BST ekr 500 User manual

Web Guiding System
Operating Manual
ekr 500 digital Unit Touch
Master-Slave Guiding with Sensor Positioner
MD.535.EN.02
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 – Master-Slave Guiding with Sensor Positioner iii
Table of contents
1 About This Document........................................................................................ 5
1.1 What You Need to Know............................................................................................... 5
1.2 Target Group................................................................................................................. 5
1.3 Storage and Distribution............................................................................................... 5
1.4 Meanings of the Safety Instructions and Symbols........................................................ 6
1.4.1 Safety Instructions ........................................................................................................ 6
1.4.2 Symbols......................................................................................................................... 6
1.4.3 Operation Using Keys.................................................................................................... 6
1.5 More Detailed Information........................................................................................... 7
2 About Safety ..................................................................................................... 8
2.1 Intended Use................................................................................................................. 8
2.2 Non-intended Use......................................................................................................... 8
2.3 Safety Instructions ........................................................................................................ 8
3 Design and Function.......................................................................................... 9
3.1 Functional Principle....................................................................................................... 9
3.2 Guiding Modes............................................................................................................ 10
3.3 Web Guiding Components Used................................................................................. 11
3.3.1 Web Guiding Controller .............................................................................................. 11
3.3.2 Guiding Device ............................................................................................................ 11
3.3.3 Sensor Positioners....................................................................................................... 11
4 Installation.......................................................................................................12
5 Electrical Connection........................................................................................13
5.1 Safety Instructions ...................................................................................................... 13
5.2 Fitting the Cable Connections..................................................................................... 14
5.2.1 Required Accessories .................................................................................................. 14
5.2.2 Wiring Diagrams.......................................................................................................... 14
5.3 Connector Assignment................................................................................................ 15
5.3.1 Master-Slave Guiding with Two Edge Sensors............................................................ 15
5.3.2 Master-Slave Guiding with Four Edge Sensors ........................................................... 17
5.3.3 Terminal Assignment of Terminal Strip X12 (Connection Sensor 4) ........................... 18
6 Commissioning.................................................................................................19
6.1 Safety Instructions ...................................................................................................... 19
6.2 Requirements.............................................................................................................. 20
6.3 Enabling Master-Slave Guiding ................................................................................... 21
6.4 Performing the Material Setup ................................................................................... 21
6.5 Commissioning the Sensor Positioners....................................................................... 22
6.5.1 Calling Up the Setting Menu ....................................................................................... 22
6.5.2 Overview Setting Menu .............................................................................................. 23
6.5.3 Activating Retract Mode ............................................................................................. 25
6.5.4 Activating Automatic Setpoint Acceptance ................................................................ 26
6.5.5 Setting Automatic Sensor Tracking............................................................................. 27
6.5.6 Activating Automatic Edge Sensor Standardization.................................................... 28
6.5.7 Entering the Position Offset for the Sensor Slides...................................................... 29
7 Operation ........................................................................................................31
7.1 Safety Instructions ...................................................................................................... 31
7.2 Switching On the Master-Slave Guiding...................................................................... 32
7.3 Operation Display ....................................................................................................... 34
7.4 Performing the Material Setup ................................................................................... 35
7.4.1 When does a material setup have to be carried out?................................................. 35
7.4.2 Manual or automatic material setup? ........................................................................ 35
7.4.3 Generating bright / dark values .................................................................................. 35

Table of contents
iv ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
7.4.4 Activating the Material Setup ..................................................................................... 36
7.4.5 Automatic Material Setup........................................................................................... 37
7.4.6 Manual Material Setup ............................................................................................... 38
8 Accessories and Spare Parts .............................................................................40
8.1 Order Address............................................................................................................. 40
8.2 Accessories.................................................................................................................. 40
A Wiring Diagrams ..............................................................................................41
A1 Master-Slave Guiding (Web Edge Guiding)................................................................. 41
A1.1 Guiding to the Left Web Edge..................................................................................... 41
A1.2 Guiding to the Right Web Edge................................................................................... 42
A2 Master-Slave Guiding (Web Edge/Web Center-line Guiding)..................................... 43
Index................................................................................................................44

About This Document 1
ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner 5/45
1 About This Document
1.1 What You Need to Know
These instructions describe the special function Master-Slave Guid-
ing with Sensor Positioner of the ekr 500 digital Unit Touch web
guiding controller. They are a supplement to the operating manual
for the ekr 500 digital Unit Touch controller (document number
MD.492).
These instructions must only be used in conjunction with
the operating manual for the ekr 500 digital Unit Touch
web guiding controller. Every user must be familiar with
the operating manual for the controller and observe the
safety instructions contained therein.
These supplementary instructions only include information for the
Master-Save Guiding with Sensor Positioner that are not already
listed in the operating manual for the controller.
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 and in the operating manual for the ekr 500 digital Unit
Touch web guiding controller.
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
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 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.

1About This Document
6/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
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.
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 – Master-Slave Guiding with Sensor Positioner 7/45
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.
Component Document Document
Number
Web guiding controller
ekr 500 digital Unit Touch
Operating manual MD.492
Installation and
commissioning manual MD.497
Sensor positioner
FVGPOS100 Operating manual MD.476

2About Safety
8/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
2 About Safety
Please refer to the operating manual for the ekr 500 digital Unit
Touch web guiding controller (document number MD.492).
2.1 Intended Use
The special function Master-Slave Guiding with Sensor Positioner
of the ekr 500 digital Unit Touch web guiding controller is only
determined for web guiding. It is used when two webs of material
have to be guided together precisely to the web edge or web
center-line.
The function may only be used observing the operating manual
for the ekr 500 digital Unit Touch web guiding controller.
All information regarding safety as well as intended and non-
intended use listed there, also apply for the special function
Master-Slave Guiding with Sensor Positioner.
2.2 Non-intended Use
For this web guiding system the same use is non-intended that is
described in the operating manual for the ekr 500 digital Unit Touch
controller.
2.3 Safety Instructions
Every user must read and follow the safety instructions in this
manual and in the operating manual for the ekr 500 digital Unit
Touch web guiding controller before working with or on the system.

Design and Function 3
ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner 9/45
3 Design and Function
3.1 Functional Principle
The Master-Slave Guiding with Sensor Positioner is used when
two webs of material have to be guided together precisely to the
web edge or web center-line (laminating control). In doing so, the
positions of the unguided MASTER web (guide web) and the
guided SLAVE web (following web) are detected by edge sensors
that are positioned by motor-powered sensor positioners.
(guided)
SLAVE web
Sensor 1
Guiding device
Sensor 2
Sensor positioner
SLAVE web
Sensor 3
Sensor 4
MASTER web
(unguided)
Sensor positioner
MASTER web
Distance
web edges
Fig.1: Master-slave guiding for guiding together two webs of material precisely to the web edge or web center-line

3Design and Function
10/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
The number of required edge sensors depends on the desired
guiding modes.
Master-Slave Guiding Possible Guiding Modes Reference Point for Guiding
with two edge sensors Web edge guiding left or right web edge
with four edge sensors Web edge guiding left and right web edge
Web center-line guiding web center-line
With the displayed version of the master-slave guiding with four
edge sensors, sensors 3 and 4 detect the position of the unguided
MASTER web and sensors 1 and 2 the position of the guided SLAVE
web (following web). If the MASTER web moves laterally to the
web running direction during the laminating process, the control
automatically guides the SLAVE web by the respective adjusting
movement of the guiding device (e. g. rotating frame guide).
In this way, during web edge guiding the master-slave guiding
keeps the preset distance (offset) of both web edges constant
(offset ≠ 0) or ensures that both web edges are positioned pre-
cisely over one another (offset = 0).
During web center-line guiding the master-slave guiding ensures
that the SLAVE web is guided exactly to the middle of the MASTER
web (offset = 0) or that the lateral displacement between the cen-
ter-lines of the SLAVE and the MASTER web remains constant (off-
set ≠ 0).
3.2 Guiding Modes
For the laminating process the Master-Save Guiding with Sensor
Positioner permits the following guiding modes.
Guiding to the left web edge Guiding to the right web edge Web center-line guiding
SLAVE web
MASTER web
SLAVE web
MASTER web
SLAVE web
MASTER web

Design and Function 3
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3.3 Web Guiding Components Used
The web guiding system for the Master-Slave Guiding with Sensor
Positioner consists of the components described in the following
chapters.
3.3.1 Web Guiding Controller
The ekr 500 digital Unit Touch web guiding controller is used to
control and operate the Master-Slave Guiding.
Requirements
The following requirements must be fulfilled for using the Master-
Slave Guiding with Sensor Positioner with the ekr 500 digital Unit
Touch web guiding controller:
■Firmware version of the controller ≥ 2.2.2
■Firmware version of the ekrcommander control panel ≥ 1.4.3
■DIL switch S6.6 = ON (Master-Slave Guiding enabled, see
Enabling Master-Slave Guiding, page 21)
3.3.2 Guiding Device
The guiding device (e.g. rotating frame guide) is used to correct
the position of the SLAVE web across the web running direction.
If the unguided MASTER web moves laterally to the web running
direction during the laminating process, the guiding device tracks
the SLAVE web by an appropriate turning movement.
3.3.3 Sensor Positioners
The FVGPOS100 sensor positioners are used for the motor-driven
positioning of the edge sensors at the MASTER and the SLAVE
web. The design and number of the sensor positioners used de-
pends on the desired guiding mode.
Requirement
The following requirement must be fulfilled for using the
FVGPOS100 sensor positioner for Master-Slave guiding:
■Firmware version of the sensor positioner ≥ 1.7.2

4Installation
12/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
4 Installation
The installation of the web guiding components used for the
Master-Slave Guiding is described in separate documents.
Component Document Document
Number
Web guiding controller
ekr 500 digital Unit Touch
Installation and
commissioning manual MD.497
Sensor positioner
FVGPOS100 Operating manual MD.476

Electrical Connection 5
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5 Electrical Connection
5.1 Safety Instructions
DANGER
Mortal danger from electric shock!
Life threatening injuries caused by incomplete switching off or
residual current.
►Switch the machine off completely, switch to zero potential and
wait 10 minutes before carrying out the electrical connection.
►Check that the unit is voltage-free.
►Secure the machine against being switched back on.
►Cover or fence off any adjacent parts that are still live.
WARNING
Mortal danger and property damage caused by incorrect electric
connections / insufficient PE connection!
Life-threatening electric shock and destruction of system compon-
ents caused by short-circuits.
►Have electrical connections carried out by qualified electricians
only.
►Carry out PE connections for all live system components profes-
sionally.
►Use suitable safety equipment (RCD switch) upstream for all live
system components.
NOTICE
Damage to components resulting from incorrect voltage connec-
tion!
Damage to components caused by connecting to the wrong mains
voltage, incorrect terminal connection or from incorrect polarity.
►Before connecting, observe the connecting diagram and cable
lettering.
►Before connecting, make sure that the mains voltage corres-
ponds with the details specified on the nameplate of the com-
ponents.
►Select the correct terminals and polarity when connecting the
power supply.
►Please also read and follow all safety instructions contained in
the installation and operating manual for the ekr 500 digital
Unit Touch controller (document number MD.497).

5Electrical Connection
14/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
5.2 Fitting the Cable Connections
5.2.1 Required Accessories
For connecting the edge sensors to the ekr 500 digital Unit Touch
web guiding controller you need optional extension cables.
Only original accessory components from BST may be used.
Neglecting this information leads to warranty claims being invalid-
ated.
The number and length of the required extension cables depends
on the number of edge sensors used and on the distances to the
web guiding controller. The table specifies the respective minimum
amounts required.
Accessory Part Length Order Number Amount Required
Master-Slave Guiding
with Two Edge Sensors
Master-Slave Guiding
with Four Edge Sensors
Extension cable
2 m 131993
2 45 m 131994
10 m 131995
It is also possible to combine cable extensions of different
lengths. However, the maximum permitted total length of
20m of the connecting cable must never be exceeded!
5.2.2 Wiring Diagrams
You will find wiring diagrams for the following Master-Slave Guiding
types in the appendix of this document:
Master-Slave Guiding with two edge sensors
■Guiding to the left web edge
■Guiding to the right web edge
Master-Slave Guiding with four edge sensors
■Web edge and web center-line guiding

Electrical Connection 5
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5.3 Connector Assignment
The assignment of the connectors at the ekr 500 digital Unit Touch
controller housing depends on the number of edge sensors used
for the Master-Slave Guiding.
5.3.1 Master-Slave Guiding with Two Edge Sensors
5.3.1.1 Guiding to the Left Web Edge
Fig.2: Connector assignment on the controller
Connector Assignment
Component Web of Material Connector
ekrcommander X101
Sensor1 SLAVE web X102
Sensor3 MASTER web X100

5Electrical Connection
16/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
5.3.1.2 Guiding to the Right Web Edge
Fig.3: Controller with optional cable tail for the connection of sensor 4
With this Master-Slave Guiding version the controller is factory
equipped with an additional cable tail. The edge sensor 4 is con-
nected to connector socket X104 of the cable tail.
Connector Assignment
Component Web of Material Connector Remark
ekrcommander X100
Sensor2 SLAVE web X103
Sensor4 MASTER web X104
Leads to terminal strip X12 in the controller (see
Terminal Assignment of Terminal Strip X12
(Connection Sensor 4), page 18).

Electrical Connection 5
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5.3.2 Master-Slave Guiding with Four Edge Sensors
Fig.4: Controller with optional cable tail for the connection of sensor 4
With this Master-Slave Guiding version the controller is factory
equipped with an additional cable tail. The edge sensor 4 is con-
nected to connector socket X104 of the cable tail.
Connector Assignment
Component Web of Material Connector Remark
ekrcommander X101
Sensor1 SLAVE web X102
Sensor2 X103
Sensor3
MASTER web
X100
Sensor4 X104
Leads to terminal strip X12 in the controller (see
Terminal Assignment of Terminal Strip X12
(Connection Sensor 4), page 18).

5Electrical Connection
18/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
5.3.3 Terminal Assignment of Terminal Strip X12 (Connection Sensor 4)
The following figure shows the position of the terminal strip X12
on the processor board of the controller.
Fig.5: Processor board of the controller
Terminal Assignment
X12
Terminal
X104
Pin
Function Wire Colour Note
66 1 +24V⎓brown Power supply Sensor4
67 2 CAN4-H white CAN4 high
68 3 GND blue Ground CAN4
69 4 CAN4-L black CAN4 low

Commissioning 6
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6 Commissioning
This manual only describes the steps that are required to commis-
sion the Master-Slave Guiding with Sensor Positioner on the ekr
500 digital Unit Touch controller. Any further necessary commis-
sioning work is described in the installation and commissioning
manual for the ekr 500 digital Unit Touch controller (document
number MD.497).
6.1 Safety Instructions
WARNING
Danger of death and material damage caused by incorrect com-
missioning!
►Have the commissioning carried out by BST service personnel or
authorized personnel only.
DANGER
Danger of death caused by the machine starting up!
Parts of your body could be crushed, cut, drawn in or hit.
►Switch off the machine completely and secure it against it being
switched back on.
WARNING
Danger of crushing due to motor-driven movement of the sensor
slides!
Body parts could be crushed, sheared or impacted.
►Never reach into the positioning range of the sensor slides.
►Prior to set-up/operation, ensure that no persons are in the
positioning range of the sensor slides.
There is a danger of crushing during the sensor slide movement, in
particular when reaching into the hazard zones identified below.
Fig.6: Hazard zones

6Commissioning
20/45 ekr 500 digital Unit Touch – Master-Slave Guiding with Sensor Positioner
The operator must ensure that suitable protective devices are
installed to prevent reaching into the positioning range of the
sensor slides.
WARNING
Danger of death from actuator movements!
During function tests, parts of your body may be crushed, cut or
hit.
►Before starting the commissioning work, make sure that no per-
sons are in the vicinity of the pivot / traversing area of machine
components that are positioned by the actuator (e.g. pivoting
frame guide, swiveling roller guide, rewind, unwind).
►Cordon off the work area before starting the commissioning
work to prevent access by unauthorized persons.
►Please also read and follow all safety instructions contained in
the installation and commissioning manual for the ekr 500 digital
Unit Touch controller (document number MD.497) and in the
operating manual for the FVG POS 100 sensor positioner
(document number MD.476).
6.2 Requirements
■The web guiding system has been fully wired up, i.e. the cable
connections between the separate web guiding components
(controller, sensors, actuator) have been made (see Wiring Dia-
grams, page 14).
■The controller is connected to the power supply.
■All transport locking devices on the guiding device and actuator
have been removed.