BST ekr 500 Guide

Web Guiding System
Installation and
Commissioning Manual
ekr 500 digital Unit Touch
MD.497.EN.08
Translation of the Original Manual

BST GmbH
Remusweg 1
D-33729 Bielefeld
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.bst.group
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
ekr 500 digital Unit Touch – Installation and Commissioning Manual iii
Table of contents
1 About This Document........................................................................................ 7
1.1 What You Need to Know............................................................................................... 7
1.2 Target Group................................................................................................................. 7
1.3 Storage and Distribution............................................................................................... 7
1.4 Meanings of the Safety Instructions and Symbols........................................................ 7
1.4.1 Safety Instructions ........................................................................................................ 7
1.4.2 Symbols......................................................................................................................... 8
1.4.3 Operation Using Keys.................................................................................................... 8
1.5 More Detailed Information........................................................................................... 9
2 About Safety ....................................................................................................10
2.1 Intended Use............................................................................................................... 10
2.2 Non-intended Use....................................................................................................... 11
2.2.1 Non-intended Infringement of Guidelines.................................................................. 11
2.2.2 Non-intended Operation............................................................................................. 11
2.2.3 Non-intended Modification of Electronic Data........................................................... 12
2.3 Safety Instructions ...................................................................................................... 13
2.3.1 General Safety Instructions......................................................................................... 13
2.4 Qualification of the Personnel .................................................................................... 15
2.5 Duties of the Operating Company and Personnel ...................................................... 16
2.5.1 Duties of the Operating Company .............................................................................. 16
2.5.2 Duties of the Personnel............................................................................................... 17
2.6 Conduct in the Event of Danger and Accidents .......................................................... 17
2.7 Personal Protective Equipment .................................................................................. 18
2.8 Guarantee and Liability............................................................................................... 18
2.8.1 Disclaimer ................................................................................................................... 18
2.8.2 Exceptions to the Disclaimer....................................................................................... 19
2.8.3 License and Liability for Software Supplied ................................................................ 19
3 Design and Function.........................................................................................20
3.1 Design ......................................................................................................................... 20
3.1.1 Controller.................................................................................................................... 20
3.1.2 Control Panel .............................................................................................................. 20
3.2 Function ...................................................................................................................... 21
3.3 Message Output “System OK“ .................................................................................... 22
3.4 Connectable Components........................................................................................... 23
3.5 Designation of the Sensors ......................................................................................... 24
3.5.1 Edge Sensors (Sensor1/2) .......................................................................................... 24
3.5.2 Line, Contrast and Object Sensor (Sensor3)............................................................... 25
3.5.3 CCD Cameras (Sensor 1/2) .......................................................................................... 26
3.6 Accessories.................................................................................................................. 27
3.7 Nameplates................................................................................................................. 27
4 Technical Specifications ...................................................................................28
4.1 Controller.................................................................................................................... 28
4.1.1 Ambient Conditions .................................................................................................... 28
4.1.2 Protection Category.................................................................................................... 28
4.1.3 Power Supply .............................................................................................................. 28
4.1.4 Analogue Inputs.......................................................................................................... 29
4.1.5 Digital Inputs / Outputs............................................................................................... 30
4.1.6 Output Motor Output Stage ....................................................................................... 30
4.1.7 Message Output "System OK" .................................................................................... 31
4.1.8 Bus Interface............................................................................................................... 31
4.1.9 Weight and Dimensions.............................................................................................. 32
4.2 ekr commander Control Panel.................................................................................... 33
4.2.1 Ambient Conditions .................................................................................................... 33
4.2.2 Protection Category.................................................................................................... 33

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iv ekr 500 digital Unit Touch – Installation and Commissioning Manual
4.2.3 Power Supply .............................................................................................................. 33
4.2.4 Touchscreen Display ................................................................................................... 33
4.2.5 Weight and Dimensions.............................................................................................. 33
4.3 Power Pack.................................................................................................................. 34
4.4 Sensors........................................................................................................................ 35
4.4.1 Edge Sensors............................................................................................................... 35
4.4.2 Line and Contrast Sensor CLS Pro 600 ........................................................................ 37
4.4.3 Object Sensor CLS CAM 100........................................................................................ 38
4.4.4 CCD Cameras............................................................................................................... 38
4.5 Sensor Positioner ........................................................................................................ 38
4.6 Electric Motor Powered Actuators.............................................................................. 39
4.7 RoHS Conformity......................................................................................................... 41
5 Transport, Delivery and Storage .......................................................................42
5.1 Transport..................................................................................................................... 42
5.2 Scope of Delivery ........................................................................................................ 43
5.3 Unpacking the Delivery............................................................................................... 43
5.4 Storage........................................................................................................................ 43
6 Installation.......................................................................................................44
6.1 Safety Instructions ...................................................................................................... 44
6.2 Selecting the Installation Location.............................................................................. 45
6.3 Installing the Controller .............................................................................................. 46
6.3.1 Installation Positions................................................................................................... 46
6.3.2 Securing Hole Template.............................................................................................. 47
6.3.3 Space Needed to Open the Housing Cover................................................................. 47
6.3.4 Installing the Controller .............................................................................................. 48
6.3.5 Turning the Control Panel........................................................................................... 49
6.4 Installing the Control Panel......................................................................................... 50
6.4.1 Attachment Alternatives............................................................................................. 50
6.4.2 Cable Extension........................................................................................................... 50
6.4.3 Wall Mounting ............................................................................................................ 51
6.4.4 Console Installation..................................................................................................... 53
6.4.5 Magnet Attachment.................................................................................................... 56
7 Electrical Connection........................................................................................58
7.1 Safety Instructions ...................................................................................................... 58
7.2 Cable Routing.............................................................................................................. 59
7.3 Connecting the Cables ................................................................................................ 60
7.4 EMC Suitable Wiring ................................................................................................... 61
7.5 Ensuring Equipotential Bonding.................................................................................. 62
7.6 Connections on the Controller.................................................................................... 63
7.7 Terminal Strips............................................................................................................ 64
7.8 Terminal Assignment .................................................................................................. 65
7.8.1 Overview..................................................................................................................... 65
7.8.2 Terminal Strip X1 - Sensor 1/2 (Analogue Connection) .............................................. 66
7.8.3 Terminal Strip X6 - Power Supply................................................................................ 66
7.8.4 Terminal Strip X7 - Actuator, OMG 4 .......................................................................... 67
7.8.5 Terminal Strip X8 - Sensor 1/2 (CAN Bus) ................................................................... 68
7.8.6 Terminal Strip X9 - ekr commander Control Panel, Sensor 3, Drive Module 160....... 68
7.8.7 Terminal Strip X10 - Controller Interlock, OMG 4, OMG 8, CK 37, EFE1 .................... 69
7.8.8 Terminal Strip X11 - Message Output "System OK".................................................... 69
7.8.9 Terminal Strip X12 - CAN Bus 4 ................................................................................... 69
7.8.10 Terminal Strip X14 - Digital Inputs 1...6, EFE 1000...................................................... 70
7.8.11 Terminal Strip X15 - Digital Inputs 7...12, EFE 1000.................................................... 70
7.8.12 Terminal Strip X16 - Digital Outputs 1 ... 4.................................................................. 70
7.9 Plug Connection.......................................................................................................... 71
7.9.1 X60 - Actuator Connection EMS 17/18/21/22 ............................................................ 71
7.9.2 X70 - Power Supply ..................................................................................................... 72

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ekr 500 digital Unit Touch – Installation and Commissioning Manual v
7.9.3 X100 ... 103 - Connection of CAN Bus Participants ..................................................... 73
8 Commissioning.................................................................................................74
8.1 Safety Instructions ...................................................................................................... 74
8.2 Requirements.............................................................................................................. 75
8.3 Setting the DIL Switches of the Controller.................................................................. 76
8.3.1 DIL Switch Overview ................................................................................................... 76
8.3.2 Using the DIL Switch ................................................................................................... 77
8.3.3 Setting DIL Switch S4................................................................................................... 78
8.3.4 Setting DIL Switch S5................................................................................................... 79
8.3.5 Setting DIL Switch S6................................................................................................... 80
8.3.6 Setting DIL Switch S7................................................................................................... 80
8.4 Setting the DIL Switches of the Control Panel ............................................................ 81
8.5 Setting the Jumper...................................................................................................... 82
8.6 Checking the Device Addresses .................................................................................. 83
8.6.1 Controller Device Address........................................................................................... 83
8.6.2 Control Panel Device Address..................................................................................... 84
8.7 Setting the Terminating Resistors............................................................................... 85
8.7.1 Terminating Resistor of the Controller ....................................................................... 85
8.7.2 Terminating Resistor of the Control Panel.................................................................. 87
8.8 Calling up the Setup Menu.......................................................................................... 89
8.9 Setting the Dimension Unit......................................................................................... 92
8.10 Setting the Motor Rotation Direction ......................................................................... 93
8.11 Commissioning the Actuator Without Position Feedback .......................................... 94
8.11.1 Setting the Guiding Direction for Center Positioning.................................................. 94
8.11.2 Setting the Gain of the Servo Center Transducer ....................................................... 95
8.12 Commissioning the Actuator With Position Feedback................................................ 97
8.12.1 Setting the Guiding Direction for Center Positioning.................................................. 97
8.12.2 Setting Stroke Limitation and Servo-Center Position.................................................. 98
8.12.3 Activating the Normalized Display of the Actuator Position..................................... 101
8.12.4 Activating Position Control ....................................................................................... 104
8.13 Setting the Guiding Direction.................................................................................... 105
8.13.1 Guiding Direction for Web Edge Guiding and Web Center-Line Guiding (Sensor 1/2) .105
8.13.2 Guiding Direction for Line / Contrast / Feature Guiding (Sensor 3).......................... 106
8.14 Performing the Material Setup ................................................................................. 106
8.15 Adjusting the Controller Gain ................................................................................... 107
8.16 Commissioning the CCD Camera............................................................................... 109
8.16.1 CCD Camera Calibration............................................................................................ 109
8.16.2 Material Thickness Compensation............................................................................ 113
8.16.3 Setting the Material Thickness (After Changing the Material).................................. 116
8.16.4 Entering the Position Offsets .................................................................................... 117
8.17 Commissioning the Sensor Positioner ...................................................................... 119
8.17.1 Calling Up the Setting Menu ..................................................................................... 119
8.17.2 Overview Setting Menu ............................................................................................ 120
8.17.3 Activating Retract Mode ........................................................................................... 121
8.17.4 Activating Automatic Setpoint Acceptance .............................................................. 122
8.17.5 Setting Automatic Sensor Tracking........................................................................... 123
8.17.6 Activating Automatic Edge Sensor Standardization.................................................. 124
8.17.7 Entering the Position Offset for the Sensor Slides.................................................... 125
8.18 Commissioning the Positioning Unit......................................................................... 127
8.18.1 Utilization.................................................................................................................. 127
8.18.2 Calling Up the Setting Menu ..................................................................................... 128
8.18.3 Overview Setting Menu ............................................................................................ 128
8.18.4 Reversing the Operating Direction of the Arrow Keys.............................................. 129
8.18.5 Entering the Position Offset for the Sensor Slides.................................................... 131
8.19 Commissioning the Electronic Remote Precision Adjustment (Optional)................. 133
8.19.1 EFE 1.......................................................................................................................... 133
8.19.2 EFE 1000.................................................................................................................... 134

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vi ekr 500 digital Unit Touch – Installation and Commissioning Manual
9 Remote Control (Digital Inputs / Outputs)......................................................135
9.1 Safety Information .................................................................................................... 135
9.2 Digital Inputs / Outputs............................................................................................. 135
9.2.1 Digital Inputs............................................................................................................. 135
9.2.2 Digital Outputs.......................................................................................................... 135
9.2.3 Truth Tables .............................................................................................................. 136
9.2.4 Digital Inputs / Outputs Configuration...................................................................... 137
9.3 Remote Control With External Control Keyboard ekr commander .......................... 150
10 Service LEDs ...................................................................................................151
10.1 Status Display of Remote Control Inputs .................................................................. 152
10.2 Status Display of Digital Outputs .............................................................................. 152
10.3 Display of CAN Bus Status......................................................................................... 153
10.4 Display of Device Status............................................................................................ 153
10.5 Status Display of Message Output "System OK"....................................................... 153
10.6 Status Display of Power Supply................................................................................. 153
10.7 Status Display of Controller Interlock ....................................................................... 153
11 Accessories and Spare Parts ...........................................................................154
11.1 Order Address........................................................................................................... 154
11.2 Accessories................................................................................................................ 154
12 Customer Services..........................................................................................155
13 Connection Diagram.......................................................................................156
13.1 Application with Edge Sensors.................................................................................. 156
13.2 Application with CCD Cameras.................................................................................. 157
13.2.1 Application with CCD CAM 100................................................................................. 157
13.2.2 Application with CCDPro 30000/5000 ...................................................................... 158
13.3 Application with Sensor Positioner FVG POS 100 ..................................................... 158
Index..............................................................................................................159

About This Document 1
ekr 500 digital Unit Touch – Installation and Commissioning Manual 7/162
1 About This Document
1.1 What You Need to Know
These instructions help you to install and start up the system in a
safe manner. The following instructions must be observed in order
to avoid hazards and incorrect operation:
■Every user that has been assigned with the installation and the
start-up of the system 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.
■The basic operation and the system functions are described in
the operating manual. Every user must be familiar with the
operating manual and observe the safety instructions contained
therein.
1.2 Target Group
These instructions are directed to all persons that have been
assigned with the installation and the start-up of the system. The
operating company of the entire system and supervising
personnel must also be familiar with these instructions.
1.3 Storage and Distribution
These instructions must be stored at the workplace in such a
manner 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.

1About This Document
8/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
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. Prompt for you to act. Namely ...
2. ... in the listed sequence.
►Requirement for you to take actions - without any certain
sequence.
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.

About This Document 1
ekr 500 digital Unit Touch – Installation and Commissioning Manual 9/162
1.5 More Detailed Information
►Observe the accompanying documents (e.g. order confirmation)
for this system and the operating instructions of the entire sys-
tem.
The latest version of these instructions in all available languages
as well as further documents on this system can be found in the
Internet on our help portal BST.Help. Simply click on the docu-
ment number in the table. The link will lead you directly to the se-
lected document on BST.Help.
Document Document
Number
Operating manual
ekr500digitalUnitTouch MD.492
Installation and operating manual
ekr500digitalUnitTouch –
Application with wide array edge sensors
MD.503
Operating manual
ekr500digitalUnitTouch –
Master-slave guiding with sensor positioner
MD.535
Interface description
ekr500digitalUnitTouch –
CANopen user gateway
MD.520

2About Safety
10/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
2 About Safety
The system has been designed according to the state of the art
and fulfils the latest safety standards.
When using the system, risks may occur that could threaten your
life or health or lead to material damage. In order to avoid these
risks, all instructions in this manual concerning safety and all
relevant documentation of the entire system must be observed.
2.1 Intended Use
The system is only determined for web guiding. It permits guiding
according to the web edges, web center-line, printed lines,
contrast edges or print features.
The system is integrated in a machine or connected with another
machine to form a machine as defined by machinery directive
2006/42/EC. All machines and the overall machine line must meet
the requirements of the machinery directive after integration of
the system.
The system and all of its components are exclusively intended for
commercial use in an industrial environment.
Moreover, the system may only be started up, if the following
regulations are adhered to:
■The product must only be installed or operated in a non-
explosive atmosphere.
■The product and all components may only be used while in
perfect condition.
■All safety devices must be in perfect condition.
■The product may only be operated with the components
belonging to the system. The only third-party components
exempt from the above are those supplied by BST or explicitly
approved for use with the system.
■Parts that are not in perfect condition must immediately be
replaced with original spare parts.
■All work on or with the product may only be performed by
instructed and qualified personnel, see chapter Qualification of
the Personnel, page 15.
■Always adhere to this operating manual and all safety instruc-
tions.
■The operating conditions and performance limits indicated in
the technical data must be observed.

About Safety 2
ekr 500 digital Unit Touch – Installation and Commissioning Manual 11/162
2.2 Non-intended Use
Every use is non-intended, that is not described in the chapter
Intended Use or does not comply with the guidelines specified
there, see Intended Use, page 10.
2.2.1 Non-intended Infringement of Guidelines
■Infringement of operating, maintaining or installation instructions
■Unsuitable, incorrect or unauthorized use of the product
■Operating the product in an environment not intended for its
use
■Operating the product in breach of the legal safety guidelines
relevant at the location of use
■Neglecting the warning and safety instructions in the relevant
documents for the product
■Operating the product under faulty safety and protective condi-
tions
2.2.2 Non-intended Operation
■Operation by unauthorized or insufficiently qualified personnel
■By-passing, disassembling, switching off or manipulation of
safety equipment
■Incorrect or negligent handling by the customer
■Any intervention, modification or conversions on the product
without the express approval of BST GmbH
■The use of unsuitable operating materials or spare parts
■Operation of the product near to sources of interference, e.g.
electro-magnetic fields (high voltage lines) or sources of heat
■Operation of the product under the influence of chemical,
electro-chemical or electrical factors

2About Safety
12/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
2.2.3 Non-intended Modification of Electronic Data
■No virus scanners, firewalls or similar items may be installed on
any products of BST GmbH. Virus scanners or other scan or
registration programs must not (be able to) access products via
networks.
■Writing, deleting and editing of system data / files on BST
products is not permitted. Exempt from this is service work
carried out at the instruction of BST GmbH.
■Access of any external software to BST products via networks is
not permitted.
■USB memory sticks may only be used together with BST
products if they are free of viruses and harmful software.
■Products or supplied software from BST GmbH must never be
modified without permission.
■All software supplied is protected by copyright and must not be
edited, copied or made available to third parties. Except where
explicit approval has been sought from BST GmbH or the
respective owner of the copyright.

About Safety 2
ekr 500 digital Unit Touch – Installation and Commissioning Manual 13/162
2.3 Safety Instructions
Every user must read and follow the safety instructions in these
instructions before working with or on the system.
The following contains general safety instructions that always
have to be observed. Special safety information that must be
observed for certain work will be specified at the start of the
respective chapter of these instructions.
2.3.1 General Safety Instructions
DANGER
Danger of death when operated in potentially explosive areas!
►The system must not be installed or operated in potentially
explosive areas.
DANGER
Danger to life due to moving machine components!
Crushing, shearing, scraping, pulling in or impact injuries of body
parts may occur.
►Never reach into the area containing moving rollers or machine
components.
►Do not wear necklaces, scarves or similar near moving rollers/
machine components.
►Never stay within the swivel/movement range of moving
machine components or reach into these areas.
►Prior to set-up/operation of the system, ensure that no persons
are in the operating range of moving machine components.
DANGER
Danger to life due to electrocution!
Fatal injuries due to incomplete shut-down or residual currents.
►If insulation defects or defects on live components occur,
immediately shut down the power supply and have the system
repaired by a qualified electrician.
►Completely switch off the system, disconnect it from the power
supply and wait for ten minutes before carrying out any main-
tenance, repair, cleaning or assembly work.
►Secure the system against being switched on again.
WARNING
Danger of cutting on sharp edges of the material web!
Severe cutting injuries caused by the edges of the moving material
web.
►Never touch the edges of moving material webs.

2About Safety
14/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
WARNING
Danger to life caused by movements of the setting drive!
If position control is active, the setting drive may execute auto-
matic movements in manual mode . Body parts could be crushed,
sheared or impacted.
►Ensure that no persons remain in the swivel or positioning
range of machine components positioned by the actuator.
WARNING
Danger of falling and damage to assets caused by stepping/climb-
ing onto components!
Stepping/climbing onto components (e.g. traverse bars or camera
housing) can lead to life-threatening falling accidents and to the
destruction of the components.
►Never climb or step onto components.
WARNING
Danger to life due to missing Emergency Stop devices!
Severe injuries may occur, if no Emergency Stop device (Emer-
gency Stop button) is installed on the overall machine line. Only an
Emergency Stop device permits an immediate stop of the machine
line in emergencies. It is not permitted to operate the overall ma-
chine line without an Emergency Stop device.
►If one is not already installed, have an Emergency Stop button
and Emergency Stop systems installed by the owner/user/
machine manufacturer prior to using the machine line.
WARNING
Severe injuries due to unfamiliarity with/non-observance of
Emergency Stop devices and safety information!
►Prior to starting work, familiarize yourself with the Emergency
Stop and rescue devices of the overall machine line, e.g. Emer-
gency Stop button.
►Prior to starting work, ensure that all safety regulations and
instructions are observed.
NOTICE
Damage to electronic components caused by ESD (electrostatic
discharge)!
Destruction/loss of capacity of electronic assembly elements
caused by contact with electro-statically charged persons/objects.
►Only open system components at ESD-compliant workplaces
(according to 61340-5-1).
►If there is no ESD-compliant workplace, take ESD protection
measures (according to DIN EN61340-5-1) to discharge electro-
static charges in a controlled manner.
►When returning electronic assembly elements, adhere to DIN
EN 100015 (“Protection of protection of electrostatic-sensitive
devices”).
►To transport electronic components, only use suitably marked,
electrically conductive ESD packaging.

About Safety 2
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NOTICE
Damage to the touchscreen due to faulty operation!
Use of sharp, strong or coarse objects (e.g. pens, gloves) may dam-
age the surface of the touchscreen.
►Touch the touchscreen only using bare fingers or a special input
pen (touchpen).
2.4 Qualification of the Personnel
The qualifications required by the personnel are defined as follows:
Instructed personnel have been instructed comprehensively by
the operating company and informed about the following points:
■Tasks assigned
■Possible hazards when carrying out the tasks
■Possible hazards in the event of incorrect conduct
■Measures for avoiding the hazards
Moreover, qualified personnel have sufficient experience or
practice in the safe implementation of the tasks assigned.
Specialists are in addition in the position to deal with the follow-
ing tasks by themselves due to their training, knowledge and ex-
perience as well as knowledge in the relevant regulations:
■Carrying out the tasks assigned to them
■Recognizing possible hazards
■Undertaking appropriate measures for avoiding the hazards
Specialists must only carry out tasks according to their profes-
sional training.
Qualified electricians have in addition an electrical engineering
training according to the applicable guidelines (in Germany,
DINVDE1000-10).
Moreover, all personnel must satisfy all requirements that are
derived from the following documentation or directives:
■Operating instructions for the entire system
■National guidelines, laws and applicable guidelines for protecting
employees, general safety at workplaces and for accident pre-
vention

2About Safety
16/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
2.5 Duties of the Operating Company and Personnel
2.5.1 Duties of the Operating Company
The operating company of the entire system is responsible for
safety in the workplace as well as for the information and training
of the personnel. In particular, for the entire life-cycle of the system
and the entire system, the operating company must ensure that:
■All relevant legal safety, accident prevention and environ-
mental guidelines are maintained
■All hazards are determined that result from the special operating
conditions at the operating location of the system and from the
construction of the entire system
■All hazards determined are avoided. This means, in particular:
- Constructive prevention of hazards
- Assembly of protection and safety equipment and checking
that these are working properly
- Mounting of warning signs at hazard sites and checking their
correct condition
- Information and training of the personnel for safe conduct,
intended use, safety equipment, prevention of hazards and
conduct in the event of emergencies
- Provision of the necessary personal protective equipment
- Supervision of the personnel with regard to safety-relevant
conduct
■The system is integrated into the safety concept of the entire
system
■The system is stopped immediately if the safety of people or
the environment is endangered or changes occur that could
impair the safety
■All employees have read and understood these instructions
before working on or with the system
■Only personnel are assigned that are qualified and trained for
the respective task
■The responsibility of the personnel is determined for the task
to be completed and that the personnel are informed

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2.5.2 Duties of the Personnel
Each and every employee is responsible for their own safety. In
particular, each and every employee must abide by the following
instructions:
►Read these instructions completely before working on or with
the system and follow all safety instructions.
►Observe all warning instructions on the system and entire system.
►Observe the operating instructions for the entire system and
the separate machines as well as all safety instructions included
in it.
►If required, wear the necessary personal protective equipment.
►Before starting work, check if the safety equipment is intact.
►Stop the system immediately if the safety of people is at risk
and secure against being switched back on unintentionally.
►The system must be visually inspected for any recognizable
damage or problems at least once per shift.
►If sections of these instructions are unclear, inform your super-
visor and ensure for clarification.
2.6 Conduct in the Event of Danger and Accidents
Preventative Measures
Emergency and rescue equipment must be ready for use in every
company. These include, for example, emergency stop buttons,
fire extinguisher, first aid kit and equipment for reporting acci-
dents.
►Always be prepared for emergencies, accidents and fire.
►Familiarize yourself as to where the emergency and rescue
equipment is located and how to use it.
►Keep emergency and rescue equipment at hand and ready for
use.
►Ensure all access routes for rescue vehicles and escape routes
are kept free.
If an emergency is impending or has occurred
1. Press the emergency stop button immediately.
2. Make sure that the system cannot be switched on again.
3. Rescue the persons from the danger zone if your personal
safety is not at risk.
4. Initiate first aid measures.
5. Warn the emergency doctor and / or fire brigade.
6. Inform the responsible person at the operating location.
7. Clear the access route for the emergency vehicles.

2About Safety
18/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
2.7 Personal Protective Equipment
When carrying out certain activities, you have to wear personal
protective equipment in order to avoid accidents and injuries.
Personal protective equipment includes, depending on the activity:
■Protective clothing
■Safety helmet
■Safety shoes
■Safety gloves
■Eye protectors
■Ear protectors
►Observe the safety information in these instructions and the in-
formation signs on the system for personal protective equip-
ment.
2.8 Guarantee and Liability
The warranty terms are specified in the sales documentation.
2.8.1 Disclaimer
BST GmbH is not liable for damage or defects arising from any
incorrect or non-intended use of the product, see Non-intended
Use, page 11.
Liability for defects does also not apply if the fault originates from
one or more of the following causes:
■Catastrophic events and force majeure
■Natural wear
■Incorrect operation of the product resulting from the effect of
connected or neighboring third party devices
■Malfunction of the product due to unsuitable operating
resources, spare parts, chemical, electro-chemical or electrical
factors.
■Unsuitable or faulty execution of the maintenance work
described by the operating company

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2.8.2 Exceptions to the Disclaimer
In the cases listed above BST GmbH shall also not be liable (for
damages) unless:
■The damage results from a willful or grossly negligent breach of
duty on the part of BST GmbH or its legal representatives or
vicarious agents
■The damage is associated with injury to life, body or health and
results from a willful or grossly negligent breach of duty on the
part of BST GmbH or its legal representatives or vicarious
agents
■The form of damage can usually and typically be insured
against by means of third-party liability insurance taken out by
BST GmbH on reasonable conditions
This applies in particular to claims for damages associated with
fault or negligence occurring before or upon conclusion of the
contract, the infringement of secondary obligations and claims
associated with impermissible actions; this does not affect claims
asserted in accordance with the German Product Liability Act or
those associated with a guarantee.
Otherwise, the specific terms of license of BST GmbH apply.
2.8.3 License and Liability for Software Supplied
Software supplied that has not been produced by BST GmbH
underlies the respective liability and license agreements of the
manufacturer.

3Design and Function
20/162 ekr 500 digital Unit Touch – Installation and Commissioning Manual
3 Design and Function
3.1 Design
The ekr 500digital UnitTouch comprises the controller and the
removable ekrcommander control panel.
3.1.1 Controller
The housing of the controller includes the entire control electrics
and connections for all necessary web guiding components
(sensors, actuator, servo center transducer, remote controls, etc.).
3.1.2 Control Panel
Controller with control panel fitted
The ekr commander control panel is fitted on the front of the
device in the factory.
Fig.1: Controller with ekrcommander control panel fitted
Controller with control panel detached
If necessary (e.g. if the controller is installed in a position difficult
to access on the machine) the ekrcommander control panel can
be detached and installed in a central operator panel or a cus-
tomer-supplied control station. In this case the connection
between the controller and the control panel is completed using a
cable extension that is available as an optional extra.
Fig.2: Controller with ekrcommander control panel detached