BST CLS Pro 600 User manual

Web Guiding System
Installation and
Operating Manual
CLS Pro 600
Line and Contrast Sensor
MD.323.EN.08
Translation of the Original Manual

BST eltromat International GmbH
Heidsieker Heide 53
D-33739 Bielefeld
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.bst-eltromat.com
This documentation is protected by copyright. The translation as well as reproduction and distribution in any form is forbidden without the approval
of the rights holder and will be pursued under civil and criminal law. Technical modifications reserved.

Table of contents
CLS Pro 600 – Line and Contrast Sensor iii
Table of contents
1 About This Document........................................................................................ 6
1.1 What You Need to Know............................................................................................... 6
1.2 Target Group................................................................................................................. 6
1.3 Storage and Distribution............................................................................................... 6
1.4 Meanings of the Safety Instructions and Symbols........................................................ 6
1.4.1 Safety Instructions ........................................................................................................ 6
1.4.2 Symbols......................................................................................................................... 7
1.4.3 Operation Using Keys.................................................................................................... 7
1.5 More Detailed Information........................................................................................... 7
2 Description ....................................................................................................... 8
2.1 General Information ..................................................................................................... 8
2.2 Intended Use................................................................................................................. 8
2.3 System Description ....................................................................................................... 9
2.3.1 System Design............................................................................................................... 9
2.3.2 Functional Principle..................................................................................................... 10
2.4 Terms Used in this Manual ......................................................................................... 12
2.4.1 General Information ................................................................................................... 12
2.4.2 Set Position ................................................................................................................. 13
2.4.3 Measuring Range ........................................................................................................ 14
2.4.4 Search Area................................................................................................................. 14
2.4.5 Status Bar.................................................................................................................... 15
2.4.6 Footer.......................................................................................................................... 15
2.4.7 First Edge / Second Edge............................................................................................. 15
2.5 Control Panel .............................................................................................................. 16
2.5.1 Graphic Display ........................................................................................................... 16
2.5.2 Control Panel .............................................................................................................. 16
2.6 Safety Information ...................................................................................................... 17
2.7 Laser............................................................................................................................ 19
2.8 Emissions..................................................................................................................... 19
3 Assembly .........................................................................................................20
3.1 Installation Site Requirements.................................................................................... 20
3.2 Sensor Installation ...................................................................................................... 20
3.2.1 General Information ................................................................................................... 20
3.2.2 Sensor with supplied holder ....................................................................................... 20
3.2.3 Installing the Sensor Using a Holder Supplied by the Customer................................. 21
3.2.4 Setting the Gap Between the Sensor and the Sensing Roller ..................................... 22
3.2.5 Turning the Control Panel........................................................................................... 22
3.2.6 Rotating the Control Panel.......................................................................................... 24
3.3 Installing the Control Panel......................................................................................... 25
3.3.1 General Information ................................................................................................... 25
3.3.2 Dismantling the Holder............................................................................................... 25
3.3.3 Wall Mounting ............................................................................................................ 27
3.3.4 Console Installation..................................................................................................... 31
4 Installation.......................................................................................................35
4.1 Fitting the Cable Connections..................................................................................... 35
4.2 Sensor ......................................................................................................................... 35
4.2.1 Enclosure Sockets ....................................................................................................... 35
4.3 Service Indicator Displays ........................................................................................... 36
4.3.1 Bus Status LEDs ........................................................................................................... 36
4.3.2 Unit Status LED............................................................................................................ 37
4.4 Setting the DIL Switches.............................................................................................. 37
5 Commissioning.................................................................................................38
5.1 Menus ......................................................................................................................... 39

Table of contents
iv CLS Pro 600 – Line and Contrast Sensor
5.1.1 General Information ................................................................................................... 39
5.1.2 Input Options .............................................................................................................. 39
5.1.3 Main Menu.................................................................................................................. 41
5.2 Commissioning With a Controller ............................................................................... 43
5.2.1 ekrPro Com60 ............................................................................................................. 43
5.2.2 ekr 500 Plus / ekr 500 digital ...................................................................................... 44
5.2.3 EKR 1500 / CCD Line Guider and C2M Coupler........................................................... 44
6 Operation ........................................................................................................45
6.1 General Information ................................................................................................... 45
6.2 Operating Display........................................................................................................ 45
6.2.1 Setup Mode Display Window...................................................................................... 45
6.2.2 Scanning Mode Display Window................................................................................. 47
6.2.3 Status Bar.................................................................................................................... 48
6.3 Remote Control of ekrPro Com60 / ekr 500 Plus / ekr 500 digital Controllers........... 48
6.3.1 Manual Mode.............................................................................................................. 49
6.3.2 Automatic ................................................................................................................... 49
6.3.3 Servo Center Position.................................................................................................. 49
6.3.4 Moving the Set Point Position (W-value).................................................................... 50
6.3.5 Moving the Guiding Device......................................................................................... 50
6.3.6 Setting the Controller Gain ......................................................................................... 50
6.4 Operation.................................................................................................................... 51
6.4.1 General Information ................................................................................................... 51
6.4.2 Activating Line Setup / Edge Setup ............................................................................. 51
6.5 Standard Operation .................................................................................................... 51
6.5.1 Selecting a Job............................................................................................................. 51
6.5.2 Edge Setup Mode........................................................................................................ 52
6.5.3 Line Setup Mode......................................................................................................... 54
6.6 Extended Operation.................................................................................................... 56
6.6.1 Change User................................................................................................................ 56
6.6.2 Job Administration...................................................................................................... 57
6.6.3 Assigning User Levels to the Parameters.................................................................... 58
6.6.4 Setting up Quick Menus.............................................................................................. 59
6.6.5 Setup Administration .................................................................................................. 60
6.7 Main Menu Parameter Meanings............................................................................... 61
6.7.1 Configuration .............................................................................................................. 61
6.7.2 Parameter ................................................................................................................... 68
6.7.3 Remote Control EKR.................................................................................................... 75
6.7.4 Display......................................................................................................................... 76
6.7.5 System Info ................................................................................................................. 77
7 Factory Default Settings ...................................................................................78
7.1 Device Addresses ........................................................................................................ 78
7.1.1 Sensor Device Address................................................................................................ 78
7.1.2 Control Panel Device Address..................................................................................... 79
7.2 Terminator Resistors................................................................................................... 80
7.2.1 Sensor Terminator Resistors....................................................................................... 80
7.2.2 Control Panel Terminator Resistor.............................................................................. 81
7.3 Restoring Factory Default Settings.............................................................................. 82
8 Troubleshooting / FAQ.....................................................................................83
9 Technical Data .................................................................................................84
9.1 Sensor ......................................................................................................................... 84
9.1.1 Environmental Conditions .......................................................................................... 84
9.1.2 Power Supply .............................................................................................................. 84
9.1.3 Digital Inputs............................................................................................................... 84
9.1.4 Digital Outputs............................................................................................................ 84
9.1.5 Analogue Output......................................................................................................... 84
9.1.6 Measuring Window Cover .......................................................................................... 85

Table of contents
CLS Pro 600 – Line and Contrast Sensor v
9.1.7 Control Panel Interface............................................................................................... 85
9.1.8 Weight / Dimensions .................................................................................................. 85
9.2 Control Panel .............................................................................................................. 85
9.2.1 Environmental Conditions .......................................................................................... 85
9.2.2 Power Supply .............................................................................................................. 85
9.2.3 Display......................................................................................................................... 85
9.2.4 Weight / Dimensions .................................................................................................. 85
9.2.5 Space Requirement (Details in mm) ........................................................................... 86
9.2.6 Plug Assignment.......................................................................................................... 88
10 Maintenance....................................................................................................90
10.1 General Information ................................................................................................... 90
10.2 Sensor ......................................................................................................................... 90
10.3 Control Panel .............................................................................................................. 90
11 Transport / Storage..........................................................................................91
11.1 Transport..................................................................................................................... 91
11.2 Storage........................................................................................................................ 91
12 Decommissioning.............................................................................................92
Index................................................................................................................93
A Appendix 1 - Commissioning as a Stand-Alone System .....................................95
A1 Blockage...................................................................................................................... 95
A2 Control Signal.............................................................................................................. 95
A3 Commissioning............................................................................................................ 95
A4 Configuring the Guiding Block Output ........................................................................ 96
A5 Defining the Mounting Position.................................................................................. 97
B Appendix 2 - Saving Parameters and Loading Firmware....................................98
B1 Save Parameters ......................................................................................................... 98
B2 Loading Firmware ....................................................................................................... 98
B2.1 Loading Sensor Firmware............................................................................................ 99
B2.2 Loading Panel Firmware.............................................................................................. 99
C Appendix 3 - Factory Default Settings.............................................................100
D Appendix 4 - BST eltromat STB 1 Connections ................................................104
D1 Installation Instructions For EMC-Wiring.................................................................. 105
E Appendix 5 - Teach-in Template .....................................................................107
E1 Aligning the Teach-In Template in Front of the CLS Pro 600 .................................... 108

1About This Document
6/108 CLS Pro 600 – Line and Contrast Sensor
1 About This Document
1.1 What You Need to Know
These instructions help you to work with the system in a safe,
simple and successful manner.
The following instructions must be observed in order to avoid haz-
ards and incorrect operation:
■Every user must have read these instructions in full before
working with or on the system.
■Every user must follow the safety information in these instruc-
tions.
1.2 Target Group
These instructions are directed to all persons that work with or on
the system. The operating company of the entire system and su-
pervising personnel must also be familiar with these instructions.
1.3 Storage and Distribution
These instructions must be stored at the workplace in such a man-
ner that the user has access to them at all times.
These instructions and all other applicable documents are a com-
ponent of the product and must be handed over to the operating
company of the system.
1.4 Meanings of the Safety Instructions and Symbols
1.4.1 Safety Instructions
DANGER
Danger that will lead to death or severe injuries!
►Here you can find how to avoid the danger.
WARNING
Danger that may lead to death or severe injuries!
►Here you can find how to avoid the danger.
CAUTION
Danger that may lead to medium or minor injuries!
►Here you can find how to avoid the danger.
NOTICE
Danger that may lead to damage to assets!
There is no risk of injury.
►Here you can find how to avoid the danger.

About This Document 1
CLS Pro 600 – Line and Contrast Sensor 7/108
1.4.2 Symbols
Information that is essential for successful operation.
Information that makes operation easier.
Action requirements may include the following symbols:
›› Requirements that must be fulfilled for the action steps.
1. Requirement for you to take actions. And ...
2. …in the sequence specified.
►Requirement for you to take actions - without any certain se-
quence.
1.4.3 Operation Using Keys
Operations using the keys are indicated by the following symbols:
►Press key ①.
►Press key ① or key ②.
►Press key ① and key ② at the same time.
1.5 More Detailed Information
►Observe the accompanying documents (e.g. order confirma-
tion) for this system and the operating instructions of the en-
tire system.
The latest version of these instructions can be obtained in all
available languages at:
www.bst-eltromat.com

2Description
8/108 CLS Pro 600 – Line and Contrast Sensor
2 Description
2.1 General Information
WARNING
Please note:
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 theCLS Pro
600line and contrast sensor after you have read the accompany-
ing 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 theCLS Pro 600sensor must abide by
this operating manual and the safety instructions in particular.
You must read, without fail, the safety instructions  given in
Chapter 2.6 of this operating manual prior to starting the installa-
tion and commissioning work!
Solely BST-eltromat staff or other persons specifically authorized
by BST-eltromat 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 ex-
plicitly states otherwise.
The latest version of the operating manual for the CLS Pro 600line
and contrast sensor can be obtained via the Internet in all avail-
able languages under the following address:
http://www.bst-eltromat.com
2.2 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
2006/42/EC (machine directive). Start-up of the system is forbid-
den until the user / operator has determined that the machine, in
which the system is installed, conforms to the conditions of this
directive.

Description 2
CLS Pro 600 – Line and Contrast Sensor 9/108
The CLS Pro 600line and contrast sensor is an integral part of our
BST-eltromat web guiding systems. You are only allowed to use
BST-eltromat 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-eltromat 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-eltromat web guiding
systems and other equipment. Therefore BST-eltromat web guid-
ing systems are only to be used if they are working correctly and
in a technically safe condition. Any part found to be working incor-
rectly 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 con-
ditions and safety regulations. In this case any guarantee claims
made against the BST-eltromat web guiding system will be invalid-
ated. Only qualified personnel who have been trained on the sys-
tem are allowed to undertake any work required on the BST-eltro-
mat web guiding system (i.e. installation, commissioning, opera-
tion, maintenance, etc.). Intended use also includes adhering to
the instructions given in this operating manual. Use for any pur-
pose other than those mentioned above is considered as contrary
to the intended use. BST eltromat International GmbH does not
accept liability for any damage resulting from this type of use.
2.3 System Description
2.3.1 System Design
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.
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.

2Description
10/108 CLS Pro 600 – Line and Contrast Sensor
Fig.1: Sensor with fitted control panel
Sensor with Removable Control Panel
If necessary (i.e. if the sensor is installed in a difficult to access po-
sition on the machine) the control panel can be removed and in-
stalled in a central control console or a customer-supplied control
station. In this case the connection between the sensor and con-
trol panel is completed using a cable extension that is available as
an optional extra.
Sensor
Control Panel
Cable Extension
(2 m, 5 m, 10 m)
Fig.2: Sensor with control panel removed
NOTICE
Please note:
The length of the connection cable between the sensor and the
control panel must never exceed 20 m (maximum).
2.3.2 Functional Principle
The sensor records the actual position of a line or a contrast trans-
ition point on the material web in automatic mode and then trans-
mits 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 configura-
tions:

Description 2
CLS Pro 600 – Line and Contrast Sensor 11/108
Stand-Alone Mode:
Customer's machine
controller
Sensor CLS Pro 600
with control panel
BST eltromat Signal
Terminal Box1
Fig.3: Stand-Alone Mode
Application with ekrPro Com60 controller:
Customer's
machine
controller
Sensor CLS Pro 600
with control panel
BST eltromat Signal
Terminal Box1 (optional)
CAN bus connection
(optional)
Fig.4: Application with ekrPro Com60 controller
Application with ekr 500 digital controller:
Customer's
machine
controller
Sensor CLS Pro 600
with control panel
BST eltromat Signal
Terminal Box1 (optional)
CAN bus connection
(optional)
Fig.5: Application with ekr 500 digital controller

2Description
12/108 CLS Pro 600 – Line and Contrast Sensor
Application with EKR 1500 / CCD line guider as CCD 2004 replacement:
Sensor CLS Pro 600
with control panel
(from software version 1.8.1)
CAN – Module bus coupler
EKR 1500
CCD Line Guider
Fig.6: Application with EKR 1500 / CCD line guider as CCD 2004 replacement
2.4 Terms Used in this Manual
2.4.1 General Information
In principle, the windows displayed on the keyboard’s graphics
display are laid out as follows:
Fig.7: Display Layout
①Status Bar
②Footer

Description 2
CLS Pro 600 – Line and Contrast Sensor 13/108
③Display Area
The content shown in this area depends on the mode set-
ting. Detailed descriptions can be found in Section 6.2.1 for
the setup mode and in Section 6.2.2 for the scanning mode.
2.4.2 Set Position
The set position is the required line / contrast transfer point posi-
tion in the sensor scanning area. It can be set up in Automatic
mode using the control panel’s arrow keys (see Chapter 6.3.2).
The set point position will be indicated by a white triangledis-
played on the control panel’s screen.
Fig.8: SET POINT Position without deviation
①Center of Measuring Range
②Contrast Quality (graphical)
③Standard SET Position
The deviation will be faded in as plaintext during displacement of
the set position. The deviation can take positive values and negat-
ive values as well.

2Description
14/108 CLS Pro 600 – Line and Contrast Sensor
Fig.9: Deviation of the SET POINT Position
④Standard SET Position
⑤Numeric Indication of the Deviation
⑥Center of Measuring Range
The contrast quality will be graphically displayed in the bottom
section of the window.
2.4.3 Measuring Range
The sensor’s measuring range is 25 x 3 mm (W x H).
Fig.10: Measuring Range
2.4.4 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.

Description 2
CLS Pro 600 – Line and Contrast Sensor 15/108
2.4.5 Status Bar
The actual sensor status and the controller’s actual operating
status are both displayed in the status bar. See Section 6.2.3 as
well regarding this.
The controller details are not displayed in the stand-alone version.
2.4.6 Footer
Operating help is integrated in the footer. This tells you when op-
timisations can be implemented in the displayed window or what
the actual setting of the selected parameter is and how it can be
configured.
2.4.7 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 avail-
able for use as options.
The edge position on the left of the display must be used for set-
ting up the First Edge.
Fig.11: First Edge / Second Edge
①First Edge
②Second Edge
The second edge is used for setting up the Second Edge

2Description
16/108 CLS Pro 600 – Line and Contrast Sensor
2.5 Control Panel
Fig.12: Control Panel
The control panel contains all of the display and operating con-
trols needed to operate the CLS Pro 600.
2.5.1 Graphic 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 meaning of the individual symbols is described in chapter 6.2.
2.5.2 Control Panel
Three different groups of keys are integrated in the control panel
and they have the following functions:
SETUP Keys Used to select setup mode
Blue Keys:
Used to access the menu; import the
parameters or exit the parameter enter-
ing process
Arrow Keys: Used to enter settings as shown in the
operating help page
You will find the separate key meanings listed in the table on the
following page.

Description 2
CLS Pro 600 – Line and Contrast Sensor 17/108
Function Key Designation Description
Setup
Mode
Edge SETUP
Calls up the edge guid-
ing setup mode (only
possible in MAN
mode)
Line SETUP
Calls up the line guid-
ing set-up mode (only
possible in MAN
mode)
Arrow Keys
Used to enter settings
as shown in the oper-
ating help page
ENTER
■Imports the mode /
parameter settings
■Exit the Setup 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 menu)
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 para-
meter
ESC
Pages back by one
menu level and might
also close the menu
2.6 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 in-
stalling the BST-eltromat equipment in the production machine,
these include:
■There must always be a safe distance between the BST-eltro-
mat equipment and the machinery already installed on-site,
such as machine panels, building structures, etc.

2Description
18/108 CLS Pro 600 – Line and Contrast Sensor
■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 pas-
sage 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.
NOTICE
Please note:
Only trained specialist personnel are permitted to undertake the
assembly, installation and commissioning!
DANGER
Danger of cuts!
Never touch the edges of running material webs.
DANGER
Danger of crushing!
Never reach into the area in between the fixed lower frame and
the guiding device’s moving upper frame (rotating frame or swivel-
ling roller guide). Never reach into the area in between moving
rollers!
DANGER
Caution!
Ensure the equipment is electrically isolated before starting work.
To this end always carry out the following activities:
►Switch off.
►Prevent the device from being restarted.
►Determine that the unit is ‘voltage-free’
►Earth the unit.
►Cover or fence off any adjacent parts that are still live.
ðOnly then can the relevant work be undertaken!
WARNING
Caution!
Do not use the chassis or machine frame as a climbing aid or a ste-
pladder. Do not remove any of the safety devices.

Description 2
CLS Pro 600 – Line and Contrast Sensor 19/108
WARNING
Caution!
Actuator movements will be run by the drive even during function
checks away from the production machine and/or during commis-
sioning. The relevant safety arrangements must implemented dur-
ing performance checks! Monitor the overall safety concept of the
production machine during commissioning!
2.7 Laser
CAUTION
Please note:
A laser is used as a positioning aid when positioning the sensor.
This laser unit has been classified by the manufacturer as a Class 2
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.
2.8 Emissions
The A-rated equivalent continuous sound level of the equipment
is less than 70 dB(A).

3Assembly
20/108 CLS Pro 600 – Line and Contrast Sensor
3 Assembly
3.1 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 oper-
ator must be able to access the control panel easily. Ensure
that sunlight or other external light sources do not cause un-
wanted reflections on the screen.
■Strong electro-magnetic fields in the immediate vicinity of the
sensor, the control panel or the sensors can result in malfunc-
tions.
■Take note of the permitted ambient conditions.
Temperature: 0 to max. 45 °C
Humidity: 5 - 90%, no condensation
WARNING
Sensor is not ATEX certified
• 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!
3.2 Sensor Installation
3.2.1 General Information
This chapter describes the procedure for installing the sensors us-
ing the holders supplied in the package or the connection options
available if using a holder supplied by the customer.
3.2.2 Sensor with supplied holder
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 sensor.
Now tighten up the securing bolt to clamp the holding device into
place on the square bar.
See drawing on the next page.