Maxcess FIFE-500 User manual

FIFE-500 MAX
User Manual
EN
Narrow Web Guiding System
MI 2700XXXXX 18
FIFE GUIDING SYSTEMS

CONTENTS
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1. INTRODUCTION ...................................................................................................................1
1.1 Copyright information .............................................................................................. 1
1.2 Language .................................................................................................................. 1
1.3 Theory of operation .................................................................................................. 1
2. SAFETY INSTRUCTIONS ........................................................................................................3
2.1 Instructions for use ...................................................................................................3
2.2 Symbols used ............................................................................................................3
2.3 Basic safety information ............................................................................................4
2.4 Warnings ...................................................................................................................6
3. DISPLAY DEFINITIONS .........................................................................................................7
3.1 Button Functions and Definitions ..............................................................................9
3.2 Status Bar Definitions ........................................................................................... 11
3.3 Manual Menu Tree ................................................................................................... 14
3.4 Servo-Center Menu Tree ..........................................................................................16
3.5 Automatic Menu Tree ...............................................................................................18
3.6 Security Strategy ...................................................................................................... 20
3.6.1 Authorization Levels .............................................................................. 20
3.6.2 Access Modes ................................................................................................ 21
3.7 Keypad Operation .................................................................................................... 22
4. MENU DESCRIPTIONS .........................................................................................................24
4.1 SECURITY ................................................................................................................. 24
4.1.1 LOGOUT ........................................................................................................24
4.1.2 LOGIN ............................................................................................................ 24
4.1.3 PASSWORDS ................................................................................................... 25
4.14 MENU PROTECTION ........................................................................................26
4.2 DISPLAY .................................................................................................................. 27
4.2.1 LANGUAGE ..................................................................................................... 27
4.2.2 BRIGHTNESS ................................................................................................... 28
4.2.3 ROTATE ..........................................................................................................29
Navigation: ..............................................................................................................29
4.2.4 CALIBRATE TOUCH .........................................................................................30
4.2.5 OI SETTINGS ..................................................................................................31
4.3 SERVICE ...................................................................................................................32
4.3.1 ABOUT ........................................................................................................... 32
4.3.2 MEASURE ......................................................................................................33
4.3.3 CONTROL OUTPUTS ....................................................................................... 35
4.3.4 COLOR TEST ...................................................................................................37
4.3.5 MOTOR TYPE ..................................................................................................38
4.3.6 COM STATISTICS ........................................................................................39
4.4 REMOTE CONTROL ...................................................................................................40
4.5 ASC .......................................................................................................................... 41
4.6 GAIN ........................................................................................................................ 44
4.7 SENSOR SETUP ......................................................................................................... 46
4.8 AUTOSETUP ..............................................................................................................49

CONTENTS
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4.9 GUIDE SETTINGS .......................................................................................................51
4.10 CONTROL OPTIONS ................................................................................................53
4.11 POWER ON MODE ...................................................................................................55
4.12 BACKUP ..................................................................................................................56
4.13 RESTORE ................................................................................................................ 57
4.14 HARDLOCK .............................................................................................................58
4.15 NAME ..................................................................................................................... 59
4.16 MOTOR TYPE ..........................................................................................................60
4.17 Internet ..................................................................................................................61
4.18 Ethercat ................................................................................................................. 62
4.19 DLS-8 .................................................................................................................... 63
4.19.1 Normal mode ...............................................................................................63
4.19.2 Expert setting mode .................................................................................... 71
5. SYSTEM NOTES ..................................................................................................................74
6. TROUBLESHOOTING .......................................................................................................... 75
7. SERVICE .............................................................................................................................76
7.1 Return Shipment Instructions ...................................................................................76
7.2 Service Requests and Replacement Parts ................................................................. 76

CHAPTER 1
INTRODUCTION
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1. Introduction
1.1 Copyright
information
All of the information herein is the exclusive proprietary
property of Maxcess International, and is disclosed with the
understanding that it will be retained in confidence and will
neither be duplicated nor copied in whole or in part nor be
used for any purpose other than for which disclosed.
1.2 Language
These are the original instructions, written in English.
1.3 Theory of
operation
The FIFE-500 MAX Web Guiding System is designed for use
in industrial equipment that is involved with processing a
moving web. It is typically installed in line with web travel to
provide lateral steering of the web in critical areas such as
winding, rewinding, or any important mid-stream process.
It is not uncommon to find multiple web guides steering the
same web at different locations of web travel. Guiding a web
is accomplished by applying several concepts with each
directed at a particular part of the task. The basic concepts
are:
Sense the lateral position of the web edge (sensors)
Generate a correction signal proportional to the error
(signal processor)
Apply forces to the web to non-destructively move it to
the desired location (motor-controlled mechanical
pivoting rollers)
Sensing
Sensing the lateral position of the web edge can be done by
a variety of sensing technologies with the most common
being infrared or ultrasonic. The sensing technology
employed in any given application is driven by the
respective web properties in combination with the amount
sensor proportional band that is needed. For optically
opaque webs, infrared sensors are common, but for webs
that are highly transparent, ultrasonic methods are more
successful.

CHAPTER 1
INTRODUCTION
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Theory of operation
(continued)
Infrared sensing
Infrared sensors direct infrared light from a transmitter
through the sensing gap to the opposing receiver. In this
arrangement, web lateral position is determined by the
amount of light that arrives at the receiver. Modulation
techniques and infrared filtering is commonly used to
combat interference from ambient light sources.
Ultrasonic sensing
Ultrasonic sensors work similar to infrared methods
except they use high frequency sound waves instead of
light.
Correction signal
The sensor information is provided to a signal processor that
can provide many types of signal conditioning, including
amplification, guide point offset compensation, etc. The final
result however, is simply a motor drive signal of the proper
polarity to cause web movement to the desired web position.
Additional provisions are present in the signal processor to
control manual guide positioning, select from multiple sensor
inputs, perform automatic guide centering, and remote control
support.
Web guiding
The output of the signal processor is fed to a motor that is
coupled to a set of pivoting rollers. In order to ensure enough
friction exists between the moving web and the guide rollers,
the web path and location of the guide rollers are designed to
ensure a certain amount of surface area contact with the roller
surface. Under these conditions, the pivoting roller set in
combination with web movement over the rollers, provides the
forces needed to control lateral web displacement.
As a system, these concepts work together to sense the
web lateral position and generate a motor drive signal of
proper polarity to cause the web to move toward the
desired location. This cycle is repeated continuously thus
forming a closed loop control system to actively maintain
the web at the desired position.

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CHAPTER 2
SAFETY INSTRUCTIONS
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2. Safety Instructions
2.1 Instructions for use
To ensure safe and problem free installation of the FIFE-500 MAX
web guiding system, the web guiding system must be properly
transported and stored, professionally installed and placed in
operation. Proper operation and maintenance will ensure a long
service life of the device. Only persons who are acquainted with the
installation, commissioning, operation and maintenance of the
system and who possess the necessary qualifications for their
activities may work on the web guiding system.
Note: The safety information may not be comprehensive.
Please note the following:
The content of these operating instructions
Any safety instructions on the device
The machine manufacturer’s specifications
All national, state, and local requirements for
installation, accident prevention and environmental
protection
Information about
safety instructions
The safety instructions and symbols described in this
section are used in these operating instructions. They are
used to avoid possible dangers for users and to prevent
material damage.
SIGNAL WORD
Source of danger and its results
Avoiding dangers
The signal word DANGER refers to the danger of death or
serious bodily injuries.
The signal word WARNING refers to the danger of moderate
to severe bodily injuries.
The signal word CAUTION refers to the danger of slight to
moderate bodily injuries or material damage.
The signal word NOTICE refers to the possibility of damage to
equipment.
2.2 Symbols used
The following safety identification symbols are used in these
operating instructions.
WARNING /CAUTION-DUE TO ROTATION ROLLING
Reference to danger of injury caused by rolling.

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BASIC SAFETY INFORMATION
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2.3 Basic safety
information
Proper use
The web guiding system is intended to be used on
machines or systems to guide a web of material.
For indoor operation, see environmental specifications.
Improper use
Operation outside the technical specifications.
Operation in an Ex-area or intrinsically safe area.
Operation as a safety component. The web guiding
system does not hold the web position if power fails.
Outdoor operation.
Any other use than the proper use shall be deemed
inappropriate.
Installation and commissioning
Disconnect power from the FIFE-500 MAX before
connecting or disconnecting any cables.
All cable connectors must be tightened sufficiently to
provide the required connection for the cable shielding.
Any web guiding system which is damaged must not be
installed or put into operation.
Only perform installation, maintenance or repair tasks on
the web guiding system when the machine has been
stopped and is secured from being turned on.
Only perform installation, maintenance or repair tasks on
the web guiding system when there is no electrical power
in the system.
The web guiding system must be securely mounted
before being placed in operation.
Only replacement parts obtained from Maxcess may be
used.
No modifications may be made to the web guiding
system.
Do not place electrical cables under mechanical strain.
WARNING – Death or injury can result from static electric
shocks. Moving webs of material can produce large static
voltage potentials. Protect against electric shocks by
installing a conductive connection between the terminal
marked with the PE symbol on the power connector and the
PE circuit of the building or machine.

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Basic safety information
(continued)
WARNING – The web guiding system contains rotating and
moving parts which could cause injury due to crushing.
Appropriate protective guards must be installed by the user
according to his use of this product.
WARNING – Death or injury can result from unexpected
movement.
Protect against unexpected movement by removing electrical
power from the web guiding system and the machine into
which the web guiding system is being installed.
WARNING – Danger of falling down or muscle or skeletal
injury during installation.
These web guiding systems, especially the larger designs, are
heavy. Appropriate equipment is to be used and the safety
rules of the company must be observed.
Operation
WARNING – The web guiding system contains rotating and
moving parts which could cause injury due to crushing. Do
not touch anything on or in the vicinity of the moving or
rotating parts. Appropriate protective guards must be
installed by the user according to his use of this product.
Maintenance and Repair
WARNING – Death or injury can result from unexpected
movement.
Protect against unexpected movement by removing electrical
power from the web guiding system and the machine into
which the web guiding system is installed.
WARNING – Danger of injury from crushing.
Maintenance and repair tasks on the web guiding system
must be performed only when the machine has been stopped
and has been secured from being turned on again.
WARNING – Danger of falling down or muscle or skeletal
injury during maintenance and repair.
These web guiding systems, especially the larger designs, are
heavy. Appropriate equipment is to be used and the safety
rules of the company must be observed.
Decommissioning
The web guiding system must be disposed of in accordance
with all the applicable national, state and local regulations.

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CHAPTER 2
WARNINGS
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2.4 Warnings
The FIFE-500 MAX Web Guiding System may be remotely
controlled via a digital port connection. As with any
remotely-controlled device, when remote control of the
device is implemented, there is the possibility of movement
of the guiding structure when remote commands are issued.
Therefore, any time personnel are near the guiding structure,
it is recommended that standard safeguards be taken to
prevent injury. During servicing of the equipment, to prevent
injury to personnel, it is recommended that standard
Lockout/Tagout procedures be used.
The FIFE-500 MAX Operator screen should not be used while
the machine is running. If it is necessary for the operator to
use the Operator screen while the machine is running,
precautions must be taken to protect the operator from
injury due to moving material and machinery. This can be
accomplished by either surrounding the Operator screen with
a safety screen, or by remote mounting the Operator screen
in a safe location.

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CHAPTER 3
DISPLAY DEFINITIONS
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3. Display Definitions
The FIFE-500 MAX uses a 5 inch Touchscreen for Operator command inputs and status
displays. This Control Panel is divided into 5 sections of information for which brief
descriptions follow. Refer to Figure 1 for the button locations in the standard, horizontal
Control Panel.
The vertical section on the left side (Section 1) contains the Operation Mode selection
buttons(Automatic, Servo Center, and Manual) and indicates the current Operation Mode
selection by displaying the corresponding button in a green color. (Other buttons are
blue)
The horizontal section (Section 2) at the top, above the line, contains the status bar
which always contains the screen number. It may also indicate statuses, errors, and
digital I/O.
The text in the middle section (Section 3) shows the current "operating mode", bar graph
showing web position information in this active sensor mode, and the slider below it
indicates the position of the system guide point. S1/mm and S2/mm indicate the web
position information acquired by the sensor(Unit:mm).This section also contains buttons
for Guidepoint Shift and Guidepoint Reset.
The lower middle section (Section 4) contains the Left and Right Jog buttons and Jog
speed button.
The vertical section(Section 5) on the right side contains the Sensor Selection and Setup
buttons and indicates the current Sensor Mode selection by displaying the proper sensor
symbol in the Sensor Select button.This section also contains Lock screen button that
can lock or unlock the the screen.
Figure 1.
FIFE-500 MAX CONTROL PANEL
(0° AND 180° ROTATION)
1
2
3
4
5

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The Control Panel can also be configured in a vertical orientation. For the vertical orientation,
the following display descriptions apply. Refer to Figure 2 for the button locations.
The horizontal section (Section 1) along the top, above the line, contains the status bar
which always contains the menu number. It may also indicate statuses, errors, and
digital I/O.
The horizontal section near the top (Section 2), just below the line, contains the
Operation Mode selection buttons (Automatic, Servo Center, and Manual) and indicates
the current Operation Mode selection by displaying that button in a green color.
The section (Section 3) just below the Operation Mode buttons, indicates the current
Operation Mode, the selected sensor signal level in a bar graph, and the position of the
system guide point. S1/mm and S2/mm indicate the web position information acquired
by the sensor(Unit:mm).This section also contains the Guidepoint Shift buttons and the
Guidepoint Reset button.
The section (Section 4) below that, just above the Sensor Select and Setup buttons,
contains the Left and Right Jog buttons,Jog speed button.
The horizontal section along the bottom (Section 5) contains the Sensor Selection and
Setup buttons and indicates the current Sensor Mode selection by displaying the proper
sensor symbol in the Sensor Select button. This section also contains Lock screen button
that can lock or unlock the the screen.
Figure 2.
FIFE-500 MAX CONTROL PANEL
(90° AND 270° ROTATION)
1
2
3
4
5

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CHAPTER 3
BUTTON FUNCTIONS AND DEFINITIONS
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3.1 Button Functions and Definitions
AUTOMATIC Initiates the Automatic mode. Correction is
applied to the web by moving the guide in response to the
output of the sensor(s) that have been selected.
SERVO-CENTER Initiates the Servo-Center mode. The guide is
centered in its travel in response to the output of the internal
Servo-Center transducer.
MANUAL Initiates the Manual mode. No correction is applied
to the guide.
SENSOR Use to select the sensor(s) to be used for monitoring
the web position when the system is in Automatic mode. Sensor
selection is allowed in Manual and Servo-Center modes only.
SETUP Use to enter the Setup Menus for configuring and
adjusting the guiding system.
ARROWS Use these buttons to jog the guide. The direction of
guide movement is configurable.
JOG SPEED The button is used to adjust the speed of jogging
the guide.
LOCK SCREEN Hold 3s to lock the screen or unlock the
screen.
GUIDE POINT CONTROL Use the two arrow buttons to adjust
the System Guide Point while in Automatic Mode or Manual
Mode. Use the center button to reset the System Guide Point to
the default value, which is 50% of the sensor bandwidth. The
slider control indicates the guide point position.
GUIDE POINT CAPTURE This optional button (which can be
enabled from the “OI Settings” menu) sets the guide point of the
active sensor mode to the current web location. This allows
guiding to begin at the current web location when the Automatic
mode is initiated.
BACK Use this menu navigation button to return to the
previous menu level.

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HOME Use to return to the Operator Level screen.
MENU ARROWS Use in the menu system to page forward or
backward when multiple pages of menu choices are available.
The arrows are disabled (grayed-out) when no more choices are
available in the respective direction.
ACCEPT Use to save a changed value and return to the
previous screen.
REJECT This button is used to discard a changed value and
return to the previous screen.

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CHAPTER 3
STATUS BAR DEFINITIONS
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3.2 Status Bar Definitions
The status bar located horizontally across the top of the FIFE-500 MAX Web Guide Operator
Level screen remains visible at all times. The number on the right side of the status bar
indicates a hierarchical screen number. The first numerical value indicates the operation
mode (1=Manual, 2=Servo-Center, 3=Automatic). The second alphabetic character indicates
the sensor mode (A=S1, B=S2, C=S1-S2). This screen number uniquely identifies each
screen of the FIFE-500 MAX Web Guiding System(Refer to Figure 2 status bar "1A"). The
status bar also displays various icons which are described below. You can view the
description of the icons by clicking on them when needed.
OPERATION MODE One of these icons will appear to indicate
the operation mode of the FIFE-500 MAX Web Guiding System.
SENSOR SELECTION One of these icons will appear to indicate
the currently selected sensor mode.
These are the icons of the horseshoe ultrasonic sensor. You
can select only the left or right sensor or both.
If you have aDLS-8 Sensor installed, then one of these icons
will appear in the status bar.You can select only the left or
right sensor or both.The icons can also show line edge or line
center status according to your calibration.
Indicates that the left sensor and the right sensor are in use at
the same time, and the current status of both is line edge.
Indicates that the current status of the left sensor is line edge.
Indicates that the current status of the right sensor is line
center.
MENU TIMEOUT The menu screens in the FIFE-500 MAX Web
Guiding System close automatically after 3 minutes of touch
screen inactivity. The inactivity timeout option and the timeout
value are configurable. The clock icons will appear during
stages of the timeout process as the inactivity timer counts
down. If a timeout occurs, the respective menu will abort any
changes applied and return to the Operator Level screen. Some
service-related screens are immune from the timeout option
and are indicated by the presence of the orange clock icon.
LOGIN AUTHORIZATION LEVEL When security has been
configured, one of these icons will appear to indicate the
authorization level of the current user. Level 1 has the least
access while level 3 has the most. Security is disabled in the
factory default configuration so these icons will not be
displayed. All menu screens are accessible when security is
disabled.

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STATUS BAR DEFINITIONS
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READ ONLY MENU When security is enabled, options are
available to make menus “read only”, allowing an operator to
view the settings but not change them. This icon will appear
when the active menu is a “read only” menu.
DIGITAL INPUT COMMAND This icon appears when a valid
digital input command is present. Depending on the command,
some touch panel controls may be disabled during this time. A
red arrow in the down direction indicates digital input
influence is disabled. A red up arrow indicates the digital
outputs are disabled.
GUIDE POINT CHANGED This icon appears when a new
System Guidepoint has been applied. This icon will appear on
the status bar until the System Guidepoint remains unchanged
for approximately 20 seconds.
EXTERNAL LOCK This icon indicates the acceptance of the
“External Lock” digital input command. Automatic guide
movement is prohibited while in this state.
ASC ON Automatic Sensor Control (ASC) is enabled for the
current sensor mode. See the menu description for ASC for
more information about ASC operation.
ASC ACTIVE Automatic Sensor Control (ASC) is enabled and
the ASC state has been triggered. Automatic guide movement
is prohibited. See the menu description for ASC for more
information about ASC operation.
MOTOR BLOCKED This icon indicates the motor is blocked.
COMMUNICATION ERROR This error icon indicates
communication is not working between the operator screen
and the motor controller.
VOLTAGE ERROR This error icon appears when the input
voltage, motor rail voltage, or internal 12 volt power is outside
acceptable range.
MOTOR TYPE FAULT This icon appears when the motor type
is incorrect.
MOTOR HALL STATE FAULT This icon appears when a
problem is detected with the motor hall state transitions or the
encoder signals from the motor.

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STATUS BAR DEFINITIONS
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Target tracking This green icon indicates the tracking target
of the DLS-8sensor is in the field of view.
Red icon means the target is not in the field of view of the
DLS-8 sensor.
If two DLS-8 sensors are used and either one of them loses the
target or one of the sensors is disconnected, a red icon will be
displayed.

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CHAPTER 3
MANUAL MENU TREE
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3.3 Manual Menu Tree
The menus that are available in the FIFE-500 MAX Web Guiding System vary depending on
the active operation mode. The following information provides a quick reference to
summarize the menu tree for each mode. Each menu is described in more detail later in this
document.
1X MANUAL
SETUP
1X.1.1 SECURITY
1X.1.1.1.1 LOGOUT
1X.1.1.1.2 LOGIN
1X.1.1.1.3 PASSWORDS
1X.1.1.1.4 MENU PROTECTION
1X.1.2 DISPLAY
1X.1.2.1.1 LANGUAGE
1X.1.2.1.2 BRIGHTNESS
1X.1.2.1.3 ROTATE
1X.1.2.1.4 CALIBRATE TOUCH SCREEN
1X.1.2.1.5 OI SETTINGS
1X.1.3 SERVICE
1X.1.3.1.1 ABOUT
1X.1.3.1.2 MEASURE
1X.1.3.1.3 CONTROL OUTPUTS
1X.1.3.1.4 COLOR TEST
1X.1.3.1.5 MOTOR TYPE
1 X.1.3.1.6 COM STATISTICS

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1X.1.4 REMOTE CONTROL
1X.1.5 ASC
1X.1.5.1.1 ASC OFF
1X.1.5.1.2 ASC ON
1X.1.5.1.3 ASC SETTINGS
1X.1.6 GAIN
1X.1.7 SENSOR SETUP
1X.1.8 AUTOSETUP
Page forward/back
1X.2.1 GUIDE SETTINGS
1X.2.2 CONTROL OPTIONS
1X.2.3 POWER ON MODE
1X.2.4 BACKUP
1X.2.5 RESTORE
1X.2.6 Hardlock
1X.2.7 Name
1X2.8 Motor type
Page forward/back
1X3.1 Internet
1X3.2 Ethercat
1X3.3 DLS-8

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CHAPTER 3
SERVO-CENTER MENU TREE
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3.4 Servo-Center Menu Tree
2X SERVO-CENTER
SETUP
2X.1.1 SECURITY
2X.1.1.1.1 LOGOUT
2X.1.1.1.2 LOGIN
2X.1.1.1.3 PASSWORDS
2X.1.1.1.4 MENU PROTECTION
2X.1.2 DISPLAY
2X.1.2.1.1 LANGUAGE
2X.1.2.1.2 BRIGHTNESS
2X.1.2.1.3 ROTATE
2X.1.2.1.4 CALIBRATE TOUCH SCREEN
2X.1.2.1.5 OI SETTINGS
2X.1.3 SERVICE
2X.1.3.1.1 ABOUT
2X.1.3.1.2 MEASURE
2X.1.3.1.3 CONTROL OUTPUTS
2X.1.3.1.4 COLOR TEST
2X.1.3.1.5 MOTOR TYPE
2 X.1.3.1.6 COM STATISTICS
2X.1.4 REMOTE CONTROL
2X.1.5 ASC

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2X.1.5.1.1 ASC OFF
2X.1.5.1.2 ASC ON
2X.1.5.1.3 ASC SETTINGS
2X.1.6 GAIN
2X.1.7 CONTROL OPTIONS