environmental conditions Working temperature: 0 to 45°C

Storage temperature: -10.3V to +70°C

Working humidity: 5 - 90%, not condensing

Protection class: IP 50

8.2.2 Power supply Voltage: 24V DC

(power supplied by the sensor)

8.2.3 Display LCD TFT color graphics module

Resolution: 320 x 240 pixels, LED background lighting

8.2.4 Weight, dimensions Weight: approx. 0.26 kgs Dimensions: See Chapter 8.2.5

Technical data 8 6


8.2.5 Space requirement Sensor with mounted control panel and holder: Sensor with holder but without control panel:

(Details in mm)

Swiveling panel View A

Material web

74 52(4) 17

52(4)

10,5

43,5

60

Scan point

85 77

Sensing roller

112 A

Adapter

160

25(1

)

1,5 25(1) 20

116

123,5(2) / 128,5(3)

175(2) / 180(3)

Scan point

Material web

112

190

25(1

)

1,5

25(1) 20

116

175(2) / 180(3)

123,5(2) / 128,5(3)

(1) The details refer to the use of a 25x25 mm square bar. The adapter is not needed if a 35x35 mm square bar is used. (2) Gap when using a 25x25 mm square bar. (3) Gap when using a 35x35 mm square bar. (4) Sensor offset by 180°

Sensing roller

Technical data 8 6


Sensor with mounted control panel but without holder: Holder must be provided by the customer; See Section 2.2.3 for the connection dimensions Sensor without control panel and holder: Holder must be provided by the customer; See Section 2.2.3 for the connection dimensions

Swiveling panel Securing points for customer’s holder (on both sides)

min

. 170

mm

sp

ace

need

ed to

sw

ivel

the

pane

l

Material web

Scan point

85 77

1 Sensing roller

1

Note interference

contours 90

1,5

90 20 Measuring

area 145143 min. 75

B Laser position

Securing points for customer’s holder (on both sides)

Material web

Scan pointSensing roller

49.8

90

60

Measuring area

143

Laser position

min. 75

Customer’s holder

20

1,5

90

Technical data 8 6


Control panel:

8.2.6 Plug pin assignments A 4-pin micro style M8 connector is used to connect the control panel to the sensor and the sensor to the controller. Contact assignments in the plug connector:

8.2.6.1 Plug X100; control panel Plug (male)

8.2.6.2 Plug X101; controller connection Socket (female)

Contact Signal Remark

1 +24 V +24 V power supply 2 CAN_H CAN Bus 3 GND Power supply ground 4 CAN_L CAN Bus

21 105

693

93

105

100

X

View X

1

2

3

4

1

2

3

4

X

View X

Technical data 8 6


8.2.6.3 Plug X80; I/O connection

Contact assignments in the plug connector: Socket (female) Plug (male)

Contact Function Remark 1 GND Ground for Contact 2 and Contact 3 2 DOUT +24V output 3 LAMP_PLUS External lighting

+24V output 4 LAMP_TRIG External lighting, trigger O/P, +12V / 5 mA 5 ANALOG_OUT Analog output 0 - 10V 6 EXT_GND Insulated ground for Contact 7 and Contact 8 7 EXT_GEAR External synchronization cycle 8 EXT_RESET External synchronization reset

X

View X

12

3

4 5

6

7

8

1 2

45

6

7 X

View X

3

8

Maintenance 9 1


9. Maintenance 9.1 General information

Beware! Maintenance and cleaning work must only be undertaken on the sensor and the control panel after the power supply has been switched off.

Ensure the equipment is electrically isolated before you start any work. To this end always carry out the following measures: 1. Switch off and disconnect. 2. Protecting against the voltage being switched back on 3. Determine that the unit is ‘voltage-free’ 4. Earth the unit. 5. Covering or protect yourself from any adjoining part that are still

live. Only then can the relevant work be undertaken! The maintenance and/or cleaning intervals depend on the environment conditions at the installation site. If the customer is processing very dusty materials then the maintenance / cleaning intervals must be reduced accordingly. In principle, cable connections can only be disconnected after the sensor itself has been disconnected from the power supply. Any guarantee claims will be invalidated if this instruction is ignored.

9.2 Sensor The sensor is classified as an optical instrument. It must be looked after accordingly.

The cleaning of the casing should be carried out with a dry, clean and soft cloth. A commercial liquid cleaner may be used if the casing is very dirty. Adhere to protection class IP 54! The measuring window’s protective lens cover must be cleaned regularly in order to obtain optimum guiding results. Spotted or homogeneous dirtying of the lenses can result in wrong readings.

9.3 Control panel The control panel is a maintenance-free unit.

The cleaning of the casing should be carried out with a dry, clean and soft cloth. A commercial liquid cleaner may be used if the casing is very dirty. Adhere to protection class IP 54!

Transport/Storage 10 1


10. Transport / Storage 10.1 Transportation

The equipment will be shipped in accordance with the details stipulated in the order: • Completely assembled and interconnected to the web guiding

control system • as component parts in standard cardboard boxes with cellular

lining material The unit must only be transported when it is packed in the original BST transport packing. BST International GmbH will not be liable for damage to the sensor or control panel caused by incorrect transport packaging!

10.2 Storage If the sensor and the control panel have been shipped as individual parts and will not be installed immediately, they must be stored in a dry room prior to installation. Storage conditions: Temperature: -10°C up to +70°C (max.)

Humidity: 10 - 90%, no condensation

Decommissioning 11 1


11. Decommissioning Decommissioning (scraping) of the system must be carried out together with the entire machine. The necessary procedures must be prepared by the manufacturer of the machine. You must take into consideration that the edge and line contrast sensor is generally considered to be an electrical / electronic device, which must be disposed of in accordance with the current legal requirements. You may also be able to return the system to BST International GmbH. The corresponding agreement must be made first.

Index I 1

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Index with removable control panel Date: 07.11.2008 Page: 84/86

Index Assigning user levels to the parameters ......... 50 ATEX ......................................................... 11, 13 Automatic mode............................................... 41 Benutzerebene zuordnen ................................ 48 Bus status........................................................ 24 Cable connections ............................... 11, 23, 81 Cable extension........................................... 4, 17 Commissioning

Stand alone system..................................... 37 Commissioning with controller CCD Line Guider

..................................................................... 36 Commissioning with controller EKR 1500 ....... 36 Commissioning with controller ekr 500 Plus.... 36 Commissioning with controller ekrPro Com60 33 Control panel ................................................. 4, 9

Cable guide ................................................. 16 Connection cable........................................... 4 Console mounting ....................................... 21 Dimensions.................................................. 79 Display......................................................... 76 Environmental conditions ............................ 76 Installation ................................................... 17 Installation cut-out ....................................... 21 Installation versions..................................... 17 Key functions............................................... 10 Maintenance................................................ 81 Power supply............................................... 76 Securing hole diagram ................................ 18 Securing kit.................................................. 21 Securing set ................................................ 17 Setting the device address.......................... 70 Technical data ............................................. 76 Terminator resistors .................................... 72 Turning the control panel ............................ 15 Wall mounting.................................. 17, 18, 19 Weight ......................................................... 76

Decommissioning ............................................ 83 Deleting a job................................................... 49 Device addresses ............................................ 69 DIL switch

DIL switch S4 .............................................. 25 Setting for stand-alone system.................... 25 Setting for use with ekrPro Com60............... 25

Display............................................................. 76 Scan mode .................................................. 39 Set-up Mode................................................ 38

Emissions ........................................................ 12 Environmental conditions ................................ 13 Expanded operation ........................................ 48 Factory default settings ............................. 69, 73

Resetting factory default settings ................ 73 Fehlersuche (FAQ) .......................................... 74 Firmware

Firmware adding ........................................... 2 First edge / second edge................................... 8 Free headroom................................................ 11 Graphics display................................................ 9 Input options.................................................... 27

Alphanumerical input .................................. 28 Installation ....................................................... 23 Installation site................................................. 13 Intended use...................................................... 3 Laser................................................................ 12 Laying of cables .............................................. 11 LED operating statuses..................................... 1 Main menu....................................................... 30

Navigation ................................................... 30 Maintenance.................................................... 81 Manual mode................................................... 41 Menu structure ................................................ 32 Menus.............................................................. 27 Operating display ............................................ 38 Operating manual

Use................................................................ 2 Operating Manual

Symbols ........................................................ 1 Operating mode

Center positioning ....................................... 42 Operating modes

Automatic .................................................... 41 Manual mode .............................................. 41

Operating principle ............................................ 5 Operation................................................... 38, 43 Operation display ............................................ 39 Parameters of the main menu

Configuration............................................... 52 Commander ................................................ 52 edit menu configuration............................... 59 mounting position........................................ 59 remote control ekr ....................................... 57 Sensor......................................................... 54 Display ........................................................ 67 Parameter ................................................... 60 adaption settings......................................... 64 contrast detection........................................ 61 contrast tracking.......................................... 61 destination................................................... 61 illumination .................................................. 60 jobs.............................................................. 60 line width tolerance ..................................... 65 position averaging....................................... 65 recapture factor ........................................... 66 splice misalignment..................................... 65 web stop detection ...................................... 66 Remote control ekr...................................... 66 System info ................................................. 68

Plug pin assignments ...................................... 79

Index I 2

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Index with removable control panel Date: 07.11.2008 Page: 85/86

Potentially explosive areas................................ 3 Remote control ................................................ 41

Move the guiding device ............................. 42 Move the set point ....................................... 42

Safety information........................................ 2, 11 Saving a job..................................................... 49 SC mode.......................................................... 42 Selecting a job ................................................. 49 Sensor

Analog output .............................................. 75 Control panel interface ................................ 76 Digital inputs................................................ 75 Digital outputs.............................................. 75 Dismantling the BST holder ........................ 18 Enclosure socket ......................................... 23 Environmental conditions ............................ 75 Installation ................................................... 13 Installation with BST holder......................... 13 Installation with holder supplied by the

customer ................................................. 14 LED ............................................................. 24 Maintenance................................................ 81 Measuring window cover............................. 75 Power supply............................................... 75 Service indicator displays............................ 24 Setting the device address.......................... 69

Setting the gap between the sensor and the scanning roller ........................................ 15

Structure........................................................ 4 Technical data............................................. 75 Terminator resistor...................................... 71

Set position........................................................ 7 Setting up quick menus................................... 51 Set-up.............................................................. 43

Activating set-up ......................................... 43 Edge mode.................................................. 45 Line mode ............................................. 46, 47 Standard...................................................... 46 Tracking area .............................................. 47

Space requirement .................................... 77, 78 with holder, with panel ................................ 77 with holder, without panel ........................... 77 without holder, with panel ........................... 78 without holder, without panel ...................... 78

Status bar ........................................................ 40 Storage............................................................ 82 System

Standard working ........................................ 43 Technical data ........................................... 75, 76 Terminator resistors ........................................ 71 Terms used ....................................................... 7 Transportation ................................................. 82

Commissioning example A1

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Chapter: A1 with removable control panel Date: 07.11.2008 Page: 1/1

A1 Commissioning example

Saving parameters A2


A2 Saving the parameters and

loading the firmware

A2.1 Save parameters System configurations and saved jobs can be backed-up and saved on an external medium (a PC running MS Windows). Use the sensor’s USB interface to transfer the data. Procedure:

1) Unscrew the stop from the sensor enclosure that is fitted in front of the USB interface and then find the button that activates the memory function .

2) Use a mini USB cable to connect the sensor up to a PC or a laptop.

3) Activate the sensor’s memory function. In this case you must press the function activation button. The sensor will now be seen as another PC / laptop drive.

4) Copy the required data from the settings directory into a directory that you previously created for this purpose in the PC / laptop.

5) Call up the ”Safely remove hardware“ function from the task-bar after you have saved the data and then cancel the connection.

6) Disconnect the cable afterwards and then screw the stop back into the sensor enclosure.

7) Now run a sensor restart (mains OFF / ON).

2 1

2 1 +24 V

4

3

3

4



A2.2 Loading the firmware

If the sensor or control panel firmware has been modified then the firmware must be loaded separately for both devices. Use the control panel and sensor USB interfaces to load the firmware updates.

A2.2.1 Loading the sensor firmware Procedure:

1) Unscrew the stop from the sensor enclosure that is fitted in front of the USB interface and then find the button that activates the memory function .

2) Use a mini USB cable to connect the sensor up to a PC or a laptop.

3) Activate the sensor’s memory function. In this case you must press the function activation button . The sensor will now be seen as another PC / laptop drive.

4) Load the new firmware. Sensor firmware can be recognised by the ‘S’ in the file name, e.g. CLSPro600_S_1.6.1_A.bim. The new firmware must be copied into the Update directory. The directory must be created if it does not exist.

5) Call up the ”Safely remove hardware“ function from the task-bar after you have loaded the firmware and then cancel the connection.

6) Disconnect the cable afterwards and then screw the stop back into the sensor enclosure.

7) Now run a sensor restart (mains OFF / ON). The restart should take approx. 40 seconds. The firmware will be automatically loaded into the system during this time.

32

1

4

2 1 +24 V

3

4



A2.2.2 Loading the panel firmware

1) Unscrew the stop from the back of the panel that is fitted in front of the USB interface and then find the button that activates the memory function .

2) Use a mini USB cable to connect the panel up to a PC or a laptop.

3) Activate the panel’s memory function. In this case you must press the function activation button . The panel will now be seen as another PC / laptop drive.

4) Load the new firmware. Panel firmware can be recognised by the ‘C’ in the file name. The new firmware must be copied into the Update directory. The directory must be created if it does not exist.

5) 6) Call up the ”Safely remove hardware“ function from

the task-bar after you have loaded the firmware and then cancel the connection.

7) Disconnect the cable afterwards and then screw the stop back in.

8) Now run a panel restart. The restart should take approx. 40 seconds. The firmware will be automatically loaded into the system during this time.

2 4

1

2 1 3

+24 V 3

4

Default settings A3


A3 Factory default settings Menu Sub-menu 1 Sub-menu 2 Parameters Access

password level Default value

Application

Change User User level Operator Operator display dim time [min]

Admin 5 commander

active USB Admin Manual settings enable alter-

native edge Admin Deactivated

enable alter-native 2nd edge

Admin Deactivated

enable alter-native line

Admin Deactivated

hide menu Admin activated disable

operating error dialog

Admin activated

guiding mode Admin keep value active USB Admin white balance Admin adjust sensor Service guiding block delay [ms}

Admin 20

dig. Out reset delay [ms]

Admin 0

dig. Out set delay [ms]

Admin 0

mode digital out Admin

sensor

guiding edge Admin median of 1 and 2

internal W-Val Admin Deactivated enable remote control

Admin activated

unit of guiding position

Maintenance mm

step width of guiding position

Maintenance 0.05 mm

fast step width of guiding position

Maintenance 0.2 mm

remote control ekr

time to increase step width

Maintenance Deactivated

select Admin A (A) Teach in Admin (A) Sensor inverted

Admin Deactivated

(A) Guiding direction

Admin Deactivated

(A) Remote control inv.

Admin Deactivated

Configuration

mounting position config. position A

(A) W-Value control inv.

Admin Deactivated

Default settings A3


Menu Parameter level 1

Parameter level 2

Parameter level 3

Access password level

Default value Application

(B) enable Admin Deactivated (B) Teach in Admin Deactivated (B) Sensor inverted

Admin Deactivated

(B) Guiding direction

Admin Deactivated

(B) Remote control inv.

Admin Deactivated

config. position B

(B) W-Value control inv.

Admin Deactivated

(C) enable Admin Deactivated (C) Teach in Admin Deactivated (C) Sensor inverted

Admin Deactivated

(C) Guiding direction

Admin Deactivated

(C) Remote control inv.

Admin Deactivated

config. position C

(C) W-Value control inv.

Admin Deactivated

(D) enable Admin Deactivated (D) Teach in Admin Deactivated (D) Sensor inverted

Admin Deactivated

(D) Guiding direction

Admin Deactivated

(D) Remote control inv.

Admin Deactivated

config. position D

(D) W-Value control inv.

Admin Deactivated

edit menu configuration

Admin

select configuration

Admin

save configuration

Admin

delete configuration

Admin

choose job Operator save job Admin

jobs

delete job Admin time [ms] Maintenance 2 internal Operator Automatik brightness Maintenance 7 automatic Maintenance activated optional Operator brightness Maintenance 0

Parameter

illumination

automatic Maintenance Deactivated

Default settings A3


Menu Parameter level

1 Parameter level

2 Parameter level

3 Access

password level Default value

Application

external Operator Deactivated brightness Maintenance

automatic Maintenance destination [%] Maintenance 100

quality Maintenance 45 auto adjustment Maintenance activated

contrast detection

min. line width [mm]

Maintenance 0.3

edge color Operator All edge intensity Maintenance Deactivated line color Maintenance Deactivated line intensity Maintenance Deactivated edge polarity Maintenance activated edge sharpness


environment Maintenance activated

contrast tracking plausibility check

contrast quality Maintenance Deactivated general balancing Maintenance 256 value color Maintenance activated contrast Maintenance activated edge sharpness Maintenance activated line width Maintenance activated

adaption settings

environment Maintenance activated splice misalignment [mm]

Maintenance 3

line width tolerance [mm]

Maintenance 0,1

position averaging


recapture factor

Maintenance 00.050

web stop detection

Maintenance activated

remote guiding controller

gain factor Xp 006.00

display signal view type Maintenance extended contrast view

System info Operator

Connection BST STB 1 A4


A4 BST Signal Terminal Box 1 (BST STB 1) connections General information

The sensor can be connected up to the customer’s controller using via a terminal strip (optional). A BST STB 1 must be used in this case. This will link to the sensor via a cable and plug. The separate cable wires will be fed to a terminal strip inside the BST STB 1. The connections to the customer’s machine can then be made from here.

Terminal Function Remark 1 GND Ground for Pin 2 and Pin 3 2 DOUT +24V output 3 LAMP_PLUS External lighting

+24V output 4 LAMP_TRIG External lighting, trigger O/P,

+12V / 5 mA 5 ANALOG_OUT Analog output 0 - 10V 6 EXT_GND Insulated ground for Pin 7 and

Pin 8 7 EXT_GEAR External synchronization cycle 8 EXT_RESET External synchronization reset

Installation

Warning! Only qualified and trained personnel are permitted to undertake the electrical connections!

The system must be wired according to the accompanying connection diagram or plugged into the appropriate cable sockets.

Standard wiring sleeves with collars (DIN 46228/ Part 4) must be used with all cable connections up to 0.75 mm². Wiring sleeves must not be used with cables from 0.75 mm² up to a maximum of 1.5 mm².

Using wiring sleeves: The crimping is also gas-tight (no cross crimping) i.e. there is no gap between the conductor and the wiring sleeve. We recommend using VarioCrimp-4-Zange 206-204 crimping pliers made by WAGO. The length of the metal sleeves fitted on the wiring sleeve must be at least 8 mm.

Connection cable (from X80)

Terminal strip

M16 cable screws Optional outputs (sealed by plugs)

!

Metal sleeve



Using cable without wiring sleeves: For fine and multi-core cable and for fine-wired cable, whose kink resistance is not sufficient due to its small diameter, in order to overcome the contact force of the clamping springs, the clamp must be correctly opened using a screwdriver. Check that all the cables are fitted tightly after the connections have been made (in both cases). Installation instructions for EMC-wiring

1. Unscrew in the union nut for the cable

screw-in cable glands. 2. Pull out the clamping insert from the

intermediate supports. 3. Strip cable back by 8 mm so that the

screen braiding is uncovered. 4. Pull the union nut onto the cable 5. Feed the cable into the cable clamp

and bend the screening back over the cable clamp.

Union nut

Clamp insert

Enclosure wall

Attention! Do not squash the clamping insert when

removing it (do not press down on it

Intermediate support



6. Push the clamping insert to the

intermediate support. 7. Fit the screws.

Teach-in model A5


A5 Teach-in model

CLS Pro 600

Teach-in model

Aligning the teach-in model in front of the CLS Pro 600

Material web

Documents

BST CLSPro 600 User manual