60

ekrPro Com
with analog sensors

Translation of the
Original Operating Manual

BST International GmbH

Heidsieker Heide 53
33739 Bielefeld, Germany

Telephone: +49 5206/999 – 0

Telefax: +49 5206/999 – 999
E-Mail: info@bst-international.com

Ohne unsere Zustimmung darf diese Unterlage weder vervielfältigt, noch Dritten zugänglich gemacht werden, und sie darf
durch den Empfänger oder Dritte auch nicht in anderer Weise missbräuchlich verwertet werden. BST International GmbH

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22

with analog sensors Date: 20.06.2011
 Content 0

Table of contents
1  Description 1 
1.1  Symbols used in this operating manual 1 
1.1.1  Warning signs 1 
1.1.2  Using the keys 1 
1.1.3  LED operating status indicatuions 1 
1.2  General information 2 
1.3  Intended use 3 
1.4  General definitions 4 
1.4.1  Assignment of sensors to the guiding mode
selection keys 4 
1.4.2  Inverting of the sensor signal 5 
1.4.3  Size of oscillation amplitude related to sensor
measuring range 5 
1.4.4  SC-Oscillation – The oscillation amplitude height
depends on the software limit switch setting 6 
1.4.5  Oscillation types and oscillation curves 6 
1.4.6  Allocation of FVGs for a FVGPro 2MK 6 
1.5  Connectable components 7 
1.6  Control panel 7 
1.6.1  Graphics display 7 
1.6.2  Keypad 7 
1.7  Navigating within the system 9 
1.7.1  Entering the path 10 
1.7.2  Function keys (F-Keys) 11 
1.7.3  Arrow keys 13 
1.7.4  Buttons 14 
1.8  Safety instructions 15 
1.9  ESD protection 17 
1.10  Emissions 17 
2  Technical data 18 
2.1  Controller 18 
2.1.1  Ambient conditions 18 
2.1.2  Power supply 18 
2.1.3  Controller inputs 18 
2.1.4  FVG inputs 18 
2.1.5  Digital inputs 18 
2.1.6  Power supply outputs 19 
2.1.7  Controller outputs 19 
2.1.8  Digital outputs 19 
2.1.9  Controller output stage 19 
2.1.10  FVG ouput stage 19 
2.1.11  CAN Bus 19 
2.1.12  Display 19 
2.1.13  Weight, dimensions 19 
2.2  Sensors 20 
2.2.1  Infrared sensors 20 
2.2.2  Ultra-sonic sensors 20 
2.2.3  Opto electronic analog sensor IRS-U-2 A 21 
2.2.4  Reflection sensor TW54 C5 21 
2.2.5  Line sensor T62 D1 21 
2.2.6  Line and contrast sensor CLS Pro 600 22 
2.2.7  Reflected light measuring light barrier R42 D ... 22 
2.2.8  Fork light barrier G53 C2/5 22 
2.2.9  Digital Reflectionsensor RS20/RS30 23 
2.3  Electric motor-driven actuators 23 
2.4  Power pack 25 

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22

with analog sensors Date: 20.06.2011
 Content 0

3  Transport/storage 26 
3.1  Transport 26 
3.2  Storage 26 
4  Mounting 27 
4.1  Installation site requirements 27 
4.2  Assembly of the controller 27 
4.2.1  General 27 
4.2.2  Installation as built-on unit (wall mounting) 27 
4.2.3  Installation the reflection / line sensor 29 
4.2.4  Installation Line and contrast sensor CLS Pro 600 32 
4.2.5  Installation Digital reflectionsensor RS20/RS30 32 
5  Installation 33 
5.1  General 33 
5.2  Fitting the cable connections 34 
5.3  Installation instructions for EMC wiring 35 
6  Commissioning 36 
6.1  General 36 
6.2  Start-up with CAN-Bus 37 
6.2.1  Checking the unit address and setting up if necessary 37 
6.2.2  Terminator activation 40 
6.3  Adjust password 43 
6.4  Commissioning standard system 45 
6.4.1  Standard system with analog sensors 45 
6.4.2  Standard system with CLS Pro 600 52 
6.4.3  FVG – Sensor positioning device 53 
6.5  Additional Functions 54 
6.5.1  Additional function with analog sensor 3 54 
6.5.2  Oscillation 63 
6.6  Save/load settings 65 
6.7  Set-up menu 66 
6.7.1  Change User – Selection of user level 66 
6.7.2  Add Functions – Special functions 66 
6.7.3  Material Set-up - Sensor compensation 66 
6.7.4  Sel. Std. system – Selection of a standard system 66 
6.7.5  Save/Load Settings 66 
6.7.6  Saving and restoring equipment data 67 
6.7.7  General Set-up - Setting up system parameters 74 
7  Operation 111 
7.1  General 111 
7.1.1  Graphics display 111 
7.2  Changing the settings during operation 116 
7.2.1  Operating functions 116 
7.2.2  Guiding modes 117 
7.2.3  Gain adjustment 118 
7.2.4  Changing the setpoint 118 
7.3  Sensor positioning device 119 
7.3.1  Using the FVG function, general 119 
7.3.2  Using the FVGPro 2MK function 119 
7.3.3  Arrow keys functions and the function of the inputs 119 
7.4  Material set-up 121 
7.4.1  General 121 
7.4.2  Automatic material set-up 122 
7.4.3  Manual material set-up 122 
7.4.4  Special procedure with analog refelction sensor
connected as sensor 3 123 
7.4.5  Manual material set-up for sensors T62 D1 and
TW54 C5 124 
7.5  Tear-off detection 126 

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22

with analog sensors Date: 20.06.2011
 Content 0

7.6  Oscillation 127 

7.7  Pre-positioning 128 
7.8  Pre-positioning to machine center-line
(with FVG 2MK only) 129 
7.9  Master-Slave guiding 130 
7.9.1  Manually setting the distance 130 
7.9.2  Setting the distance by entering the value 130 
7.9.3  Using the arrow keys to set up the distance 131 
8  Remote control 132 
8.1  Remote control via CAN bus 132 
8.2  Remote control via digital inputs and outputs 133 
8.2.1  Selection of digital table and activation of
inputs/outputs 133 
8.3  Configuration of the digital inputs 134 
8.3.1  Truth table 137 
8.4  Display of the actual statuses of the digital inputs 140 
8.5  Configuration of the digital ouputs 140 
8.6  Remote control using electronic remote fine
adjustment device 143 
8.6.1  Configuration 143 
8.6.2  Operation 144 
8.6.3  Speed dependent oscillation frequency 144 
9  Default settings 145 
10  Trouble shooting 150 
11  Maintenance 154 
11.1  General 154 
11.2  Controller 154 
11.3  Sensors 154 
11.4  Electric motor-driven actuator 155 
11.5  Hydraulic unit 155 
11.5.1  Safety instructions 155 
11.5.2  Maintenance work 155 
11.6  FVG stepping motor 156 
12  Decommissioning 157 

I Index

A1 Annex 1 Commissioning examples A1

A2 Annex 2 Structure of the set-up menu A2
A3 Annex 3 Connecting plate A3
A4 Annex 4 Components connectable A4
A5 Annex 5 Terminal assignments and
signification of the service LEDs A5

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22

with analog sensors Date: 20.06.2011
 Description 1
17
1 Description
1.1 Symbols used in this operating manual
1.1.1 Warning signs
Symbols are used in this operating manual in order to clearly
indicate particularly important places.

Attention!

! You must obey this type of warning, in order to protect

yourself, as the operator, from bodily injuries arising
from mechanical movements.

Beware!
You must obey by this type of warning without fail, in
order to protect yourself, as the operator, from life
threatening injuries caused by electrical voltages.

Note
This symbol is used to point out additional useful tips,
which will help you to make optimum use of all of the
functions.

1.1.2 Using the keys

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

Press key.

+ Key combinations,
keys have to be pressed
simultaneously.

1) 2) Press keys in the specified order.

1.1.3 LED operating status indicatuions

Some keys on the front panel of the ekrPro Com60 controller have
LED´s (light-emitting diodes) integrated in them. The different LED
operating states are represented as follows:

LED off

LED constantly lit = activated phase

LED flashing

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 1/157
 Description 1
17
1.2 General information

The start-up, maintenance and installation

! instructions described in this operating manual
must be strictly adhered to!

• The ekrPro Com60 web guiding controller must be mounted and

operated only according to the knowledge of the relevant
operating manual.
This will help avoiding hazards and preventing damages to the
controller caused by improper assembly or operation.

• This operating manual, and particularly the safety instructions

must be observed by all persons working on or with the
ekrPro Com60 controller.

• Before operating the system for the first time as well as

before carrying out maintenance work you must read the
safety information provided by chapter 1.8 of this manual!

• Changing or loading firmware on this system must be carried

out exclusively by BST personnel or personnel duely
authorised to do so by BST. Non observance of this may
cause the loss of the warranty rights!

• The values and data shown in this manual (e. g. in the display)
are to be considered as examples, unless otherwise expressly
stated.

• The current version of the operating manual for the

ekrPro Com60 web guiding controller in all available languages
can be found on the Internet at the following address:

http://www.bst-international.com

This controller family includes:

• ekrPro Com60: controller with keyboard
• ekrPro Key60: external control keyboard.
Devices in the controller family can be interconnected at different
levels into a system network via a CAN-Bus.

The control unit ekrPro Com60 is available in the housing version:

• ekrPro Com60 XT: Mounting unit

(e.g. for wall mounting)

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 2/157
 Description 1
17
1.3 Intended use
The ekrPro Com60 is a microprocessor-controlled web guiding
controller. It may be used together with additional BST components
fort he following web guiding modes:
• Web edge guiding
(guiding to the right or left web edge)
• Web center-line guiding
• Guiding on continous or interrupted printed lines
(in conjunction with CLS Pro 600 line and contrast sensor)
• Guiding on continous or interrupted contrast edges
(in conjunction with CLS Pro 600 line and contrast sensor)
• Web width measuring with special equipment

The ekrPro Com60 web guiding controller has been designed to be

installed in another machine or to be integrated with other
machines to form a single system in compliance with directive
2006/42/EU (Machinery Directive).
It is forbidden to commission the system until the user/operator has
determined that the machine in which the system has been
installed, complies with the specifications given in this directive.

You are only allowed to use BST web guiding systems to correct
the position of web-shaped materials (e.g. those made from paper,
film, cardboard, rubber, etc.).
The controller and the control panel must never be installed in
potentially explosive areas.
Operation is only guaranteed if carried out using the BST web
guiding components listed in the system overview (Annex A4).

BST web guiding systems have been designed and built in

accordance with state-of-the-art standards and the recognized
safety rules.
Nevertheless, its use may constitute a risk to life and limb of the
user or of third parties or damage the BST web guiding systems
and other equipment.
Therefore BST web guiding systems are only to be used if they are
working correctly and in a safe technical condition. Any part found
to be working incorrectly must be replaced immediately.
Only original spare parts are to be used for this. Spare parts
obtained from third parties cannot be guaranteed to comply with
the design and manufacturing conditions and safety regulations.
In this case any guarantee claims made against the BST web
guiding system will be invalidated.
Only qualified personnel who have been trained on the system are
allowed to undertake any work required on the BST web guiding
system (i.e. installation, commissioning, operation, maintenance, etc.).
Intended use also includes adhering to the instructions given in this
operating manual.

Using the machine for purposes other than those mentioned above
is contrary to its intended use. BST International GmbH does not
accept liability for any damage resulting from this type of use.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 3/157
 Description 1
17
1.4 General definitions

1.4.1 Assignment of sensors to the guiding

mode selection keys

In this operating manual, the edge sensors that are connected to

the controller are designated with Sensor 1 and Sensor 2. On the
operating keyboard of the controller, the guiding mode selection
keys have the lettering SENSOR LEFT and SENSOR RIGHT
respectively.

According to the BST definition, the following link applies:

SENSOR LEFT = Sensor 1

SENSOR RIGHT = Sensor 2

The following is valid in respect of the sensor mounting positions:

The sensor, which is located to the left of the material in the

web movement direction (when looking from the material top
side), is sensor 1.
The material top side is the side of the material web which is not in
direct contact with the deflection pulleys of the pivoting frame.

Example 1: Example 2: Example 3:

Sensor right
(Sensor 2)

Sensor right
Sensor left (Sensor 2)
(Sensor 1)

Sensor left Sensor left

(Sensor 1) (Sensor 1)

Sensor right
(Sensor 2)

As standard, sensor 1 (Sensor left) must be connected to

connector X50 (terminal X1), while sensor 2 (Sensor right) must be
connected to connector X51 (terminal X2) of the terminal board.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 4/157
 Description 1
17
1.4.2 Inverting of the
sensor signal
If a BST edge sensor, of typical C-design, is mounted according to
the BST definition (see section 1.4.1) as Sensor left (sensor 1),
then no inversion of the sensor signal is necessary.
If a BST edge sensor is mounted according to the BST definition
as Sensor right (sensor 2), then inversion should be activated via
the setup menu.

When the control units is delivered, inversion of the

sensor signal for sensor 2 is activated (factory setting).

Sensor left
Not permitted!

Sensor right
Invert!

(Sensor looks to the left in web

running direction.)

1.4.3 Size of oscillation amplitude related

to sensor measuring range

0% 100 % Sensor coverage

30 % 70 %
Centre of sensor measuring range
(viewing range)

Oscillating web position

100 % of the sensor viewing range

80 % of the sensor viewing range =
maximum oscillation amplitude

40 % of the sensor viewing range

The maximum possible oscillation amplitude is 80% of the sensor

viewing range.
As an example, the oscillating web position is shown herewith an
attitude of 40% in Sensor oscillation" mode.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 5/157
 Description 1
17
1.4.4 SC-Oscillation – The oscillation
amplitude height depends on the Software limit switch 1
software limit switch setting (0%)
Adjustment range of the amplitude

Software limit switch 2

(100%)

Amplitude 30%

Only the actuator oscillates in compliance with the set value when
using this oscillation method.
The maximum possible amplitude is 98% of the gap between
the two software limit switches.
An amplitude of 30% is shown in the example above.

1.4.5 Oscillation types and

oscillation curves
An oscillation can be implemented either as a sensor oscillation or
an FVG oscillation.
In the case of the sensor oscillation, the curve described is a delta
function.
The FVG oscillation describes a curve in accordance with a sine
function.

Selection and settings are desribed in point 6.5.2 or point 6.7.7.8.

1.4.6 Allocation of FVGs for a FVGPro 2MK

Move the FVG using the appropriate

keys in the menu window.
<<< >>>
>>> <<<

web running
FVG 1 direction >>> <<<
<<< >>>

FVG 2
inner
limit switches

outer limit
switches

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 6/157
 Description 1
17
1.5 Connectable components
The general plan (annex A4) shows the components that can be
connected to the ekrPro Com60 controller.

1.6 Control panel

The control panel contains all of the operating and display controls
needed to operate the web guiding system.

The signal settings on the controller’s remote

control inputs block any keys on the control panel
that have counter functions..

1.6.1 Graphics display

A contrast-rich LCD display with LED background illumination.
Display has 6 lines, each of 28 characters.
The graphics display is used for displaying the operating statuses,
all relevant parameters and the set-up menu.

1.6.2 Keypad
There are four different groups of keys located on the keypad that
have the following functions:

Green keys: Operating mode selection

Grey keys: Guiding mode selection

Blue keys: Setup mode

White keys: Manual positoning of the guiding device,

Adjustment of setpoint and gain,
Changing of parameter values

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

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 7/157
 Description 1
17
Function Key Designation Description

Automatic Automatic web guiding

Operating mode Manual mode Manual positioning

selection of the guiding device

Servo-center Center positioning of the guiding

device

Sensor 1 Guiding to the left web edge

Guiding mode Sensor 2 Guiding to the right web edge

selection

Web center-line guiding

+

Sensor 3 Guiding to an edge / contrast

Contrast transition: bright/dark

Sensor 3 Guiding to an edge / contrast

Contrast transition: dark/bright

Manual Operating mode “Manual“:

Arrow key
positioning • Manual positioning of the guiding
left / right
of the device to the left/right
guiding device

Operating mode “Automatic“:

Shifting of the Arrow key
• Shifting the setpoint to the
setpoint left / right
left/right

MENU Menu selection

Menu navigation:
ESC
Setup mode • Jump back by one level
In editing box:
• Cancels the last entry

• Acknowledge parameter selection

ENTER
• Store value and exit setup mode

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 8/157
 Description 1
17
Function Key Designation Description

Arrow key • Parameter selection

Setup mode up / down

Arrow key
left / right • Decrease/increase parameter
value

Function keys • Different functions, depending on

F1 to F4 the menu/submenu selected

Arrow key • Toggles between operating status

Operating mode
up / down displays

Function keys • Activates special functions

Operating mode F1 and F2 (e. g. oscillation)

• Select setpoint resp. gain for

SETUP change the settings

Arrow key • Decrease/increase parameter

left / right value

1.7 Navigating within the system

Use the arrow keys and the F1 – F4 function keys to navigate

within the system.
The different functions are explained in the following.

If incorrect entries are made, or if functions are active which, for

example, prevent entering of parameters (e.g. keyboard lock) the
appropriate message windows are shown on the display for
5 seconds
This gives the user information about which error is present in the
current case. The message can be deleted using the OK key.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 9/157
 Description 1
17
1.7.1 Entering the path
The relevant path going to the description of a specific main menu
section will be displayed alongside the description. Only the
relevant window will be displayed in the actual description.

Example: Proceed as follows to set up the Actuator parameters:

1. Press the Menu key.

2. Now select General Setup by means of the vertical arrow

keys.
Press ENTER for confirmation.

3. Use the vertical arrow keys to select the submenu Actuator

and then the directory Type (EMS/Hydr.).
Confirm the respective selection by pressing ENTER.

Material Setup
Actuator
Sel. Std. Type
System
(EMS&Hydr.)
Sensors/EFE
Save/Load Settings Add-on
Hydraulics
Control Loop
General Setup
Direction
opt.FVG
LogicSC-Transducer

12 3 45 6 789 0

4. The selection window for the actuators appears in the

display and you can select the required actuator.

The path details will then be displayed in the description as

General Setup > Actuator > Type (EMS&Hydr.).

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 10/157
 Description 1
17
1.7.2 Function keys (F-Keys)

The F-keys functions are assigned in different dialog windows. The

associated abbreviated names are displayed at the bottom edge of
the screen.
Press the relevant F-key several times to select the required
numerical value. The time interval in between pressing the button
twice must never exceed 0.5 seconds.

Shortcut functions

The function keys are assigned numbers in the equipment menu.

Therefore a menu option can be selected by using the arrow keys
to navigate to the required menu sub-option or it can be selected
directly by using the shortcut number instead.

For example: Selecting the actuator

The associated menu sub-option is 611

(see navigation overview as well).

1. Press key.The set-up menu appears.

Current position
in device menu

Assignment of allocated
function keys

To enter the shortcut number:

2. Press F2 key 3x = 6.

61

The General setup menu including the submenu Actuator

is called up.

3. Press F1 key once = 1

Material Setup 611
Actuator
Sel. Std. Type
System
(EMS&Hydr.)
Sensors/EFE
Save/Load Settings Add-on
Hydraulics
Control Loop
General Setup
Direction
opt.FVG
LogicSC-Transducer

12 3 45 6 789 0

The required dialog will be displayed and you can now use the
arrow keys to select the parameter that has to be modified.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 11/157
 Description 1
17
Entries in the editing box

The parameter values are entered directly in the editing box. This
can also be realised using the F-keys.

1. Open the required submenu and then press the ENTER key
to activate the editing box.

2. Use the horizontal arrow keys to markt he initial

position fort he setting.

Width Measure Offset

current width:
mm
opened
enter ref.width 078.5
editing box
123 456 789 0

3. Enter the number. For example: press F4 x 1 = 0.

The actual position will jump automatically by 1 place to the
right after 0.5 seconds without an entry being made.

4. Now enter the next number in the same way as described

above in Section 3.

5. Press the ENTER button to import the modified value.

6. Press the ESC button to cancel the value.

Editing box

The arrow keys can also be used to enter a value in the editing box
in addition to using the F-keys.

Width Measure Offset

current width: Selected digit
mm

enter ref.width 078.5 opened

editing box
123 456 789 0

Use the horizontal arrow keys to position the cursor on

the number to be modified.
Now use the vertical arrow keys to increase or decrease
the number.
Press ENTER to import the entered value.
Press the ESC button to cancel the value if you do not want to
save it.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 12/157
 Description 1
17
Entering negative numbers
Use the horizontal arrow keys to mark the initial
position for the setting.

Now use the vertical arrow keys so that the minus sign
is entered or removed.
After this, enter the digit sequence as described above.

1.7.3 Arrow keys

Various entries can be made and options can be selected from the
menu mode dialog windows.
The procedure for the various controls and lists is as follows:
Control elements
Use the arrow keys to mark the required control if there are several
control elements displayed in the same dialog window.
For example:
sens.mode W XP
0 5.00
0 5.00
0 5.00
0 5.00

Use the ’right’ arrow key to scroll forward and

use the ’left’ arrow key to scroll backwards.

The vertical arrow keys do not have a function here.

Option lists

An entry from a default list can be selected from an option list. This
is realised by pressing the ENTER button to open the selected
option list.
Example:

The “▼“ or “▲“ symbols displayed on the right of the option list
indicate that there are more entries in list than are displayed on the
screen.

Use the vertical arrow keys to mark the position in the

list.
Confirm the selection by pressing ENTER.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 13/157
 Description 1
17
Checkbox

Use the vertical arrow keys

Arrow keys option using the checkbox control element.

Example:

(de)activate speed control

X = Option active
active X
= Option inactive

Read-only Checkbox

Read-only checkboxes only have a display function.

These give the operator reports about the current status of the
components (e.g. stop switch statuses).

Example:

= activated

= not activated

1.7.4 Buttons
Button control elements are present in certain dialog windows

Select a sensor type Inv.

sensor1 IR 2005
<<<
dark 7% bright
-2048 abs. 1775 2047
auto dark bri.

If a button is marked and the ENTER button is pressed afterwards,

an action will be executed (e.g. traversing the actuator).
The button will be displayed as being pressed down and the action
will continue to be executed all the time that the ENTER button is
kept pressed down.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 14/157
 Description 1
17
1.8 Safety instructions
The safety relevant instructions in accordance with
DIN EN ISO 13857, DIN EN 349 and the industry specific safety
regulations must be taken into consideration when installing the
BST equipment in the production machine, these include:

There must be a safe distance between the BST equipment and

the machinery already installed on-site, such as machine panels,
building structure, etc.

The connecting cables between the different components must be

laid so that nobody can trip over them, they are not taught and they
are well anchored.
Verbindungsleitungen zwischen den einzelnen Systemkompo-
nenten stolperfrei, zugentlastet und gut verankert verlegen.

Ensure that there is sufficient headroom.

If the free passage is restricted, the relevant building components
causing the restrictions must be padded and a danger warning
signs must be attached to them (yellow/black).

As a matter of course, cable connectors (e. g. between controller

and sensors) should only be disconnected when the system is no
longer connected to the mains supply (mains plug has been
removed). Any infringements will result in the warranty claim being
invalidated..

In principle, the controller does not have ATEX certification, i.e. you
are not permitted to use it in area where the danger of an explosion
exists!

Any transport safety devices that were used must be removed prior
to commissioning.

Only trained specialist personnel are permitted to

! undertake the assembly, installation and

commissioning!

!
Danger of cuts!
Never touch the edges of moving webs of material!

Danger of crushing!

! Never reach inbetween the fixed lower frame and the

moving upper frame of the guiding device (rotating
frame guide or swivel roll guide).
Never reach into the moving rollers!

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 15/157
 Description 1
17

Please do not open the controller until the line voltage

is switched off.
When operation at open unit is necessary, only
protection class IP 20 is present.
There will be an increased risk of danger by line
voltage!

Before starting work, ensure the equipment is

electrically isolated. To this end always carry out the
following measures:

1. Switch off.
2. Prevent switching back on.
3. Check the equipment is isolated.
4. Earth.
5. Cover or shield any adjacent parts that are still live.

Only then you can carry out the relevant work.

Please do not use the guiding frame as a tread or a

! Stepp ladder.
Do not remove any safety devices.

Positioning movements will be undertaken by the

! actuator during functional testing away from the

production machine and/or during the commissioning!
The relevant safety arrangements must be
implemented during performance checks!
Monitor the overall safety concept of the production
machine during commissioning!

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 16/157
 Description 1
17
1.9 ESD protection

Attention!
Hazards caused by electrostatic discharge
(ESD = Electro Static Discharge).

The device contains components which can be damaged by

electrostatic discharge. This component can receive permanent
damage, which can lead to loss of performance, failure or destruction
of the part, if it contacts electrostatically-charged persons or objects.

System component housings may only be opened at an ESD-

protecting workplace (ESD workplace in accordance with
DIN EN 61340-5-1). If there is no ESD-protected workplace
available, ESD precautionary measure in accordance with
DIN EN 61340-5-1 must be taken to ensure that electrostatic
charges are carefully discharged.

If making return shipments of electronic components or assemblies,

regulations in accordance with DIN EN 100 015 “Protection of
electrostatically-endangered components“ must be observed.
You should therefore only use the electrically conductive ESD
packaging provided for transport, and label it correctly.

BST International GmbH is not liable for any damages caused

by the nonobservance of the ESD protective measures
described here.

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

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 1

with analog sensors Date: 20.06.2011 Page: 17/157
 Technical data 2
8
2 Technical data

2.1 Controller
2.1.1 Ambient conditions
Temperature in operation: 0 ... 45°C
Storage temperature: - 10°C ... + 70°C
Air humidity in operation: 5 ... 90%, without condensing
Protection class: IP 54
Location: In closed buildings
< 2000 m above sea level

2.1.2 Power supply

Power supply: 24 V DC ± 10 % (incl. ripple)
Power consumption: 4 W (without actuator)
Input capacitance: approx. 950 µF

2.1.3 Controller inputs

2x sensors: -9,75 V ...+9,75 V or 0 V ...+9,75 V
12 Bit selectable via software.
1x sensor: -10,3 V ... +10,3 V, 12 Bit
1x EFE pot: -10,3 V ... +10,3 V, 12 Bit
1x pot return: -10,3 V ... +10,3 V, 12 Bit
1x tacho: -9,0 V ... + 9,0 V
1x blocking: input resistor 4,7 kOhm,
operating points (<4 V (low) und >8 V (high)),
but can only be used against „+“ switched
sensors (pnp),
supply 24 V DC

2.1.4 FVG inputs

1x blocking: no electrical isolation
2x reference switch: no electrical isolation
input resistor 4.7 kOhm each,
operating points (<4V (low) and
>8 V (high)),
but can only be used against „+“ switched
sensors (pnp),
supply 24 V DC

2.1.5 Digital inputs

12x digital inputs: no electrical separartion
input resistor 4.7 kOhm each,
operating points (<4 V (low) and
>8 V (high)),
but can only be used against „+“ switched
sensors (pnp),
supply 24 V DC

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 18/157
 Technical data 2
8
2.1.6 Power supply outputs
2x 24 V: for CCD Pro camera, not protected

2.1.7 Controller outputs

1x analog output: -10 V ... +10 V, 2 mA
2x IR pulses
1x lamp supply: 5 V, 1 A

2.1.8 Digital outputs

4x digital outputs: 1,0 A per output, 1,5 A in total
+24 V DC No electrical isolation.
Protected against feedback voltage
(positive voltage)
.

2.1.9 Controller output stage

1x D.C. motor: max. 3 A, short circuit protected.
24 V DC Select voltage or current control
PWM 20 kHz

2.1.10 FVG ouput stage

1x stepping motor: max. 1,5 A; not short circuit protected

2.1.11 CAN Bus

1x plug, 1x socket: no electrical isolation

2.1.12 Display
LCD graphics module with 128 x 64 pixels and LED background
illumination

2.1.13 Weight, dimensions

Weight: ekrPro Com60: approx. 2.1 kgs
ekrPro Com60 Desk: approx. 2.3 kgs

Dimensions ekrPro Com60 (built-on unit):

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 19/157
 Technical data 2
8
2.2 Sensors

2.2.1 Infrared sensors

IR 2001 IR 2002 IR 2005

Gap

reflexion foil

Power supply: from the controller

Gap (standard): 30 mm 30 mm 30 mm
Measuring range, typical: 12 mm 6 mm 12 mm
Viewing range, typical: 15 mm 8 mm 15 mm
Output: analogue
Protection class: IP 54
Ambient conditions
• Temperature 0 to max. 45 °C
• Air humidity 5 – 90%, without condensing

2.2.2 Ultra-sonic sensors

US 2003 US 2007 US 2008 US 2009

Gap

Power supply: from the controller

Gap (standard): 30 mm 40 mm 30 mm 40 mm 70 mm
Measuring range, typical: 12 mm 12 mm 6 mm 12 mm 14 mm
Viewing range, typical: 15 mm 15 mm 7 mm 13 mm 15 mm
Output: analogue
Protection class: IP 54 IP 67
Ambient conditions 0 to max. 45 °C 0 to max. 60 °C
• Temperature 5 – 90%, 5 – 90%,
• Air humidity without condensing without condensing

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 20/157
 Technical data 2
8
2.2.3 Opto electronic analog sensor
IRS-U-2 A
See the manufacturer’s data-sheet.
Use the default settings for IR 2005 for configuration.

2.2.4 Reflection sensor TW54 C5

Power supply: from the controller

Lamp voltage: 5 V; 0,8 A; from the controller for maximum of one sensor
Measuring 5,0 mm at 6 mm distance between sensor and web
rangessbereich: 2,5 mm at 13 mm distance between sensor and web
Outputssignal: negative with black areas
positive with white areas
Protection class: IP 65
Ambient conditions: Temperature: 0 to max. 50 °C
Air humidity: 5 – 90 %, without condensing
Weight: 0.240 kgs

2.2.5 Line sensor T62 D1

Power supply: from the controller

Lamp voltage: 5 V; 0,8 A; from the controller for maximum of one sensor
Measuring distance: 15 – 30 mm
Measuring range: 3 – 8 mm
Line width: 0,5 – 5 mm
Output voltage: 0 - ± 10 V
Protection class: IP 65
Ambient conditions: Temperature: 0 to max. 50 °C
Air humidity: 5 – 90 %, without condensing
Weight: 1.1 kgs

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 21/157
 Technical data 2
8
2.2.6 Line and contrast sensor CLS Pro 600
See Translation of the Original Instructions CLS Pro 600;
Line and contrast sensor with removeable control panel
(MD.323.01.xx).

2.2.7 Reflected light

measuring light barrier R42 D ...

R42 D 12 R42 D 16
Power supply: +12 V, 12 mA or
±12 V, 15 mA or
±15 V, 20 mA
Lamp voltage: 5 V; 0,8 A; from the controller for maximum of one sensor
Max. distance: 1m 2m
Measuring range 15 mm 40 mm
in front of front lens:
Diameter of light beam 25 mm 55 mm
in front of front lens:
Diameter of light beam 40 mm 55 mm
at half distance:
Output voltage: Corresponding to change in illiumination:
bright dark
at: UB = +12 V 8,5 V 2V
UB = ±12 V 8,5 V 0V
UB = ±15 V 10,5 V 0 V
Protection class: IP 65
Ambient conditions: Temperature: 0 – 70 °C (temperature compensation only up to 50 °C)
Air humitidy: 5 – 90 %, without condensing
Weight: 1 kg 1.2 kgs

2.2.8 Fork light barrier G53 C2/5

Power supply: from the controller

Lamp voltage: 5V
Fork width: 29 mm
Measuring range: ± 3,5 mm
Diameter of light beam: 11 mm
Protection class: IP 65
Ambient conditions: Temperature: –20 to max. 60 °C
Air humidity: 5 – 90 %, without condensing
Weight: 0.4 kgs
Housing dimensions: W = 21 mm
H = 85 mm
D = 87 mm

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 22/157
 Technical data 2
8
2.2.9 Digital Reflectionsensor RS20/RS30
See Translation of the Original Instructions
Digital Reflectionsensor RS20/RS30 (MD.384.01.xx).

Use the default settings Uni. 0-10V for configuration.

2.3 Electric motor-driven

actuators

Type Stroke Spindle Max. Max.

Gear ratio dimensions actuating force actuating speed
[mm]
[mm] [N] [mm/s]

EMS 1
20

not allowed for redesigns

40

EMS 5
20

1:1 8x1 80 17

40

EMS 10 16
32
46
56 1:1 12 x 2 420 20
76
96
146

EMS 16 2,4 : 1 420 20

50
5:1 840 10
2,4 : 1 420 20
100 16 x 5
5:1 840 10
2,4 : 1 420 20
200
5:1 840 10

EMS 17 2,4 : 1 420 20

50
5:1 840 10
2,4 : 1 420 20
100 16 x 5
5:1 840 10
2,4 : 1 420 20
200
5:1 840 10

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 23/157
 Technical data 2
8
Type Stroke Spindle Max. Max.
Gear ratio dimensions actuating force actuating speed
[mm]
[mm] [N] [mm/s]

EMS 18/C
2,4 : 1 420 20
50

4,2 : 1 840 10

EMS 18/CX
2,4 : 1 420 20
16 x 5
100

4,2 : 1 840 10
EMS 18/F

2,4 : 1 420 20
200
4,2 : 1 840 10

EMS 20B 2,5 : 1 840 20

100
5:1 1680 10
20 x 5
2,5 : 1 840 20
195
5:1 1680 10

EMS 21 2,5 : 1 840 20

100
5:1 1680 10
20 x 5
2,5 : 1 840 20
200
5:1 1680 10

EMS 22
2,5 : 1 1125 20
200 20 x 5

5:1 2250 10

EMS 23 7 4300 20
195
14,5 9000 10
25 x 5
7 4300 20
295
14,5 9000 10

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 24/157
 Technical data 2
8
2.4 Power pack
Power supply of the controller including the BST components
connected takes place by means of a power pack.
There are two supply possibilities:
1. over a central power pack in the machine
2. over a power pack allocated to the BST part

The following details are based on a control system comprising a

control unit ekrPro Com60, analogue sensors, sensor adjustment
device and actuator (EMS1, EMS5, EMS10, EMS16, EMS17 or
EMS20)

1. Central supply
If supply takes place centrally from the machine the following
parameters are to be fulfilled:
• Output voltage: 24 V DC ± 5%
• Output current: 4.2 A DC
• Output power: 100 W

The power pack must be able to quickly charge (~ 5 sec) the input
capacitance (approx. 950µF) of the control amplifier after switching
on without recognizing this as a short circuit and so switching off
again.
The output should be permanently resistant to short-circuiting,
overloading and idle running.

2. Separate power pack

If a separate power pack is used for the BST components, we
recommend the use of units manufactured by PULS GmbH:

Input voltage: 85 - 264 V AC or 220 – 375 V DC

Output voltage: 24 V DC ± 5%
Output current: 4.2 A DC
Output power: 100 W
BST order number: 103 837

If a number of control systems are to be supplied from a single

switched power pack, then, dependent on the total required power,
the following power packs are also available:

Input voltage Output Output Output BST order

voltage current power number
85 – 264 V AC 24 V DC 10 A DC 240 W 118 661
220 – 375 V DC ±5%
85 – 264 V AC 24 V DC 20 A DC 480 W 109 365
220 – 375 V DC ±5%
340 – 479 V AC/3Ph. 24 V DC 20 A DC 480 W 116 679
450 – 700 V DC ±5%

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 2

with analog sensors Date: 20.06.2011 Page: 25/157
 Transport/storage 3
1
3 Transport/storage
3.1 Transport
The equipment will be shipped in accordance with the details
stipulated in the order:

• completely assembled and interconnected to the web guiding

system

• as component parts in standard cardboard boxes with cellular

lining material

The unit must only be transported when it is packed in the original

BST transport packing.

BST International GmbH cannot be held liable for damage to

the controller or components which is caused by an
inappropriate transport packaging!

3.2 Storage
If the controller and the components will not be incorporated
immediately, they should be stored in a dry room until installation.

Storage conditions: Temperature: 10°C to a max. 70°C

Air humidity: 10 - 90%,
without condensing

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 3

with analog sensors Date: 20.06.2011 Page: 26/157
 Mounting 4
6
4 Mounting
4.1 Installation site
requirements
Adhere to the following points when choosing the location of the
controller:

• The controller must be installed in a dry, vibration-free area and

be ergonomically positioned.
The operator must be able to access the control panel easily.
Sunrays or external light sources must not cause reflections on
the display.

• Strong electromagnetic fields in the vicinity of the controller, the

control panel or the sensors might cause operating failures.

• Take note of the permitted ambient conditions.

Temperature: 0 to a max. 45°C
Air humidity: 5 - 90%, no condensation
See chapter 2.1.1 as well.

• The controller and the control panel do not have ATEX

certification, i.e. you are not permitted to use them in area
where the danger of an explosion exists!

4.2 Assembly of the controller

4.2.1 General
This chapter describes the procedure for installing a controller.

4.2.2 Installation as built-on unit

(wall mounting)

4.2.2.1 Mounting plan

225

Ø6

housing ekrPro Com60

125

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 27/157
 Mounting 4
6
4.2.2.2 Space needed to open the
enclosure cover
The necessary space around the enclosure must be maintained so
that the enclosure cover can be fully opened (see illustration).

Controller

Enclosure cover

4.2.2.3 Mounting

1. Drill the securing holes as

shown in the mountung
plan.

2. Screw on the enclosure

using four securing screws.

3. Wire in the electric cables (if

required) or plug in the
necessary cable
connections.

4. Close the enclosure cover (if

required).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 28/157
 Mounting 4
6
4.2.3 Installation the
reflection / line sensor

4.2.3.1 Sensor arrangement

The sensors must be arranged as follows in order to ensure clear
allocation of the two keys on the front foil of the controller to the
corresponding contrast transitions:
• The sensor connection cable points in the direction of
sensor 1.

Connecting
cable

TW54 C5

T62 D1

sensor 1 sensor 2

web running diredtion

Material web

This sensor arrangement results in the following key allocation:

→ Contrast transition
BRIGHT/DARK

→ Contrast transition
DARK/BRIGHT

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 29/157
 Mounting 4
6
4.2.3.2 Installation line sensor T62 D1

T62 D1

17
ø8

Deflection roller

Measuring arrangement T62 D1

The following points must be adhered to during installation of the

T62 D1 in order to realise optimum guiding results:
• The line sensor should be mounted on a torsionally rigid base.
• The line / contrast must be placed at right angles to the
longitudinal axis of the sensor (see drawing).
• The scanning should be carried out on a deflection roller.
This will ensure that any material web height fluctuations are
eliminated at the scanning point.
• The distance between the sensor scanning optics and the
material web must be set so that there is a light spot with a
diameter of approximately 8 mm (corresponding to a scanning
distance of approximately 17 mm) on the web.
• We recommend that the sensor angle is
5°…15° 5°…15°
reduced by 5° - 15° in the web running
direction when using very reflective materials.

Web running direction

The light spot diameter can be reduced in size by

altering the distance from the web in order to
optimise the system when working with poor
contrast or narrow lines.
The scanning distance clearance must never
exceed 30 mm.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 30/157
 Mounting 4
6
4.2.3.3 Installation reflection sensor 5°…15° 5°…15°
TW54 C5 TW54 C5

6…12

web running direction

You must abide by the following points when installing the TW54 C5
reflection sensor in order to realise optimum guiding results:
• The line sensor should be mounted on a torsionally rigid base.
• The line / contrast must be placed at right angles to the
longitudinal axis of the sensor (see drawing).
• The scanning should be carried out on a deflection roller.
This will ensure that any material web height fluctuations are
eliminated at the scanning point.
• The distance between the sensor scanning optics and the
material web has to be 6 - 12 mm, depending on the required
measuring range (diameter of the light spot).

The measuring range (light spot diameter)

depends on the distance between the contrast
transitions.

Only one contrast transition may be located within the light spot.

correct wrong wrong

Distance scanning optics D material web: 6 - 12 mm

Light spot diameter: 7.5 – 4 mm
• We recommend that the sensor angle is reduced by 5° - 15° in
the web running direction when using very reflective materials.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 31/157
 Mounting 4
6
4.2.4 Installation Line and
contrast sensor CLS Pro 600

See separate Operating Manual Line and contrast sensor

CLS Pro 600 with removeable control panel (MD.323.01.xx).

4.2.5 Installation
Digital reflectionsensor RS20/RS30

See separate Operating Manual Digital Reflectionsensor

RS20/RS30 (MD.384.01.xx).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 4

with analog sensors Date: 20.06.2011 Page: 32/157
 Installation 5
3
5 Installation
5.1 General

Attention!

! Electrical connection must be carried out by qualified

personnel.

The system must be wired according to the accompanying

connection plan or plugged into the appropriate cable sockets.

Standard wiring sleeves with collars (DIN 46228/Part 4)

must be used with all cable connections up to 0.75 mm².
Wiring sleeves must not be used with cables from
0.75 mm² up to a maximum of 1.5 mm².

Using wiring sleeves:

The crimping is also gas-tight (no cross crimping), i.e. there is no
space inbetween the conductor and the wiring sleeve.
We recommend using VarioCrimp-4 206-204 crimping tongs made
by WAGO. The metal bush of the wiring sleeve must have a length
of at least 8 mm.
Metal bush
Using cable without wiring sleeves:
For fine and multi-core cable and for fine-wired cable, whose kink
resistance is not sufficient due to its small diameter, in order to
overcome the contact force of the clamping springs, the clamp
must be correctly opened using a screwdriver.

Check that all the cables are fitted tightly after the connections
have been made (in both cases).

60
The ekrPro Com controller is protected against incorrect
connection.
If the supply voltage was inversely connected to terminals 42
and 43 of the controller, this inverse polarity would also be
connected to the 24 V output socket.
This could lead to damage to components connected to this
socket.

Attention! Applications with a sensor adjustment unit!

The stepping motor output stages are not protected against
short circuits.
You must check, without fail, using a suitable test unit
(ohmmeter) that no short circuits or cross-connections
between the two windings exist before starting the
commissioning.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 5

with analog sensors Date: 20.06.2011 Page: 33/157
 Installation 5
3
5.2 Fitting the
cable connections

Attention!

! All connecting cables must be laid without being tight

and you must ensure that there is no danger of
tripping over them.

• Install the cables between the system components (controller,

sensors, actuator, ...) as per the connecting plan.
• Take note of the EMC installation instructions (see chapter 5.3).
• Tighten all the securing screws on the plug connections.
• Ensure that the voltage supply has the correct potential
equalisation in accordance with the local regulations.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 5

with analog sensors Date: 20.06.2011 Page: 34/157
 Installation 5
3
5.3 Installation instructions
for EMC wiring
housing wall
union nut

1. Unscrew in the union nut for the cable

screw-in cable glands.

intermediate supports

2. Pull out the clamping insert from the

intermediate supports.
Attention! Do not press down on the
cable insert.
cable insert

3. Strip cable back by 8 mm so that the

screen braiding is uncovered

4. Pull the union nut onto the cable

5. Feed the cable into the cable clamp

and bend the screening back over the
cable clamp.

6. Push the clamping insert to the

intermediate support.

7. Fit the screws.

ekrPro Com60 web guide controller EDV no: MD.191.01.07/1.8.22 Chapter: 5

with analog sensors Date: 20.06.2011 Page: 35/157
 Commissioning 6
75
6 Commissioning

Attention!

! Commissioning must be carried out by qualified

personnel.

Danger from mains voltage!

Never open the controller before switching off the
mains!

Conditions:
• The web guiding system is completely wired in, i.e. the cable
connections between the individual web guiding system
components (controller, sensors, actuator, servo-center
transducer, ...) are made (see chapter 5.1 to 5.5).
• The controller is connected to the power supply.

6.1 General

The controller ekrPro Com60 is matched to the actual configuration

of the control system (connected sensors, actuator, sensor
adjustment unit, ...) using the system parameters in the individual
setup menus.
The required parameters have already been entered if the control
system is an integral part of a projected BST system. You do not
have to reset anything with regard to this.
A new system configuration is required if components or the
controller have been exchanged on-site.
The range of the settings and therefore the set-up menus that have
to be taken into consideration depend on the system being used.

To simplify commissioning, the commissioning staff can select his

system from a list of the most common standard systems (see
chapter Commissioning standard system).
Following the selection, all of the basic settings are automatically
entered in the setup menu.
Finally the commissioning staff has only to check a few application-
related settings and if necessary adjust them accordingly.

The procedures to be used with the separate menus are described

in chapter General Setup.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 36/157
 Commissioning 6
75
6.2 Start-up with CAN-Bus

6.2.1 Checking the unit address and

setting up if necessary

6.2.1.1 ekrPro Com60

If the ekrPro Com60 controller is operated via a CAN bus, then the
setting of the CAN device address must be checked.
The CAN device address setting up is carried out via the S1 rotary
switch on the processor board:

switch S1

60
The ekrPro Com address is preset to "1" in the factory (delivery
state).
• Set the S1 rotary switch to "1" if the ekrPro Com60 is the only
device connected to the CAN bus.
• If you want to run several ekrPro... family devices on one CAN
bus system, then different device addresses (1 – 8) must be set
for the devices.
One of the devices must be set to device address "1" without
fail! Device addresses 0 and 9 are reserved.

Each device address can only be used once per guiding

system!

Procedure:
1. Switch-off the power to the controller.
2. Open controller’s front cover.
3. Set S1 rotary switch to the required device address (1 – 8).
4. Close the controller’s front cover.
5. Restore the power.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 37/157
 Commissioning 6
75
6.2.1.2 ekrPro Key60 (if fitted)

There are several plugs on the rear side of the

ekrPro Key60.
The rotary switch S1 for setting the address (node
number) is behind these plugs.

Procedure:
1. Switch-off the power to the controller.
S1 rotary switch
2. Remove the plug.
3. Check setting of rotary switch S1. If necessary,
set device address to S1 = 1.
4. Refit the plug.
5. Restore the power.

6.2.1.3 FVGPro Module (if fitted)

The device address setting up is also crried out via

the S1 rotary switch mounted on the board:

Procedure:
1. Switch off the power to the FVG Pro module.
2. Open housing’s front cover.
3. Check the setting of the rotary switch S1.
If necessary, set device address to S1 = 1.
4. Close the controller’s front cover.
5. Restore the power.

S1 rotary switch

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 38/157
 Commissioning 6
75
6.2.1.4 CLS Pro 600 (if fitted)

Sensor
The sensor’s device address is set up using the S1 rotary switch.
There are four stoppers fitted on the sensor’s connection side.
The rotary switch S1 is provided behind this stopper.

Procedure:
1. Switch-off the power to the sensor.
2. Unscrew the stopper in the sensor enclosure
3. Check the S1 rotary switch setting
The S1 rotary switch must be set to position “1“.
4. Switch the S1 rotary switch to position “1“ if
necessary.
5. Screw the stopper back into the sensor enclosure.
6. Switch the power supply back on.

Control panel
The control panel’s device address is set up using the S1 rotary
switch fitted on the panel board.
The S1 rotary switch is mounted behind stopper B on the back of
the control panel.

Procedure:

1. Unplug the control panel connecting cable from the

sensor.
2. Carefully remove stopper B from the back of the
control panel.
3. Check the S1 rotary switch setting
The S1 rotary switch must be set to position “1“.
4. Switch the S1 rotary switch to position “1“ if
necessary.
5. Replace the stopper.
6. Reconnect the control panel connecting cable to the
rotary switch S1 sensor.

The device address modification will be effective after the

power has been restored.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 39/157
 Commissioning 6
75
6.2.2 Terminator activation

The terminator must be activated on each of the physical first and

last CAN bus participants. The possible settings are described
below.
.

6.2.2.1 ekrPro Com60

In the ekrPro Com60, the activation is carried out using switch S3

on the processor circuit board. Set the switch to "ON“.

Terminator S3

Procedure:
1. Switch-off the power to the controller.
2. Open controller’s front cover.
3. Activate terminator S3 (switch position ON)
4. Close the controller’s front cover.
5. Restore the power.

6.2.2.2 ekrPro Key60 (if fitted)

In the ekrPro Key60 activation

is carried out via switch S3.

Remove plug on the

back side.
Set the switch to ON.

Switch S3

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 40/157
 Commissioning 6
75
6.2.2.3 BST ProLogic (if fitted)

In the BST ProLogic activation takes place using the DIP switch
segment 1 (S1 = ON) for the CAN 1.

CAN 2

6.2.2.4 FVGPro Modul (if fitted)

In the FVGPro Module activation is carried out via switch S3 on the

processor circuit board. Set the switch to ON.

Switch S3

Procedure:
1. Switch-off the power to the module.
2. Open module’s front cover.
3. Activate terminator S3 (switch position ON)
4. Close the module’s front cover.
5. Restore the power.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 41/157
 Commissioning 6
75
6.2.2.5 CLS Pro 600 (if fitted)

Sensor
The sensor’s internal terminator resistor is switched on or off using
switch S3.
There are four stoppers fitted on the sensor’s connection side.
The switch S3 is provided behind this stopper.

Switch S3 Function
OFF Internal terminating resistor switched off
ON Internal terminating resistor switched on
(default factory setting)
switch S3
Procedure:
1. Switch-off the power to the sensor.
2. Unscrew the stopper in the sensor enclosure
3. Check the S3 switch setting.
The S3 switch must be set to the ON position.
4. Switch S3 to the ON position if necessary.
5. Screw the stopper back into the sensor enclosure.
6. Switch the power supply back on.

Control panel
The control panel’s internal terminator resistor is switched on or off
using switch S3.
The S3 switch is provided behind stopper C on the back of the
control panel.

Switch S3 Function
OFF Internal terminating resistor switched off
ON OFF ON Internal terminating resistor switched on
(default factory setting)

switch S3 Procedure:
1. Unplug the control panel connecting cable from the
sensor.
2. Carefully remove stop C from the back of the control
panel.
3. Check the S3 switch setting.
The switch must be set to the ON position.
4. Switch over to the ON position if necessary.
5. Replace the stopper.
6. Reconnect the control panel connecting cable to the
sensor.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 42/157
 Commissioning 6
75
6.3 Adjust password
User administration in the ekrPro Com60 differentiates between four
different user levels with different user rights.
The individual user levels are each protected by a password.
Dependent on the selected user level, more or fewer paths are
activated in the setup menu. Non-activated entries are greyed out
in the menus and cannot be selected.
The user levels with the corresponding user rights are shown in the
following table.

User level Rights Default Password

Operator • No rights to make changes in the setup menus. 0
(Operator)
Mainten. • Unlimited changing rights in the menu 1
Maintenance “Material Setup”.
personnel
Admin. • Unlimited rights to make changes in the setup menus. 2
Administrator
BST Support • As for “Admin.” (only for BST servicing purposes)
(BST-Service)

The unit is supplied with the user level Admin set.

The indicated default password should only be used for the first
access to the setup menu and then an application-appropriate
password entered. This is also true for the Mainten. user level.
This protects the system against unauthorized access.
Make sure these new passwords are only known to the authorized
personnel!
BST International GmbH is not liable for damage arising from the
incorrect use of the password(s).

An automatic logout time can be set for all user levels (timeout
time). If no key is pressed for the set time, the user is automatically
logged out and the controller changes to the user level Operator.

Changes to passwords and the timeout time is undertaken from the

menu General Setup > Special > Change Pwd

All passwords can be reset to the default passwords up to 20

seconds after switching on of the controller by pressing the key
combination F4 + ESC.

When the controller is switched-off, the last active user level is

stored and automatically activated after a reboot.

The procedure for selecting the user level is described in the

following pages.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 43/157
 Commissioning 6
75
Selection of user level is undertaken from the Change User menu.

1. Select Change User menu and press ENTER.

Change User

Enter user level & password

User level Operator 2. The user level selection window appears.
Password
Current
0
In the lower part of the window the active user level is
user level: Admin. displayed (Admin. in the example).
logout login

Enter user level & password

Press the ENTER button and the user level option list will
User level Operator then be opened.
Password
Current
Mainten.
Admin. Select the desired user level with the up and down arrow
user level BST Support keys.
Confirm the selection by pressing ENTER.
123 456 789 0

Enter user level & password

User level Mainten. 3. Use the right and left arrow keys to select the Password
Password
Current
00000
editing box and press ENTER.
user level: Admin

123 456 789 0

Enter user level & password

User level Mainten. Enter the password and confirm the entry with ENTER.
Password 1
Current
user level: Admin
4. Press the F3 key (login).
The controller changes to the selected user level.
logout login

5. Press ESC key.

The Setup menu selection window appears.
Entries, for which there are no user rights in the selected
user level are shown greyed out.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 44/157
 Commissioning 6
75
6.4 Commissioning standard system

To simplify commissioning, the commissioning staff can select his

own system from a list of the most common standard systems
listed under the menu Sel. Std. System.
Following the selection, all of the basic settings are automatically
entered in the setup menu and the system is switched to the
operating mode MAN.

6.4.1 Standard system with analog sensors

6.4.1.1 Select standard system
1. Press the MENU button.
The setup menu of the controller appears in the display.

Sel- Std. System 2. Select menu Sel. Std. System and press ENTER.

F1 for fa ct. defaults

Choose standard system …
3. The selection window for the standard system will appear.
select a standard config.
… & press F2 to activate

De f. Set.
4. Press the ENTER button.
The option list opens with the most common standard
systems. Individual entries each contain the following
information:
Type of connected Type of connected Type of the
sensor(s) actuator sensor positioning device
(if fitted)

5. Use the vertical arrow keys to select the system that

matches the present system.
Confirm the selection with the ENTER key.
The selected system is displayed.

6. To import the standard system configuration, press

function key F2 (set.).
The selection is confirmed by the message window
Standard System Set.
The system will now request a restart.

7. Switch off the supply voltage to the controller and then

restart again shortly afterwards
F1 for fa ct. defaults
Choose standard system …
8. The other procedures depend on whether an external efe
select a standard config. Plus control panel has been connected up (continue with
… & press F2 to activate
Chapter 6.4.1.2) or not (continue with Section 9).
De f. Set.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 45/157
 Commissioning 6
75
9. If an external efe Plus control panel has been connected up,
you can use this to call up the standard system’s option list
F1 for fa ct. defaults once again.
Choose standard system …
select a standard config.
… & press F2 to activate

De f. Set.

9.1 Select Std.Sys.+efe Plus if an

analog sensor has been connected to your
application.

9.2 If a CLS Pro 600 line and contrast sensor has

been connected up, select
CLS: EMS17/18 [+efe Plus].

10. Press ENTER to confirm your selection.

The selected system is displayed.

11. Press the F2 (Set.) function-key to take over the

configuration.
Your selection can be confirmed via the Standard System
Set information window.
The system will now request another restart. Switch off the
power supply to the controller and restart it again shortly
afterwards.

The configuration of a standard system with an external control

panel connected up to it has now been completed.
Continue with Chapter 6.4.1.2.

How to operate an ekrPro Com60 controller using efe Plus is

described in detail in the separate MD.348.01.xx operating manual.

It supports the following functions:

• Changing the operating modes
• Changing the scanning modes
• Changing the Xp control gain
• Changing the W set point

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 46/157
 Commissioning 6
75
Attention!
After selecting the standard system, adjustment for a
particular application (e.g. material properties) must
take place.
Accordingly, the following steps should be carried out:

6.4.1.2 Carry out master set-up

The sensor type will already have been set when the standard
system was set.

The procedure is described for Sensor 1.

The master set-up for Sensors 2 and 3 is the same.
The master set-up option is not needed with TW54 or T62 line /
reflection sensors. Light and dark settings have fixed values when
they are used.

1. Select Sensors/EFE in General set-up and then select the

General Setup > Sensors/EFE > Sensor 1 sub-directory afterwards. Confirm the respective
Sensor 1 selection by pressing ENTER.

2. Select the type of sensor that is connected to the system

Select a sensor type Inv. from the option list displayed in the new window that has
sensor1 IR 2005
opened up and then enter it.
<<<
7%
dark
-2048 abs. 1775
bright
2047
Attention!
auto dark bri.
If the mounting position of the selected sensor differs from
the BST General definitions or if the sensor outputs an
inverted signal (e.g. another manufacturer’s sensor is being
used), then the checkbox Inv. must be checked.
A master set-up will be carried out afterwards.
Master set-up can be run automatically or manually.

3. Automatic master set-up:

► Press the F1 button and then cover the sensor’s
scanning window with an opaque material for two
seconds afterwards.
► Remove the material from the scanning window and
press the F2 button two seconds later.
► This completes the master set-up for this sensor.

4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque
material and then press the F3 button.
► Remove the material so that the window is completely
uncovered and press the F4 button.

5. Run the master set-ups for Sensors 2 and 3.

If a sensor listed as not connected was selected, the standard

light and dark settings of 2047 or -2048 can be set up again by
first pressing the F1 button and then the F2 button.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 47/157
 Commissioning 6
75
6.4.1.3 Setting the actuator guiding direction
For standard systems, the EMS17/18 is preset as the actuator.
The direction has to be set for it.

General Setup > Actuator > 1. Select the sub-directory Direction from the menu Actuator.
Direction Confirm the selection by pressing ENTER.

If necessary, the actuator guiding direction for manual mode

can be reversed by activating the checkbox Mot. Dir.
Toggle Man Dir. until Inverted.
F2 moves to sensor 1
The rotational direction can be checked on the spot.
Mot. Dir. Inverted
Drive the actuator using the F2 or F3 key.
If key F2 is pressed, the actuator must move the material
web in the direction of sensor 1, if F3 is pressed it must
move it towards sensor 2!

Pressing F2 or F3 automatically changes the controller to

“manual” operating mode.
The sensor allocation can be checked on the spot. Press the
MENU button. The operating display is shown.

Cover one sensor. The change to the coverage range shows

the allocation.
After this, press the MENU key to ENTER to the settings
menu.

2. Press the ESC button to exit the window.

6.4.1.4 Setting the actuator path limits

From here it is possible to limit the adjustment travel of the
actuator.
General Setup > Actuator >
SC Transducer > Pos. Limit 1. Select Actuator in General Setup, then the sub-directory
SC-Transducer and finally Pos. Limit.
Deactivate to set limits Confirm the respective selection by pressing ENTER.
Activate to test limits
47% active 2. Use the vertical arrow keys to deactivate the checkbox
active. This deactivates the function of both limit switches.
-264 456 1258
<<<< The settings can only be entered in the deactivated state.
lim.l <<<< lim.r

3. Use the F2 key to drive the actuator until it reaches the

required left limit switch position.
The actual position of the actuator supplied by the position
feedback is shown in the middle above the F2 and F3 keys.

4. Confirm this position by pressing the F1 key.

The acceptance of the limit switch position is indicated by an
empty graphic bar being displayed in the middle.
The corresponding position value is shown below the
checkbox.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 48/157
 Commissioning 6
75
5. Use the F3 key to traverse the actuator until it reaches the
required right limit switch position.

Deactivate to set limits 6. Confirm this position by pressing the F4 key.

Activate to test limits
The acceptance of the limit switch position is indicated by a
47% active
filled (black) graphic bar being displayed in the middle.
-264 456 1258
lim.l <<<<
<<<<
lim.r 7. Reactivate both limit switches.
Select (x) checkbox active to do this

Import of the limit switch position is indicated by a black

circle in the read-only checkbox above the F1 and/or F4
key.

Press ENTER to confirm any fault messages that are

displayed.

8. Press the ESC button to exit the inputting menu.

6.4.1.5 Setting center position and gain

for „S-C“ operating mode

From here the centre position and the amplification for operating
mode S-C are set.

General Setup > Actuator > 1. Select Actuator in General Setup, then the sub-directory
SC Transducer > SC W&XP SC-Component and finally SC W & XP.

2. Press ENTER to open the inputting menu and enter the

parameters.

3. The current actuator position will be displayed in the field

mot.pos..

4. Use the F2 and F3 keys in MAN operating mode to traverse

the actuator into the required position.

5. Press the F4 key if you want to save the current position as

the setpoint value for the centring position.
The setting from mot.pos. will be imported into set-point W.

6. The setpoint value setpoint W and the gain gain XP can

also be entered directly in the relevant window.

7. The settings can be checked on the spot by switching over

to the S-C operating mode.

8. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 49/157
 Commissioning 6
75
6.4.1.6 Man Pos Control
Activating manual position control (option)

You must activate the position controller for use in Manual mode
in the case of drives equipped with position reporting
(e.g. EMS 18).
If the position controller has been activated the actuator will stop
when it has traversed into position in MAN mode regardless of
whether the power is applied to the drive from an external source
(self-locking).

When using an OMG 4, OMG 8 or CK 37 centre

position encoder, the position controller must be
deactivated!

General Setup > Actuator > 1. Select Actuator position in general set-up and then call up
Man Pos. Control the Man Pos. Control sub-menu.

2. Press the ”ENTER” button to enter the inputting menu.

3. Use the vertical arrow-keys to activate the active checkbox

to switch the position controller on.

Test the position controller by using the F2 or F3 keys to

traverse the actuator in manual mode into the required
position.

The function can be interrupted by pressing the F4 key if the

position controller is active (i.e. to prevent the material web
from being damaged).

4. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 50/157
 Commissioning 6
75
6.4.1.7 Carry out material set-up

Automatic adjustment of the controller to match the characteristics

of the material to be scanned is carried out during material set-up
(e.g. different material transparency at the optical sensors or
different sound absorption in the case of ultrasonic sensors).
The material set-up is the same for all three sensors.
The procedure for sensor 1 is used as the example here:

Material Setup > Sensor 1 1. Press MENU key and select Material-Setup afterwards.
Confirm the respective selection by pressing ENTER.

2. Select Sensor 1 and confirm by pressing ENTER.

Material Setup - Sensor 1 This will open the Sensor 1 material set-up window.
<<<
dark 7% bright
-2048 abs. 1775 2047
auto dark bri.

Material set-up can now be carried out either automatically or

manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.

Automatic material set-up

1. Press F1 key.

2. Completely cover the sensor’s scanning window with the

material to be scanned for approx. 2 seconds.

3. Completely remove the material from the sensor scanning

window (no material over the sensor).

4. Press F2 key.

This completes the material set-up for this sensor. Material set-up
is finished when the same procedure has been carried out for any
other sensors connected to the controller.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 51/157
 Commissioning 6
75
Manual material set-up

1. Completely cover the sensor’s scanning window with the

material to be scanned.

2. Press F3 key.

3. Completely remove the material from the sensor scanning

window (no material over the sensor).

4. Press F4 key.

The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or

the bright setting (steps 3 and 4) can be made first.

For sensors TW54 C5 and T62 D1, you must use the special
Material set-up – Sensor 3.

6.4.2 Standard system with CLS Pro 600

For commissioning of a standard system with line and
contrastsensor CLS Pro 600 see Quick Reference Guide
MD.337.01.xx.

6.4.2.1 Standard system with CLS Pro 600 and sensor positioning device
This controller software version allows the CLS Pro 600 line and
contrast sensor to be used with existing sensor adjustment units
(FVG) as well.
However, the Watchdog function is only supported in the no FVG
application.
Configure the standard system with analog sensor and FVG in
accordance with your version.
Call up the option list for standard systems once again afterwards
and then select the Std.Sys.+CLS [+efe Plus] entry.

Press ENTER to confirm.

The selected system is displayed.

Press the F2 (Set.) function-key to take over the configuration.

Your selection can be confirmed via the Set Standard System
information window.
Now restart the system. Do this by switching off the power supply
to the controller and restarting it again shortly afterwards.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 52/157
 Commissioning 6
75
6.4.3 FVG – Sensor positioning device

The stepping motor output stages are not protected against

short circuits.
You must check, without fail, using a suitable test unit
(ohmmeter) that no short circuits or cross-connections
between the two windings exist before starting the
commissioning.
The connection cable from the ekrPro Com60 control unit to
the sensor adjustment unit must not exceed the maximum
cable length of 20 m.
Power is continuously applied to the stepping motor output
stage, even when stopped. Therefore any work undertaken on
the interconnections must only be carried out with the power
switched off.

Various default settings will be displayed in the FVG sub-menu, but

these will depend on the configuration that was selected under
Select Standard System..

The values are listed in the default settings chapter.

The Feed (feed stepping motor / gearing combination) parameter

value is only to be altered, if necessary, in agreement with the
manufacturer.
The relevant procedure then has to be agreed.
The warranty rights will be invalidated otherwise.

Run a FVG-Parameter optimisation if the sensor adjustment unit

default settings do not meet the application requirements.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 53/157
 Commissioning 6
75
6.5 Additional Functions
Useful additional functions can be realised using the ekrPro Com60.
These functions can be accessed quickly under this menu point.
These functions deal with the Tear Off Detection, Oscillation and
Master-Slave.

6.5.1 Additional function with

analog sensor 3
6.5.1.1 Tear-Off Detection
Tear-off detection can be activated after the system has been
configured using the F-keys displayed in the operating screen.
Tear-off detection enables, dependent on the selected sensing
type (edge / contrast guiding) the following functions:

1. With web edge guiding:

Erkennung von Ausrissen an der Bahnkante mit Kanten-
Sensoren IR2001/2005, US2007, …
Detection of torn off sections on the web edge using edge
sensors IR2001/2005, US2007, …
This function is activated during web edge guiding, if during
operation of the web guiding system errors arise from the web
edge that is being scanned.
The function detects both tears into the material web (inward
tear) as well as projecting material (outward tear).

2. With guiding to a contrast:

Guiding on interrupted printed or contrast edges with contrast
sensors T62 D1 or TW54 C5.

Interrupted printed
or contrast edge

Light spot of the

contrast sensor

Tear-off
inwards

Tear-off
outwards

Tear-off detection can be implemented using the same sensors

that are used for web guiding.
Alternatively a second sensor can be used.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 54/157
 Commissioning 6
75
Criteria for detecting a tear:
To detect a tear, at least one of the two following criteria must be
fulfilled:

1. Exceeding / undershooting of the preset threshold value

If the sensor signal exceeds or falls below the set threshold
value (threshold), then this is recognised as a tear.
After a preset delay time (delay) has elapsed, the web guiding
system is automatically blocked.
Blocking of the guidance system is lifted, as soon as the sensor
signal again lies above/below the set threshold value and the
set run-on time (hold time) has elapsed.

2. Exceeding of the preset maximum rate of change of the sensor

signal.
The system continuously checks the rate of change speed of
the sensor signal in both positive and negative directions. If the
preset maximum permissible rate of change (sig. chg. lim.) is
exceeded, then this is recognized as a tear.
After a preset delay time (delay) has elapsed, the web guiding
system is automatically blocked.
If the set rate of change is undershot, then blocking of the
guiding system is not lifted.
Lifting of the blocking is only implemented if the preset
threshold value (threshold) is again undershot (see point 1).

Conditions for guiding on interrupted printed or contrast edges

For trouble-free operation of the control unit, the following

conditions must be fulfilled:

1. Minimum mark length

The printed or contrast edge to be sampled must not fall below
the minimum mark length Lmin. The minimum mark length
depends on the maximum web speed, vmax, the sampling cycle,
t, and the diameter, d, of the light spot of the contrast sensor
used. It can be calculated using the following formula.

Light spot

d L

Vmax [m/min] d [mm]

Lmin [m] = ¹ 3 ¹ t [s] ¬
60 s/min 1000 mm/m

Lmin = minimum marl length [m]

vmax = max. web speed [m/min]
t = sampling cycle [s] = 0,004 s
d = light spot diameter [mm]

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 55/157
 Commissioning 6
75
Example calculation:
At a maximum web speed vmax = 300 m/min and a light spot
diameter d = 8 mm the resultant minimum mark length Lmin,
equals:
300 m/min 8 mm
Lmin = ¹ 3 ¹ 0,004 s ¬
60 s/min 1000 mm/m

Lmin = 0,068 m = 68 mm

2. Alignment of the contrast sensor:

When scanning an interrupted line, correct

alignment of the contrast sensor must be observed:
• The contrast sensor must be aligned so that the
edge of the line is located in the sensor light
spot.
• Only one edge may be located within the light
spot.

correct wrong wrong

3. Operating mode setting for the contrast sensor T 62 D 1

The operating mode selection switch on the sensor must be set

to the position Kante (edge).

Operating mode
selection switch

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 56/157
 Commissioning 6
75
Parameter settings

Add. Functions > Tear Off Det. > 1. Select Add. Functions in General Setup and then select
Edge 1 /Edge 2 / Edge 3/ the Tear Off Det. sub-directory afterwards.
Center 1&2 Confirm the respective selection by pressing ENTER.

2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3,

Center 1&2) from the option list.
Confirm the selection by pressing ENTER.

3. This will open up the inputting window for the selected

guiding mode. The following separate parameters can be
set:

► Sensor: Selection of the sensor with which tear-

off detection is to be implemented.

► threshold [%]: Percentage covering of the sensor

measuring band, above which a change
is detected as a tear.
For the example value entered here
(80/20), this means that the function
detects a tear, if more than 80% or less
than 20% of the sensor measuring
band is covered.

► sig. chg. limit [%/4ms]: Maximum permissible rate of

change of the sensor signal in
% per 4 ms
(Scanning cycle = 4 ms, i.e. the
sensor measurements are read
every 4 ms).
A tear is detected, if the rate of
change of the sensor signal
exceeds the percentage per 4
ms set here.
The values to be set are
calculated according to the
formula on the following page.

► delay [ms]: Delay time in ms from detection of a

tear until blocking of the guiding
system.

► hold [ms]: Blocking hold time in ms after the

detected end of the tear until the
blocking is lifted, i.e. until the guiding
system is activated.

4. If necessary, set parameters for further guiding modes

(see points 2 and 3).

5. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 57/157
 Commissioning 6
75
Calculation of the maximum allowable rate of change of the sensor
signal (parameter sign. chg. limit)

The maximum permissible rate of change sig. chg. limit of the

sensor signal, depends of the minimum web speed vmin and
diameter d, of the contrast sensor light spot and can be calculated
using the following formula.
Vmin [m/min]
sig. chg. limit [%/4ms] = 2 ¹ * ¹ 100
60 s/min * d [mm]

sig. chg. limit = permissible rate of change [%/4ms]

vmin = min. web speed [m/min]
d = light spot diameter [mm]

Example calculation:
At a minimum web speed vmin = 30 m/min and a light spot diameter
d = 10 mm the resultant maximum rate of change of the sensor
signal equals:
30 m/min
sig. chg. limit [%/4ms] = 2 ¹ ¹ 100
60 s/min * 10 [mm]

sig. chg. limit [%/4ms] = 10 % /4ms

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 58/157
 Commissioning 6
75
6.5.1.2 Watchdog
General information
The Watchdog function is used when guiding from a print using a
reflection sensor, in order to prevent the material web from
misrouting after the complete loss of the printing.
The watchdog system is only available with ekrPro Com60 for
guiding via Sensor 3 and Sensor 3 inverted (guiding sensor).
With activated function, the guiding mode edge 1 or edge 2
(watchdog sensor) is used temporarily.
The Watchdog must be used in conjunction with activated tear-off
detection.
The arrangement of the guiding sensor and watchdog sensor must
be obtained from the following sketch.
The watchdog sensor must be aligned at the same height or
behind the guiding sensor in the web running direction.

print
web running direction

guiding sensor
e.g. CLS Pro 600

watchdog sensor

Function:

The Watchdog will be activated, i.e. guiding is carried out using a

watchdog sensor when the set threshold or the minimum
permissible rate of change of the sensor signal (sig. chg. limit) of
the guiding signal for the set time (delay), is exceeded without
being interrupted.
The set threshold will be immediately switched back to the guiding
sensor when this drops back again.
If the Watchdog delay time elapses (without falling below the
threshold in the meantime), the guiding mode will be switched over
to Watchdog and the cover of the watchdog sensor is set as the
setpoint for the Watchdog guiding mode.
The sensor value age (number of cycles) used can be set from 1 to
49 cycles (at 4 ms).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 59/157
 Commissioning 6
75
Standard application

Add. Functions > Tear Off Det. > The default settings of the system do not have to be altered for
WD Edge 3 standard applications.
In this case, the Watchdog function is only to be activated.

For this purpose, call up the Watchdog menu as illustrated on the

left and activate Watchdog (Enabled).

Press MENU.
The last operating state that was set up will be displayed on the
screen. Use the standard screen’s vertical arrow-keys to select
Sensor 3 with Watchdog activated.
This will be displayed as follows:

watchdog sensor

guiding sensor

Press F1 or F2 to activate the Watchdog function for trapping with

Sensors 1 or 2.
The Watchdog is only active when either the Edge 3 or Edge 3
inverted guiding mode has been set. During the trapping, the
original scanning mode (Edge 3 or Edge 3 inverted) is displayed by
the flashing LED of the respective button.
The watchdog guiding mode (Edge 1 or Edge 2) is indicated by the
illuminated LED inside the respective button.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 60/157
 Commissioning 6
75
Deviation from standard settings

If the preset parameters must be changed due to the application,

proceed as follows:

Parameter setting for the tear-off detection

Add. Functions > Tear Off Det. > 1. Go to the Add Functions position in the menu and then
Edge 3 select the Tear Off Det. sub-directory.
Press ENTER to confirm your selection.

2. Set Edge 3 guiding mode.

Press ENTER to confirm your selection.

3. This will open up the corresponding settings window.

The settings must be checked here and modified if
necessary.

► Sensor: Set Edge 3.

► threshold [%]: Percentage cover of the sensor

measuring range, after which the
Watchdog should be activated.
In the case of the example value
entered here (80/20), this means that
the function will detect a tear if more
than 80% or less than 20% of the
sensor measuring range is covered.

► sig. chg. limit [%/4ms]:

Maximum permissible sensor signal
change rate in % per 4 ms (see the
description of the tear-off detection for
the calculation of the values).
► delay [ms]: Delay time in ms from detection of a
tear until blocking of the guiding
system.
This value must be set to 0 (zero).

► hold [ms]: Blocking hold time in ms after the

detected end of the tear until the
blocking is lifted, i.e. until the controller
is enabled.
This value must also be set to 0
(zero).

4. Press ESC to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 61/157
 Commissioning 6
75
Parameter setting for the Watchdog

Change User Pre-requirement for running Watchdog is that WD Edge 3 guiding

Add.Tear Off Det.
Functions
Edge 1 mode has been set and that Watchdog has been activated
Osc. Mode
Material Setup
Edge 2
Osc.
Sel. Std.Params
System
Edge 3 (enabled).
Osc.params
Save/Load Add-on
WD Settings
Edge 3

123 456 789 0 The following parameters can be adapted in the setting window for
the Watchdog function:

► Delay: Time in seconds that a tear is detected

before Watchdog is activated.
The values entered in the example
means that the system will be switched
over to Watchdog guiding mode after a
tear of more than one second has been
detected.

► Sens.Val.Age: This value is used to determine how

many cycles the sensor value for the
watchdog sensor should be, which will
also be used as the setpoint when
trapping.
The value range is between 1 and 49
cycles.

Press ESC to exit the window.

Operation

Press MENU.
The last operating state that was set up will be displayed on the
screen. Use the standard screen’s vertical arrow-keys to select
Sensor 3 with Watchdog activated.
This will be displayed as follows:

watchdog sensor

guiding sensor

Press F1 or F2 to activate the Watchdog function for trapping with

Sensors 1 or 2.
The Watchdog is only active when either the Edge 3 or Edge 3
inverted guiding mode has been set. During the trapping, the
original guiding mode (Edge 3 or Edge 3 inverted) is displayed by
the flashing LED of the respective button.
The watchdog guiding mode (Edge 1 or Edge 2) is indicated by the
illuminated LED inside the respective button.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 62/157
 Commissioning 6
75
6.5.2 Oscillation

This special function enables the position of the web to be

displaced within the sensor´s viewing range using adjustable
amplitude (size of the lateral displacement) and frequencies
(displacement speed).
The format of the web displacement when the controller is
operated without a sensor positioning device follows a delta curve
( ).
When operated with a sensor positioning device, a sine-wave ( )
web displacement takes place.
See also chapter Oscillation types.

Osc. Mode – determine operating mode for oscillation mode

Add. Functions > Osc. Mode 1. I Select Add. Functions in General Setup and then select
the Osc. Mode sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. The operating mode that the oscillation has to be activated

for is determined from this window. Activation then takes
place in the operating status display using the F1 key.
The following settings are possible:

• OFF: Oscillation is deactivated

(factory setting)
• Auto: Activation in operating mode
Automatic
Repositioning of material web is
carried out within the sensor visual
area with adjustable amplitude.
• SC: Activation in operating mode S-C
using the software limit switches of the
actuator.
• FVG Auto: Oscillation with connected FVG.
An FVG oscillation with sine-shaped
web repositioning.

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 63/157
 Commissioning 6
75
Osc. Params. – Set oscillation parameters

The oscillation parameters, i.e. amplitude and frequency, are

set in this submenu.

Add. Functions > OSC. Params 1. Select the Osc. Params submenu and confirm by pressing
ENTER.

Set Oscillation Parameters 2. The parameters have the following meanings:

► Amplit. Auto [%]: Amplitude of the oscillation in operating

mode Automatic.
The percentage value relates to the
size of the sensor scanning area.
Setting range: 1 % to 99 %

► Amplit. SC [%]: Setting up the amplitude for the S-C

operating mode
The percentage wise input of the
amplitude relates to the distance
between the software limit switches.
One limit switch represents 0 % and the
other 100 %.
Setting range: 1 % to 99 %

► Amplit. FVG [mm] Amplitude of oscillation when using a

sensor positioning device.
The sample value shown here of
10 mm results in repositioning of the
web by ± 5 mm.
Setting range: 0 to 999.9 mm

► Frequency [Hz]: Oscillation frequency.

Setting range: 1 … 60 min-1

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 64/157
 Commissioning 6
75
Osc. Params Add-on – Additional functions for oscillation
(can only be used for the sensor oscillation)

Additional specifications can be set for the sequence of the

oscillation in this submenu.

Add. Functions > 1. Select the submenu Osc. Params Add-on and
Osc. Params Add-on confirm with ENTER.

Oscillation Add-on:
2. The parameters displayed in the setting menu have the
following meanings:

>> NOT FOR FVG OSC.!<< ► start/stopp at act.pos:

When the function is activated, the
oscillation will continue at the position
where it was stopped.
► start osc. after restart:
When the function is activated, the
oscillation is immediately started when
the system is switched back on.

6.6 Save/load settings

Once the parameters have been determined for the current

system, they can be saved. This enables the facility to access
them again at any time in the case that modifications have been
carried out unintentionally or by unauthorized persons.

Save/Load Settings 1. Call up Save/Load Settings menu.

2. Saving or loading the settings can now be carried out using

keys F2 or F3.
F2 = Save the entered setting
F3 = Load saved values

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 65/157
 Commissioning 6
75
6.7 Set-up menu
The system parameters are saved in the Setup menu and they can
also be modified from here. The menu structure is shown in Annex
A2.

6.7.1 Change User –

Selection of user level
User administration in the ekrPro Com60 differentiates between four
different user levels with different user rights.
The individual user levels are each protected by a password.
The procedure for selecting the user level is described in detail in
Adjust password.

6.7.2 Add Functions –

Special functions
The special functions enable to implement tear detection,
oscillation and master / slave controlling, etc.
The procedures for parameterising and setting up the special
functions can be found in: Special functions (Standard system) and
(Setting parameters).

6.7.3 Material Set-up -

Sensor compensation
Automatic adjustment of the controller to match the characteristics
of the material to be scanned is carried out during material set-up
(e.g. different material transparency at the optical sensors or
different sound absorption in the case of ultrasonic sensors).
The material set-up procedure is described for commissioning a
Standard systems and for a general setup.

6.7.4 Sel. Std. system –

Selection of a standard system
To simplify commissioning, the commissioning staff can select his
own system from a list of the most common standard systems
listed under the menu "Sel. Std. System".
Following the selection, all of the basic settings are automatically
entered in the setup menu.
The procedure for selecting a standard system is described in
detail in Startup of a standard system.

6.7.5 Save/Load Settings

You can use this function to save user-defined settings in the
system and call them up again. This gives you the facility for
accessing them at any time in the case that modifications have
been carried out unintentionally or by unauthorized persons.

The procedure for selecting a standard system is described in

detail in Save/load setting.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 66/157
 Commissioning 6
75
6.7.6 Saving and restoring equipment data
Equipment data can be saved externally using our BST Tools
software (Version 3.1.2 upwards) if you are using software version
1.6.29 or upwards and re-loaded into the system whenever it is
needed.
The data can be re-loaded via the CAN interface or the controller’s
serial connection.

6.7.6.1 Requirements
The laptop or PC that you will be using must meet the following
minimum requirements:
● Windows 2000 with as least SP2 or
Windows XP operating system
● Microsoft Net Framework 1.1 or higher
● 400 MHz processor or faster

A cable set, including the converter, has to be used to set up the

connection between the PC and the controller and it can be
ordered from BST:
(BST Part-No. for serial connection: 129136 BST part No. for CAN
connection: xxx xxx). Either set includes the software CD.

6.7.6.2 Installing the BST Tools software

The installation is run via a set-up file (setup.exe). You can run the
installation separately or automatically by inserting the CD.

1. Do not install the connecting cables now.

2. Insert the CD in the PC and install BST Tools.

Two buttons will be displayed on the desktop after the installation

has been completed, which represent the application’s two options:

Serial connection:

CAN interface:

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 67/157
 Commissioning 6
75
6.7.6.3 Procedure when using the
serial connection
Please note that the connection between the controller and the PC
must have been set up before you start the program.

1. Connect up the cable set, which includes the converter, to one

of the PC’s USB connection ports.
Now switch the controller on.
Open the controller’s front cover and plug the cable set’s green
plug into the socket on the controller (X 41).

Important: The plug must only be plugged in after the

controller has been switched on!

2. Start the program

You can start the program by clicking on

the BST Tools Serial icon displayed on
the desktop.

3. The start screen will be displayed.

4. Now press the F3 key or click on the F3 read/write parameter

list button

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 68/157
 Commissioning 6
75
5. You must select whether you want to save your data or call
existing data back up in the next step.

6.7.6.3.1 Saving device data

Press the F11-key or click on the F11 device data button if you
want to save device data.

A progress bar indicates the data transfer progress.

The “Device data read in“ status message will be displayed after
the progress bar has reached the end

and an overview window will open up automatically.

Enter a new data name here or select an existing file name that
you want to use to save the data under.
Press the Save button afterwards.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 69/157
 Commissioning 6
75
The back-up parameter is now complete. You can now close the
BST tools program. This is done by pressing the

F10-key or clicking on the button .

Unplug the green plug and then close the controller’s front cover.

6.7.6.3.2 Restore saved data

Connect up the cable set as described in Section 6.7.6.3.
Press the F7-key or click on the “Load device data“ to re-load the
saved device data.

An overview window will open up automatically.

Select the data that you want to re-load from here.
Press the Open button afterwards.

A progress bar indicates the data transfer progress. The “Device

data written in“ status message will be displayed after the
progress bar has reached the end

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 70/157
 Commissioning 6
75
Restoring the data / parameters has been completed. You can now
close the BST tools program. This is done by pressing the

F10-key or clicking on the button .

Unplug the green plug and then close the controller’s front cover.

6.7.6.4 Procedure when using a

CAN interface
Use the cable set, including the converter, to connect up the
controller (X 101 CAN connection) to the PC (USB connection).
The driver will be installed automatically.

1. Switch the ekrPro Com60 on.

2. Start the program

You can start the program by clicking

on the BST Tools CAN icon displayed
on the desktop.

Please note that the connection between the controller and the
PC must have been set up before you start the program.

3. The start screen will be displayed.

4. English or German are available for use as the menu

languages. Press the F6 key or click on the F6 Configuration
button to set up the language that you want to use

Set up the language that you want to use from the following
selection window. Press F10 to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 71/157
 Commissioning 6
75
5. Now press the F4-key or click on the F4 read/write parameter
list button

6. You must select whether you want to save your data or restore
existing data back up in the next step.

6.7.6.4.1 Saving device data

Press the F11-key or click on the “Save device data“ to save
the data

A progress bar indicates the data transfer progress. The

“Device data read in“ status message will be displayed after
the progress bar has reached the end

and an overview window will open up automatically.

Enter a new data name here or select an existing file name that
you want to use to save the data under.
Press the Save button afterwards.

The parameter back-up is now complete.

You can now close the BST tools program.
This is done by pressing the F10-key or
clicking on the button

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 72/157
 Commissioning 6
75
6.7.6.4.2 Restoring data
Press the F7-key or click on the F7 Restore device data button
to restore the device data.

An overview window will open up automatically.

Select the data that you want to re-load from here.
Press the Open button afterwards.

A progress bar indicates the data transfer progress.

The “Device data written in“ status message will be displayed

after the progress bar has reached the end.

Restoring the data / parameters has been completed. You can now
close the BST tools program. This is done by pressing the

F10-key or clicking on the button .

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 73/157
 Commissioning 6
75
6.7.7 General Set-up -
Setting up system parameters

All of the parameters that have to be set up once when aligning the
system are contained in the General set-up.

The following procedures are provided for the different operating

modes.
However, the default values should be loaded before the special
parameters are set up. This will meet the condition for a
standardised basic output.

6.7.7.1 Setting the default values

Sel. Std. System 1. Call up the Sel. Std. System menu.

F1 for fa ct. defaults

2. Press the F1-key. The default settings will be loaded.
Choose standard system …
select a standard config.
… & press F2 to activate

De f. Set.

3. Press the ESC key to exit the window.

4. The application specific parameters can be set up now.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 74/157
 Commissioning 6
75
6.7.7.2 Actuator –
Actuator settings

Type (EMS&Hydr.) – Actuator selection

The relevant servo center component must be entered before

starting the commissioning.
Any remote control which may possibly be running, must be
deactivated!

The preset actuator is the EMS 17/18.

If you use this actuator, direction of rotation, actuator path limits
and the servo-center component have to be adjusted if necessary.

If a different motor-driven or hydraulic actuator is being used it

should first be selected from the option list.
The actuator selection procedure is shown on the left.

1. Press the MENU key, select General Set-up from the

General Setup > Actuator > submenu and then press ENTER.
Type (EMS&Hydr.)
2. Select Actuator in General Setup and then select the
Type (EMS&Hydr.) sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

3. The default actuator will be displayed on the screen.

Press the ENTER button and the actuator option list will then
be opened.
Now use the vertical arrow keys to select the actual actuator
that is connected to the system.

Motor-driven actuators: EMS …

Hydraulic actuators: hyd. … mA

Note: If a hydraulic actuator is used, then

additional hydraulic settings must be made
in the menu Hydraulics Add On (see the
following page).

Confirm the selection by pressing ENTER.

Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 75/157
 Commissioning 6
75
Hydraulics Add-on – Hydraulic settings
If a hydraulic actuator is used, then additional hydraulic settings
must be made in the menu Hydraulics Add On.

General Setup > Actuator > 1. Select Actuator in General Setup and then select the
Hydraulics Add-on Hydraulics Add-on sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

Zero elevation [%] 0 2. This will open an inputting window, in which the settings for
Dither amplitude [mA] 0 the connected hydraulic actuator have to be entered.
Use teach table
Specific current control The relevant settings are listed in the following table:

Teach Unit Actuator Dither Zero Specific

name type amplitude elevation current
[mA] [%] control
SV 1-10/4 300 mA 10 0 no
SV 1-10/8 300 mA 10 0 no
SV 1-10/16 300 mA 20 0 no
SV 1-10/32 300 mA 20 0 no
SV 1-10/48 1000 mA 40 0 no
SV 1-6 300 mA 20 0 no

HR 024 300 mA 1* no
HR 040 300 mA 20 0 no

EH-St 9/3 300 mA 25 5 no

The dither frequency is 50Hz.
1* This setting is dependent on the fitted
continuously operated valve SV 1-10/x.

3. The system must be optimized to the actual settings after

the parameters have been entered. This is realised by an
integrated self-teach function.
Press the F3 key to start this function.
This will import the throughput curve for the hydraulic
actuator. The measured values are saved in table as non-
volatile settings.

Attention: The hydraulic actuator will traverse fast in one

direction up to the stop and then do the same in
Zero elevation [%] 0 the other direction during the Teach-in process.
Dither amplitude [mA]
Use teach table
0
X
The relevant safety arrangements must be
Specific current control implemented.

Teach The flow curve determined for the controller must be activated in
the window if it is to be used.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 76/157
 Commissioning 6
75
Digital blocking output (oil blocking)

If a hydraulic actuator is used, then a blocking valve can be

connected to terminal 67 (X15), in order to interrupt the oil flow.

Oil blocking is only active with a hydraulic actuator and when one
of the following conditions is fulfilled:
• Man output = 0 and position controller deactivated.
• A limit switch position is reached.
• An over-temperature and a short circuit exist.
• Missing enable for the actuator:
(see actuator enable terminal 53)

Behaviour when oil blocking is switched on:

• PWM and analogue output are blocked.
• Blocking is activated after a 150 ms delay
(O V at terminal 67 (X15)

Behaviour when oil blocking is switched off:

• Blocking is deactivated
(24 V DC at terminal 67 (X15))
• Blocking is deactivated after a 150 ms delay.

Direction – Setting the actuator guiding direction

General Setup > Actuator > 1. Select the sub-directory Direction from the menu Actuator.
Direction Confirm the selection by pressing ENTER.

If necessary, the actuator guiding direction for manual mode

Toggle Man Dir. until
F2 moves to sensor 1
can be reversed by activating the checkbox Mot. Dir.
Mot. Dir. Inverted
Inverted.
The rotational direction can be checked on the spot.
Drive the actuator using the F2 or F3 key.
If key F2 is pressed, the actuator must move the material
web in the direction of sensor 1, if F3 is pressed it must
move it towards sensor 2!

Pressing F2 or F3 automatically changes the controller to

manual operating mode.

The sensor allocation can be checked on the spot. Press the

MENU button. The operating display is shown.

Cover a sensor. The change to the coverage range shows

the allocation.
After this, press the menu key to ENTER to the settings
menu.

2. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 77/157
 Commissioning 6
75
SC-Transducer – Servo-center component settings

Type & Dir. –

Selecting the servo-center component

General Setup > Actuator > 1. Select the sub-directory SC-Transducer from the Actuator
SC Transducer > Type & Dir. menu and then select Type & Dir..
Confirm the respective selection by pressing ENTER.

not connected
2. Use the horizontal left or right arrow keys in the newly
opened window to select the servo-center component
selection window and confirm it by pressing ENTER.

3. Select and mark the relevant servo-center component from

the option list. For actuators with integrated position
feedback (EMS 17, EMS 18, EMS 20B, EMS 21, EMS 22
and EMS 23) there is a common servo-center component. In
this case EMS_Pot. has to be selected.
Select not connected if a servo-center component is not
connected to the system.

4. Confirm the selection by pressing ENTER.

The screen will ENTER to the previous window.

5. Drive the actuator using the F2 key, while monitoring the bar
indicator in the display.
Position feedback via the servo-center component must be
configured so that when the actuator is driven, the black bar
on the left side gets smaller.
If the length of the black bar increases when the F2 key is
pressed, inverting is to be switched on by selecting the
check box Inv..

Pressing key F3 must cause the black bar to increase

towards the right side.

The absolute position value supplied by the servo-center

component is displayed beneath the bar display.

Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 78/157
 Commissioning 6
75
Pos. Limit –
Setting the actuator path limits (software limit switches)

This sub-directory is only be used if an actuator with position

feedback (for example, EMS 18) is connected to the system.
This enables you to limit the actuator paths.

General Setup > Actuator > 1. Select Actuator in General Setup, then the sub-directory
SC Transducer > Pos. Limit SC-Transducer and finally Pos. Limit.
Confirm the respective selection by pressing ENTER.
2. Use the vertical arrow keys to deactivate the checkbox
Deactivate to set limits active. This deactivates the function of both limit switches.
Activate to test limits The settings can only be entered in the deactivated state.
47% active
3. Use the F2 key to drive the actuator until it reaches the
-264 456 1258 required left limit switch position.
The actual position of the actuator supplied by the position
<<<<
lim.l <<<< lim.r

feedback is shown in the middle above the F2 and F3 keys..

4. Confirm this position by pressing the F1 key.
The acceptance of the limit switch position is indicated by an
empty graphic bar being displayed in the middle.
The corresponding position value is shown below the
checkbox.

5. Use the F3 key to traverse the actuator until it reaches the

required right limit switch position.

6. Confirm this position by pressing the F4 key.

The acceptance of the limit switch position is indicated by a
filled (black) graphic bar being displayed in the middle.

7. Reactivate both limit switches.

Select (x) checkbox active to do this.
Deactivate to set limits
Activate to test limits If the relevant limit switch is tripped then this will be indicated
47% active
by a black circle being displayed in the appropriate read-
-264 456 1258 only checkbox above the F1 or F4 keys.
<<<<
lim.l <<<< lim.r
Press ENTER to confirm any fault messages that are
displayed.

8. Press the ESC button to exit the inputting menu.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 79/157
 Commissioning 6
75
SC W & XP –
Setting the centre position and the gain for the S-C operating mode

This sub-directory is only be used if an actuator with position

feedback (for example EMS 18) is connected to the system.
In this case the centre position setting option and the gain have to
be set up for the S-C operating mode.

General Setup > Actuator > 1. Select Actuator in General Setup, then the sub-directory
SC Transducer > SC W&XP SC-Transducer and finally SC W & XP.

2. Press ENTER to open the inputting menu and enter the

parameters.

3. The current actuator position will be displayed in the field

mot.pos..

4. Use the F2 and F3 keys in MAN operating mode to move

the actuator into the required position.

5. Press the F4 key if you want to save the actual position as

the set point for the servo-center position.
The setting from mot.pos. will be imported into setpoint W.

6. The setpoint value setpoint W and the gain gain XP can

also be entered directly in the relevant window.

7. The settings can be checked on the spot by switching over

to the SC operating mode.

8. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 80/157
 Commissioning 6
75
Man Pos Control – Activation of the Position Controller

The position controller for ”manual” mode can be activated for

actuators with position feedback (e.g. EMS 18).
With the position controller activated, the actuator keeps the actual
position when in manual mode, independently of any external
forces acting on the drive (self-locking).

When using an OMG 4, OMG 8 or CK 37 servo-center

component, the position controller must be deactivated!

General Setup > Actuator > 1. Select Actuator in General Setup and then select the
Man. Pos. Control Man Pos. Control sub-directory afterwards.

2. Press the ENTER button to enter the inputting menu.

3. To switch on the position controller activate checkbox active

using the vertical arrow keys.

To test the position controller the actuator can be moved in

manual mode to a desired position using the F2 and F3
keys.

If the position controller is activated, the function can be

interrupted by pressing the F4 key (e.g. to prevent damage
to the material web).

4. Press the ESC button to exit the window.

Man Speed – Setting positioning speed for manual mode

This submenu is used to set the positioning speed of the actuator

in manual operating mode.

General Setup > Actuator > 1. Select Actuator in General Setup and then select the
Man Speed Man Speed sub-directory afterwards.

2. Press the ENTER button to enter the inputting menu.

3. Enter the desired positioning speed in the editing box

MAN speed [1/1000].

Input of the positioning speed is as a percentage of the

maximum positioning speed.
The example value of 700 entered here means a positioning
speed of 700 per thousand = 70 percent of the maximum
speed.

To test the set positioning speed move the actuator using

the F2 and F3 keys.

4. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 81/157
 Commissioning 6
75
6.7.7.3 Sensors/EFE -
Commissioning sensors and remote electronic fine adjustment

Sensor 1, 2, 3 – Commissioning sensors

The types of the sensors that are actually connected can be set up
in the submenus Sensor 1, Sensor 2 and Sensor 3.

The following must be undertaken before running the master set-

up so that the correct guiding results and the correct importing of
the sensor reference setting for checking the amount of dirt can be
guaranteed:
a) Clean the lenses if using optical scanning with
infrared edge sensors
b) Clean the transmitting and receiving capsules if
scanning with ultrasonic edge sensors
The commissioning of the sensor (master set-up) only has to be
run once during the initial start up of the respective sensor.

Setting up the sensor and operation

The procedure is described for Sensor 1.
The master set-up for Sensors 2 and 3 is the same.

1. Select Sensors/EFE in General set-up and then select the

General Setup > Sensors/EFE > Sensor 1 sub-directory afterwards. Confirm the respective
Sensor 1 (Sensor 2/Sensor 3) selection by pressing ENTER.

2. Select the type of sensor that is connected to the system from

Select a sensor type Inv.
sensor1 IR 2005 the option list displayed in the new window that has opened up
<<< and then enter it.
dark 7% bright
-2048 abs. 1775 2047 Attention!
auto dark bri. If the mounting position of the selected sensor differs from the
BST setting (see General definitions) or if the sensor outputs
an inverted signal (e.g. another manufacturer’s sensor is being
used), then the checkbox Inv. must be checked.
A master set-up will be carried out afterwards.
Master set-up can be run automatically or manually.

3. Automatic master set-up:

► Press the F1 button and then cover the sensor’s scanning
window with an opaque material for two seconds
► Afterwards remove the material from the scanning window
and press the F2 button two seconds later.
► The master set-up for this sensor is finished.

4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque
material and then press the F3 button.
► Remove the material so that the window is completely
uncovered and press the F4 button.

5. Run the master set-ups for Sensors 2 and 3.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 82/157
 Commissioning 6
75
Attention! If a reflection sensor is being used as Sensor 3
then only this sensor must be selected and
entered from the option list. You do not have to
run a master set-up.

EFE Remote Adj. – Commissioning of remote electronic fine

adjustment (EFE)

General Setup > Sensors/EFE > A remote electronic fine adjustment unit is not identified
EFE Remote Adj. automatically by the controller.
It must be entered in the set-up menu.

1. Select Sensors/EFE in General Setup and then select the

EFE Remote Adj. sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. Not connected is the default factory setting.

Select EFE 1 if a remote adjustment device is available.

3. Press the ESC button to exit the window.

For using the remote electronic fine adjustment see also chapter
Remote control.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 83/157
 Commissioning 6
75
6.7.7.4 Control Loop -
Control Loop settings

The parameters for the control circuit are set up in this submenu.

Gain & Offset – Amplification and setpoint settings

General Setup > Control Loop > 1. Select Control Loop in General Set-up and confirm by
Gain & Offset pressing ENTER afterwards.

2. Mark Gain & Offset in the selection window and then

confirm by pressing ENTER.

3. This will open up a window for the set point value and gain
sens.mode W
0
XP
5.00
settings.
0 5.00 The set value (W) for the web position and the gain setting
0 5.00
0 5.00 (XP) can be set up separately here for each of the guiding
modes.
We recommend that you should use the factory default
settings for standard controllers.

Setting range: 0 – 999.99

4. Press the ESC button to exit the window after you have
entered the settings.

Adj. Done Limits – Bearing position controlled

Using the specifications (notification threshold), evaluations are

made in this submenu as to when a new position that has been
approached is termed as controlled. This can then be used as
the start position for the following working sequence. This
notification threshold must be determined empirically and
individually for each application. You can only influence the
message and not to the controlling of the system.
General Setup > Control Loop >
Adj. Done Limits 1. Mark Adj.done Limits in the selection window and then
confirm by pressing ENTER.

2. Determine the values.

Note that: Larger values require an earlier message.

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 84/157
 Commissioning 6
75
Speed Control – Speed regulation

When speed control is activated, speed variations, which can be

caused by varying loading of the actuator, are automatically
compensated.
This activation of this function is a default setting.
It must be deactivated if a tacho-generator is being used.

General Setup > Control Loop > 1. Select Speed control in the selection window and then
Speed Control confirm by pressing ENTER.

2. Activate speed control using the vertical arrow keys:

(de)activate speed control
3. Press the ESC button to exit the window.
active X

Arrow key lock – Setting it up to apply to the arrow keys

You can control the arrow key functions in normal mode that apply
when setting up the Xp control gain and the W set point.
This will, for example, prevent unauthorised re-adjustment of the
set values.

General Setup > Control Loop > The following set-up options are available for use:
Arrow key Lock
• Both functions remain active = Xp and W can be set up
using the arrow keys
• W keypress deactivated = Arrow key functions only work
with the current Xp control
gain
• XP keypress deactivated = Arrow key functions only work
with the current W setting

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 85/157
 Commissioning 6
75
6.7.7.5 FVG- Sensor positioning device

The control unit integrated in the controller for running the sensor
positioning device can be parameterised in this submenu.
A stepping motor drives the sensor adjustment unit.
The stepping motor output stages are not protected against
short circuits.
You must check, without fail, using a suitable test unit
(ohmmeter) that no short circuits or cross-connections
between the two windings exist before starting the
commissioning.
The connection cable from the ekrPro Com60 control unit to
the sensor adjustment unit must not exceed the maximum
cable length of 20 m.
Power is continuously applied to the stepping motor output
stage, even when stopped. Therefore any work undertaken on
the interconnections must only be carried out with the power
switched off.

The FVG function has been set to not activated in the factory, i.e.
no further settings are required if an FVG is not connected to the
system.

The required setting must be entered if the FVG function will be

used.

Connection – Activating the FVG connected

1. Select FVG in General Setup and confirm by pressing

General Setup > FVG >
ENTER afterwards.
Connection

2. Select Connection in the selection window and then press

ENTER to open the inputting menu.

3. Select the desired operating mode from the option list.

• Not Connected: The sensor positioning device is

deactivated (default setting).

• FVG eco: Move the sensors/FVG slides manually

by means of the controller arrow keys.

• FVG 1MK Op.: Sensor positioning device with stepping

motor. The FVG slides are moved by
the controller.
• FVG 2MK Op.: Sensor positioning device with two
stepping motors. It is fitted with a hoist.
The FVG slides are moved by the
controller.

4. Press the ESC button to exit the inputting menu.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 86/157
 Commissioning 6
75
Once the selection has been made, specific settings must be
carried out for the FVG eco, FVG 1MK Op. and FVG 2MK Op.
modes.

FVG eco
The FVG eco mode allows the sensors/FVG slides belonging to
the FVG connected to be moved using the controller arrow keys. It
effectively represents manual operation of the FVG.
For this reason, automatic edge search functions and web width
adjustment are inactive in this mode.
The specific settings are analogue to those in the Internal FVG.

Internal FVG
The Int. FVG submenu is used when the FVG 1MK Op. mode has
been selected (normally when using a FVG 1K or FVG 1MK).

Homing Direction –
Retraction direction and limit switch assignment
General Setup > FVG > The sensor’s retraction direction and the assignment of the limit
Int. FVG > Homing Dir. switches are set up in the next steps.

1. Mark Int. FVG in the FVG selection window and then

confirm by pressing ENTER. Select Homing Dir. from the
sub-directory and then press ENTER to open the inputting
menu.

2. Press the F2 key to check the selected retraction direction.

By pressing the F2 key, the FVG slide must move outwards
(into the homing position).
Int. FVG Homing Direction
After the homing position is reached, the limit switch with the
Test homing dir. using F2/F3 outer label must be activated ( ).
Homing dir. inv.
Ref. switch inv. If the FVG slide moves inwards when the F2 key is pressed,
outer inner then the checkbox Homing dir. inv. should be activated.
>><<
<<>>

If the limit switch with label inner is activated in the homing

position, then the checkbox Ref. switch inv. should be
activated.

Note: If the limit switch is activated but no checkbox

(outer or inner) is activated, then the limit switch
requires testing.

3. Press the ESC button to exit the inputting menu after you
have entered the setting.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 87/157
 Commissioning 6
75
The outside FVG1 limit switch has been determined as the
reference point for the FVG slide (offset = 0.0 mm)

Offset

Offset 2 (FVG)
FVG 1

FVG 2
Web running direction

Offset 1 – position offset to FVG1 slide position

You can use the position offset to, for example, set the home
General Setup > FVG > position (= 0.0 mm) to a fixed point, e.g. machine wall or a specific
Int. FVG > Offset 1 point within the machine. The offset value is added to the current
FVG position, which results in the "Abs. slide pos.“

absolute position
Fixed point in the machine
(e.g. machine wall

offset
actual FVG position

Home position
[Dist. from home = 0.0 mm]

Offset 2 – position offset to FVG2 slide position

General Setup > FVG > The meaning of the entry and display fields is equivalent to those
Int. FVG > Offset 2 of Offset 1.
2000 mm has been set as the default value for the FVG2 offset.
When carrying out initial start-up, this value must be adapted to the
actual FVG length.

If Sensor 2 moves in the opposite direction to Sensor 1, and if the

distance information is based on the same fixed point, you should
activate the Inverted checkbox.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 88/157
 Commissioning 6
75
Range –
Traversing range limits

The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the
operating status screen.

General Setup > FVG > 1. Select Range from the sub-directory and then press ENTER
Int. FVG > Range to open the inputting menu.

2. Press the F1 to start the retraction of the slides to the park

position (home position). After this position has been
reached, the FVG stops.

3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch
has been reached, press key F4 (set). This completes the
adjustment procedure.

4. Press key F1 to run the sensor to the park position so that

you can draw in the web at a later point.

5. Press the ESC button to exit the inputting menu after you
have entered the settings.

If material has already been placed in the FVG adjustment range,

you can also enter the inside limit position directly into the editing
box.

If you are now working with a position offset, this does not need to
be referred to in this dialog window.

The following arises from the representation in the operating

display.

The value shown gives the absolute

distance from the fixed point entered in
the offset dialog. In other words, the
position offset is included in the
numerical representation.

The relative position (bar representation) relates to

the range value entered.
In other words, the position offset is not included.

Feed – Feed for stepping motor/gearing combination

General Setup > FVG >
Int. FVG > Feed
This setting is treated as the feed per motor revolution for the
stepping motor / gearing combination.

The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the
manufacturer’s agreement.
The relevant procedure then has to be agreed.
All warranty claims will be invalidated in any other case.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 89/157
 Commissioning 6
75
FVG Pro

The FVG Pro submenu is used when the FVG 2MK Op. mode has
been selected (usually when using an FVG 2MK). In this case,
each FVG needs to be adjusted separately. The terms used here
FVG 1 (Slide 1) and FVG 2 (Slide 2) relate to the arrangements in
accordance with Allocation of FVGs.

The setting up mode for both FVGs is the same (deviations apply
to Offset). The procedure for FVG 1 (Slide 1) is used as the
example here:

Homing Direction –
Retraction direction and limit switch assignment

The retraction direction of the sensors and the assignment of the

limit switches are set up in the next steps.

1. Mark FVG Pro in the FVG selection window and then

General Setup > FVG > FVG Pro > confirm by pressing ENTER. Select Slide 1 and confirm by
Slide 1 (Slide 2) > Homing Dir. pressing ENTER.
2. Select Homing Dir. from the sub-directory and then press
ENTER to open the inputting menu.
3. Press the F2 key to check the selected retraction direction.
By pressing the F2 key, the FVG slide must move
outwards (into the homing position).
After the homing position is reached, the limit switch with
FVG Pro slide 1 Homing Dir. the outer label must be activated ( ).
Test homing dir.using F2/F3
Homing dir. inv. Exit the window without making any changes if homing
Ref. switch inv. direction and limit switch assignment are correct.
outer inner
If the FVG slide moves inwards when the F2 key is
pressed, then the checkbox Homing dir. inv. should be
>><<
<<>>

activated.
If the limit switch with label inner is activated in the homing
position, then the checkbox Ref. switch inv. should be
activated.

Note: If the limit switch is activated but no checkbox

(outer or inner) is activated, then the limit switch
requires testing.

4. Press the ESC button to exit the inputting menu after you
have entered the setting.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 90/157
 Commissioning 6
75
Offset –
positional offset to position of first FVG slide
General Setup > FVG > You can create a reference system with an absolute reference
FVG Pro > Slide 1 > Offset point using the positional offset. This reference point can, for
example, be the machine wall or another obvious point on the
machine. It is also possible to use an outer position or the centre of
the FVG. If the centre of the FVG is used, one of the FVG slides
will move in a negative direction.
The offset value is added to the current FVG position and results in
the absolute distance to this reference point (Abs. slide pos.).

The setting up of an absolute reference system is necessary for

use of the Pre-positioning function.

Example:

FVG 1
Web running
Offset FVG 1 direction

FVG 2

Reference point
(zero position) Offset FVG 2

Tape measure

1. Press the F1-key. The FVG slides move to the home

position.
2. Measure offset FVG1 (distance between reference point
Î centre sensor measurement window) and enter the
value under offset [mm].
3. Use the F2 and F3 buttons to traverse the FVG a short
path.

FVG 1

path travelled (Dist. from home)

absolute position measured

4. Now compare the value shown under Abs. slide pos. with
the measured value.
If the measured value is larger and the displayed value
smaller, then you must activate the inverted checkbox.
5. Carry out settings for the second FVG slide (Slide 2) in the
same manner.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 91/157
 Commissioning 6
75
The standard operating display now shows the position of the
centre of the measurement window belonging to the appropriate
sensor based on the reference point.

Range –
Traversing range limits for first FVG slide

The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the
operating status screen.

General Setup > FVG > 1. Select Range from the sub-directory and then press
FVG Pro > Slide 1 > Range ENTER to open the inputting menu.

2. Press the F1 to start the movement of the slide to the park

position (home position). After this position has been
reached, the FVG stops.

3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch
has been reached, press key F4 (set). This completes the
adjustment procedure.

4. Press key F1 to move the sensor to the park position so

that you can draw in the web at a later point.

5. Press the ESC button to exit the inputting menu after you
have entered the settings.

If material has already been placed in the FVG adjustment range,

you can also enter the inside limit position directly into the editing
box.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 92/157
 Commissioning 6
75
Feed –
Feed for stepping motor/gearing combination

General Setup > FVG > This setting is treated as the feed per motor revolution for the
FVG Pro > Slide 1 > Feed stepping motor / gearing combination.

The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the
manufacturer’s agreement.
The relevant procedure then has to be agreed.
All warranty claims will be invalidated in any other case.

In addition to the specific settings which depend on the FVG used,

you should also carry out general settings for the FVG application
in the menu.

Retract Mode – free-runnuing mode

The retract mode determines when the FVG will traverse into the
park position (home position) after a specific operating mode
change.

General Setup > FVG > 1. Select Retract Mode from the sub-directory and then press
Retract Mode ENTER to open the selection menu.

Select a full retract mode 2. The following retract modes are available in the selection
menu:
SC
Man.
SC & Man. • SC: The sensor positioning device will traverse into
123 456 789 0 the park position after switching over to the
SC mode

• Man.: The sensor positioning device will traverse into

the park position after switching over to the MAN
mode

• SC & Man.: The sensor positioning device will traverse into

the park position after switching over to the
SC or MAN mode.

3. Press the ESC button to exit the inputting menu after you
have made the selection.

Norming Mode – Standardization mode

The method for standardizing the FVG sensor can be selected in

Norming mode.
The sensor will be automatically adjusted to the material
characteristics during norming.
This will occur immediately if norming is active and the controller is
switched over to AUTO mode.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 93/157
 Commissioning 6
75
1. Select Norming Mode from the sub-directory and then
General Setup > FVG > press ENTER to open the selection menu.
Norming Mode
2. The following norming modes are available in the selection
Select a norming mode menu:
Bright
Bright/Dark • Bright: Only a bright setting standardisation will be
No Norming
carried out.
123 456 789 0
This standardisation mode is normally used
for the infrared sensor IR 2002 with
reflection bar.

• Bright/Dark: Both bright and dark setting standardisations

will be carried out.
This standardisation mode is normally used
for infrared sensors with film material.

• No norming: Sensor standardisation will not be carried out.

This standardisation mode is normally used
for ultrasonic sensors.

3. Press the ESC button to exit the inputting menu after you
have made the selection.

Width Adjust – FVG operating mode for center line guiding

Use Width Adjust to select FVG operating mode for center line
guiding.

General Setup > FVG > 1. Select Width Adjust from the sub-directory and then press
Width Adj. ENTER to open the inputting menu.

2. The standard values are already entered in the settings

menu. These should be adapted in accordance with the
application.

The sensor positioning unit follows the material web if more

than the portion set in the editing box Width adj. Level [%]
of the sensor scanning area is covered.
The example setting entered her (75%) means that the
sensor will follow the material web if less than 25% or more
than 75% of the sensor scanning area is covered.

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 94/157
 Commissioning 6
75
25% covering
Start of sensor tracking

50% covering
End position

75% covering
Start of sensor tracking

• Lvl. Outer: The approach of the sensor towards the

material web generally occurs from the
outside.

The FVG operating mode can be carried out in the MAN

mode, in the Automatic mode as well as the SC mode.
However, the change will only become effective in the
controller after the operating mode has been changed again.
If, for example, you want to change over and you are in
Automatic mode then you must change over to MAN mode
and then back to Automatic mode again. Only then will the
change become effective.

4. Press the ESC button to exit the window.

Repositioning – repositioning of the material after certain events in

operating mode center-line guiding
The current position of the material web is saved once an event
takes place (e.g. web tear). Once the event has been rectified,
the material is repositioned to this position. This functionality is
only effective once pre-positioning has been activated.

General Setup > FVG > 1. Select Repositioning from the submenu and then press
Repositioning ENTER.

2. Activate the required behaviour in the settings menu.

The web/sensor position is saved after a web tear has
occurred.
The web/sensor position is saved at the time of switching
over from Automatic operating mode to Manual or SC
operating mode.

3. Press the ESC button to exit the inputting menu after you
have made the selection.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 95/157
 Commissioning 6
75
Velocities – Adjustment of positioning speed

This function can be used to adapt the positioning speeds for

various actions.

General Setup > FVG > 1. Select Velocities from the submenu and then press
Velocities ENTER.

2. The standard values are already entered in the settings

menu.
These can be accepted as is or adapted to the application.

3. Press the ESC button to exit the window.

The parameters have the following meanings:

Retract mode [mm/s]:
This parameter is used to determine the sensor positioning
device retraction speed.

Edge push vel. [mm/s]:

This parameter is used to match the traversing speed of the
sensor positioning device to the displacement speed of the
actuator. This prevents the sensor mounted on the FVG
slide from being pushed into the more slowly sideways
moving material web during edge searching during web
centerline guiding.

Slow Man. vel. [mm/s]:

Speed which should be used when shifting the material web
manually in automatic operation (for example shifting the
web using remote-control arrow keys).

Fast Man. vel. [mm/s]:

Speed which should be used when moving the FVG slides in
the Manual operating mode (for example when moving the
FVG slides using a menu dialog box keys).
This can also be directly applied to the sensor positioning
device (in manual mode) at this adjustment speed via a
Profibus connection. The relevant protocol is included in the
Profibus DP module description.

Norm. vel. [mm/s]:

Speed which is run during norming.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 96/157
 Commissioning 6
75
Special – Special setting

You can also activate or deactivate the special settings used with
the FVGs or special functions in this sub-directory.

General Setup > FVG > 1. Select Special from the sub-directory and then press
Special ENTER to open the inputting menu.

2. The following options are available for use in this input

menu. Standard values have already been entered.
These can be accepted as is or adapted to the application.

Mode after Error:

Operating mode which the system switches to after an error
occurs (e.g. web tear).

Sensor-cover-guarding:
This function is only relevant with center line guiding or when
using a FVG 1MK.

Master-slave-guiding
Activating / deactivating a master / slave guiding system. In
this case a material web (slave web) is controlled in
relationship to another material web (master web).
See Commissioning example in Appendix A1 as well
regarding this.

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 97/157
 Commissioning 6
75
6.7.7.6 Width measure – Web width measurement

The parameters required when using a width-measuring unit are

set up in this submenu..

Ref. Width – Width of the calibration tool

A piece of material with a known width must be used once as a

reference for adjusting the web width measurement.

General Setup > Width Measure > 1. Select Width Measure in General Set-up and confirm by
Ref. Width pressing ENTER afterwards.

2. Ref. Width is marked in the following selection window.

Press the ENTER button to call up the inputting window.

3. Insert calibration sheet and start width measurement. To do

Width Measure Offset this you must switch over to centerline guiding and then
current width: select Automatic operating mode.
mm

enter ref.width .0 4. Enter the width under enter ref. width after the sensors
set ref have reached the edges of the calibration sheet and press
the F3 button to take over the entered value.

5. The adjustment procedure is finished.

The actual measured value (current width) and the entered
reference value (ref. width) must both show the same size.

6. Press the ESC button to exit the window.

The reference width value last entered remains saved when the
device is switched off.

Inserting the calibration sheet:

First check the dimensions of the calibration sheet.

Important:
The calibration sheet reference dimension can change marginally
due to the effects of heat. Information relating to various
temperatures is given on the calibration sheet.
To obtain the best results, use the reference dimension for the
temperature which is nearest to the actual temperature, or
interpolate the dimension between these two temperatures.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 98/157
 Commissioning 6
75
Limits – Set width, error and warning limits

The set value for the web width (Nominal Width) is entered in this
window. The lower and upper error limits (E+, E-) and the lower
and upper warning limits (W+, W-) are also set up here. The
measuring unit is mm.
These are the entries which form the basis for the operating
display when the web width measurement is active.
Five conditions are indicated.

a) Material width is in valid range.

b) Material width is too wide when related to the upper warning

limit; it lies in the W+ area (24V DC at output 66).
Material width

W+
c) Material width is too small when related to the lower warning
limit; it lies in the W- area (24V DC at output 65).
Material width

W-
d) The material width lies outside the absolute tolerance.
It lies in the error limit areas E+ (24 VDC at output 66)
Material width

E+
e) The material width lies outside the absolute tolerance.
It lies in the error limit areas E- (24 VDC at output 65)

Material width
E-

The values in brackets represent the default settings. However

the allocation is customisable.
Digital message outputs are available for the limits.
The meaning and allocation of messages relating to digital
outputs are described under Configuration of the digital outputs.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 99/157
 Commissioning 6
75
General Setup > Width Measure > 1. Select Limits in the selection window and press the ENTER
Limits key. This will open up the input window.

80.0 2. Enter the nominal value for the material width in the edit field
-5.0
5.0 Nominal Width.
-2.0
2.0
3. Enter selected values for the error and warning limits in the
corresponding edit fields.

4. Press the ESC button to exit the window after you have
entered the settings.

Opmodes – Operating modes in which the width measurement

should be active

You can use this window to determine in which operating modes

the width measurement is able to be implemented.
This makes it also possible to carry out a web width measurement
without an FVG if the checkbox has been activated for the
corresponding operating mode.

If an FVG is connected, the condition is that retraction has been

deactivated for the selected operating mode(s).
(see General Setup > FVG > Retract Mode)

General Setup > Width Measure > 1. Mark Opmodes in the selection window and then press
Opmodes the ENTER button. This will open up the input window.

2. Select the desired mode(s).

3. Press the ESC button to exit the window after you have
entered the settings.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 100/157
 Commissioning 6
75
6.7.7.7 Edge Sources – Assignment of the sensors to the guiding modes

he ekrPro Com60 controller allows the free assignment of the

connected sensors to different scanning modes.
Therefore each scanning mode can have the input signal of any
sensor allocated to it. For example, it is possible to assign the
"sensor right" sample mode selection key to the sensor connected
as "sensor left".
If the controller is operated via a CAN bus, the scanning modes
can also be assigned to the input signals of sensors which are
connected to another controller of the BUS-system.

General Setup > Edge Sources > 1. Select Edge Sources in General Setup and confirm by
Edge 1 pressing ENTER afterwards.

2. A guiding mode selection window appears.

The following selection types can be selected:

Guiding Control input Key

mode

Edge 1 Edge 1

Edge 2 Edge 2

Edge 3 Edge 3 (contrast transition)

Src. SC Servo-center component

Src. EFE Electronic remote fine —

adjustment device

3. Select sample mode using the vertical arrow keys and press
ENTER.

4. The input window appears for the selected sample mode.

5. If the selected sample mode is to be assigned to the input

signal of a sensor that is connected to another CAN bus unit,
then select the option list device and press the ENTER key
to open it.
All the units connected to the CAN bus are displayed in the
opened option list.

6. Select the desired CAN bus unit and press ENTER.

7. Select the option list edge using the horizontal arrow keys
and press ENTER.

8. Select the sensor from the option list to whose input signal
the selected sample mode is to be assigned and press
ENTER.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 101/157
 Commissioning 6
75
9. The input value supplied by the selected sensor can be
shown in this window as either an absolute or normalized
(percentage) value.
To activate normalized display, select checkbox norm..

10. If necessary, the checkbox inv. is used to invert the input

signal delivered by the sensor.
Inverting is necessary, if the input value delivered by the
sensor changes in the wrong direction when material is
brought into the sensor measurement area.

11. Use the function keys F2 and F3 to drive the actuator in

Manual operating mode.
This enables checking of the change in the sensor signal
with an inserted material web.

12. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 102/157
 Commissioning 6
75
6.7.7.8 Add.Functions – Special functions

Explanations for the requirements and function of the special

functions can be obtained under Additional functions standard
system.
The parameter settings are carried out as follows:

Tear Off Det. - Ausrisserkennung

Setting of the parameters for the function Tear-off detection is

made separately for each guiding mode. If necessary, a different
sensor can be allocated as the tear-off detection sensor for each
guiding mode. It is also possible to allocate two different guiding
modes with different parameters to a single sensor.

General Setup > Add. Functions > 1. Select Add. Functions in General Setup and then select
Edge 1 (Edge 2, Edge 3, …) the
Tear Off Det. sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3,

Center 1&2) from the option list.
Confirm the selection by pressing ENTER.

3. This will open up the inputting window for the selected

guiding mode. The following separate parameters can be
set:

► Sensor: Selection of the sensor with which tear-

off detection is to be implemented.

► threshold [%]: Percentage covering of the sensor

measuring band, above which a change
is detected as a tear.
For the example value entered here
(80/20), this means that the function
detects a tear, if more than 80% or less
than 20% of the sensor measuring band
is covered.

► sig. chg. limit [%/4ms]:

Maximum permissible rate of change of
the sensor signal in % per 4 ms
(Scanning cycle = 4 ms, i.e. the
sensor measurements are read
every 4 ms).
A tear is detected, if the rate of change of
the sensor signal exceeds the percentage
per 4 ms set here.
The values to be set are calculated
according to the formula on the following
page.
The values to be set are calculated
according to the formula in Additional
function/Tear-off detection.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 103/157
 Commissioning 6
75
► delay [ms]: Delay time in ms from detection of a
tear until blocking of the guiding
system.

► hold [ms]: Blocking hold time in ms after the

detected end of the tear until the
blocking is lifted, i.e. until the guiding
system is activated.

4. If necessary, set parameters for further guiding modes

(see points 2 and 3).

5. Press the ESC button to exit the window.

Watchdog - Function
Standard application
General Setup > Add. Functions > The default settings of the system do not have to be altered for
Tear Off Det. > WD Edge 3 standard applications.
In this case, the Watchdog function is only to be activated.

Call up the Watchdog menu as illustrated on the left and activate

Watchdog (Enabled).

Press MENU.
The last operating state that was set up will be displayed on the
screen. Use the standard screen’s vertical arrow-keys to select
Sensor 3 with Watchdog activated.
This will be displayed as follows:

watchdog sensor

guiding sensor

Press F1 or F2 to activate the Watchdog function for trapping with

Sensors 1 or 2.
The Watchdog is only active when either the Edge 3 or Edge 3
inverted guiding mode has been set. During the trapping, the
original guiding mode (Edge 3 or Edge 3 inverted) is displayed by
the flashing LED of the respective button.
The watchdog guiding mode (Edge 1 or Edge 2) is indicated by the
illuminated LED inside the respective button.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 104/157
 Commissioning 6
75
Deviation from standard settings

If the preset parameters must be changed due to the application,

proceed as follows:

Parameter setting for the tear-off detection

Add.Functions > Tear Off Det. > 1. Go to the Add Functions position in the menu and then
Edge 3 select the Tear Off Det. sub-directory.
Press ENTER to confirm your selection.

2. Set Edge 3 guiding mode.

Press ENTER to confirm your selection.

3. This will open up the corresponding settings window.

The settings must be checked here and modified if
necessary.

► Sensor: Setting Edge 3.

► threshold [%]: Percentage cover of the sensor

measuring range, after which the
Watchdog should be activated.
In the case of the example value
entered here (80/20), this means that
the function will detect a tear if more
than 80% or less than 20% of the
sensor measuring range is covered.

► sig. chg. limit [%/4ms]:

Maximum permitted sensor signal
change rate in % / 4 ms.
See Tear-off detection description for
calculating the value.

► delay [ms]: Delay time in ms from detection of a

tear until blocking of the guiding
system.
This value must be set to 0 (Null).

► hold [ms]: Blocking hold time in ms after the

detected end of the tear until the
blocking is lifted, i.e. until the guiding is
enabled.
This value must also be set to 0
(Null).

4. Press ESC to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 105/157
 Commissioning 6
75
Parameter setting for the Watchdog

Pre-requirement for running Watchdog is that WD Edge 3 guiding

mode has been set and that Watchdog has been activated
(enabled).

The following parameters can be modified in the Watchdog

function settings window :

► Delay: Time in seconds that a tear is detected

before Watchdog is activated.
The values entered in the example
means that the system will be switched
over to Watchdog guiding mode after a
tear of more than one second has been
detected.

► Sens.Val.Age: This value is used to determine how

many cycles the sensor value for the
watchdog sensor should be, which will
also be used as the setpoint when
trapping.
The value range is between 1 and 49
cycles.

Press ESC to exit the window.

Operation

Press MENU.
The last operating state that was set up will be displayed on the
screen. Use the standard screen’s vertical arrow-keys to select
Sensor 3 with Watchdog activated.
This will be displayed as follows:

watchdog sensor

guiding sensor

Press F1 or F2 to activate the Watchdog function for trapping with

Sensors 1 or 2.
The Watchdog is only active when either the Edge 3 or Edge 3
inverted guiding mode has been set. During the trapping, the
original guiding mode (Edge 3 or Edge 3 inverted) is displayed by
the flashing LED of the respective button.
The watchdog guiding mode (Edge 1 or Edge 2) is indicated by the
illuminated LED inside the respective button.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 106/157
 Commissioning 6
75
Oscillation

This special function enables the position of the web of material to

be displaced within the sensor´s visual range using adjustable
amplitude (size of the lateral displacement) and frequencies
(displacement speed).
The format of the web displacement when the controller is opeated
without a sensor positioning device follows a delta curve ( ).
When operated with a sensor positioning device, a sine-wave ( )
web displacement takes place.
See also Oscillation types and curves.

Osc. Mode – determine operating mode for oscillation mode

General Setup > Add. Functions > 1. Select Add. Functions in General Setup and then select
Osc. Mode the
„Osc. Mode“ sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. The set value for the web width (Nominal Width) is entered
in this window. Activation then takes place in the operating
status display using the F1 key.
The following settings are possible:

• • OFF: Oscillation is deactivated

(factory setting)
• Auto: Activation in operating mode
Automatic
Repositioning of material web is
carried out within the sensor visual
area with adjustable amplitude.
• SC: Activation in operating mode SC
using the software limit switches of
the actuator.
• FVG Auto: Oscillation with connected FVG
An FVG oscillation with sine-shaped
web repositioning.

3. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 107/157
 Commissioning 6
75
Osc. Params. – Set oscillation parameters
The oscillation parameters, i.e. amplitude and frequency, are
set in this submenu.

General Setup > Add. Functions > 1. The Osc. Params submenu Select Sensor 1 and confirm by
Osc. Params pressing ENTER.

2. The parameters have the following meanings:

Set Oscillation Parameters

► Amplit. Auto [%]: Amplitude of the oscillation in operating

mode Automatic.
The percentage value relates to the
size of the sensor scanning area.
Setting range: 1 % to 99 %
► Amplit. SC [%]: Setting up the amplitude for the SC
operating mode
The percentage wise input of the
amplitude relates to the distance
between the software limit switches.
One limit switch represents 0 % and the
other 100 %.
Setting range: 1 % to 99 %
► Amplit. FVG [mm] Amplitude of oscillation when using a
sensor positioning device.
The sample value shown here of
10 mm results in repositioning of the
web by ± 5 mm.
Setting range: 0 to 999.9 mm
► Frequency [1/min]: Oscillation frequency.
Setting range: 1 … 60 min-1

3. Press the ESC button to exit the window.

Osc. Params Add-on – Additional oscillating functions

(can only be used for the sensor oscillation)
Additional specifications can be set for sequence of the
oscillation in this sub-menu.

General Setup > Add. Functions > 1. Select the Osc. Params Add-on sub-directory and then
Osc. Params Add-on press ENTER to confirm your selection.
2. The parameters displayed in the setting menu have the
Oscillation Add-on: following meanings:

► start/stopp at act.pos:
>> NOT FOR FVG OSC.!<<
The oscillations will start from the
position where it was stopped if this
function is activated.
► start osc. after restart:
The oscillations will start as soon as the
system is restarted if this function is
activated.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 108/157
 Commissioning 6
75
6.7.7.9 Dig. IO Config. – Configuration of the digital inputs and outputs

Description see Remote control.

6.7.7.10 Special – Special device settings

Passwords can be changed, the firmware can be restarted and the

default delivery state can be reset from the Special submenu.
The greyed-out menu options are reserved for use by BST service
personnel.

Change Password

This window is used to set the password for current active user
level and the timeout time for an automatic logout.
The password consists of a maximum of 5 figures (0 ...9).
If no key is pressed for the duration of the set timeout time, the
user is automatically logged out and the user Operator is
activated.
All passwords can be reset to the factory set delivery
condition up to 20 seconds after switching on of the
controller by simultaneously pressing the keys F4 +
ESC.

1. Select Special in General Set-up and confirm by pressing

General Setup > Special > ENTER afterwards.
Change Pwd.

2. Change Pwd. is marked in the following window.

Press the ENTER button to call up the inputting window.
Set Password using F2
Set Timeout using F3
User level:
Password
Admin
0
3. In the now open window, the current active user level is
Timeout [min] 0 shown in the field User level (in the example Admin).
st.pwd set t/o

4. Use the right and left arrow keys to select the Password
editing box and press ENTER.

5. Enter a new password in the editing box and confirm input

by pressing ENTER.

6. Finally to store the new password, press the F2 key.

7. Use the right and left arrow keys to select the Timeout [min]
editing box and press ENTER.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 109/157
 Commissioning 6
75
8. Enter the new timeout value and confirm the entry with
ENTER.
If the timeout time is set to “0”, then no automatic logout
occurs.
Input of a timeout time greater than 0 prevents a user with
extensive user rights from forgetting to log him(her)self out.

9. Press the ESC button to exit the window.

Dev.Config. – General unit settings

The general ekrPro Com60 unit settings are entered in the

Dev. Config. submenu.

General Setup > Special > 1. Select Special in General Set-up and confirm by pressing
Dev. Config. ENTER afterwards.

2. Select Dev. Config. in the following window.

3. This will open up the unit settings window for the general
device settings. This contains the following separate
parameters:

► Bklght Tm.: Duration that the screen background

lighting will remain switched on after the
last button
The setting is entered in 1/10 second.
Entering ’0’ will switch the background
illumination on permanently.

► Show err.: The display is activated by default 7.

Every error occurring will be displayed and
a message will be generated. However,
the error will only be displayed for as long
as the error lasts (i.e. the error LED
illuminates).

► Conf. err.: Confirms the displayed error.

If the function has been activated, the error
will remain displayed until the operator
confirms it by pressing the ENTER button.
The report will continue to be displayed if
the error has not been eliminated.

► SW Ver.: Displays the version number of the firm-

ware which is installed in the controller.

► WC: only for service purposes!

► Low V cnt.: Counter for undershooting of the

admissible operating voltage range

4. Press the ESC button to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 6

with analog sensors Date: 20.06.2011 Page: 110/157
 Operation 7
21
7 Operation
7.1 General

7.1.1 Graphics display

The various operating statuses are displayed by the graphics
display.
Use the vertical arrow keys to change between the different
displays in normal control mode.
The number of displays varies between one and four, depending
on whether a sensor adjustment unit and/or sensor 3 is
interconnected or not.
Information for the assigned operating mode is shown in the
separate displays and their significances are explained in the
following.

Screen with sensor positioning device connected

Relative actuator position related to limit positions

Display of relative sensor scanning area coverage

Distance from sensor to external sensor positioning device

reference limit switch in mm

Controller setpoint (W) or controller gain (XP)

If you press the "SETUP“ key you will change between both
displays (W or XP).
The value displayed can be adapted in the "AUTO" operating mode
using the horizontal arrow keys.

50% 50% not

51%
If an analog sensor is selected as not connected it will be
M con. displayed as follows in the status display:
2000
not

W 10 con.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 111/157
 Operation 7
21
Screen without sensor positioning device (FVG)

Display of relative sensor scanning area coverage

Relative actuator position related to limit positions

Controller setpoint (W) or controller gain (XP)

If you press the "SETUP“ key you will change between both
displays (W or XP).
The value displayed can be adapted in the "AUTO" operating mode
using the horizontal arrow keys.

Screen when sensor 3 connected

Display of relative sensor scanning area coverage

Relative actuator position related to limit positions

Tear-off detection inactive

Display with tear-off detection activated:

Tear-off has been recognised

Tear-off detection active

Actuator is blocked

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 112/157
 Operation 7
21

Screen with active web width measurement

(only with connected sensor positioning device)
Graphic display of current web width

Graphic representation of:

warning limit
error limit

Entry field for intended web width

Accept current web width as intended web width

Actual system condition display
Numeric display of current web width

Screen of pre-positioning

Display when using FVGPro (FVG 2MK)

Guiding mode; E1 = Edge 1, C1&2 = centre between edge 1 and 2,

E2 = Edge 2
Position setpoint for appropriate guiding mode.
The selected entry will be displayed "inversely".
Current position value for sensor(s)

Accept current position value as

new setpoint for active guiding mode.

Pre-positioning is activated for this guiding mode.

Display when using internal sensor positioning device (FVG 1MK)

Due to the system, the C1&2 columns and the F2 key allocation
is missing here.
All other parameters have the same meaning as described
under display for external sensor positioning device.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 113/157
 Operation 7
21

Screen pre-positioning to machine centre (FVG 2MK)

Current position value for sensor(s)

Offset by which the material web has been displaced from
the machine centre.

Screen Master-Slave guiding system (FVG 2MK)

Relative master sensor measuring range cover display

Relative position of the actuator relative to the end stops

Relative slave sensor measuring range cover display

Distance between the respective sensor and the reference system,

i.e. centre of system

Which drive the arrow keys control is displayed here. Press the
SET-UP button to switch between the assignments.
mot = actuator
FVG1 = FVG 1 drive
FVG2 = FVG 2 drive

Import the distance between the two material webs for

manual positioning.

Activate / deactivate the master / slave guiding.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 114/157
 Operation 7
21
Screen of the CAN bus status

Display of CAN node number

Display of CANopen control unit operating status
CANopen network synchronisation operating status screen
No Sync = Control unit not receiving synchronisation impulse
No Sync = Control unit receiving synchronisation impulse

Checking functions for device remote control

If you press the ENTER key on the control unit, all LEDs
on the keypad belonging to the remote-controlled device
will start blinking.

Operating status screen for CAN controller integrated in control unit

Bus Off = Error in CAN controller
Bus Off = CAN controller working correctly

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 115/157
 Operation 7
21
7.2 Changing the settings
during operation

Use the keypad to set up the operating functions and the guiding
modes as well as the settings and to optimise the controller gain.

7.2.1 Operating functions

Proceed as follows to set up the required operating functions:

Automatic mode

Press the AUTO key

Manual positioning

Press the MAN key

Manual positioning of the actuator

1)
Press the MAN key

2) Use the horizontal arrow keys to carry out

positioning

Servo-center position

Press the S-C key

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 116/157
 Operation 7
21
7.2.2 Guiding modes
The required guiding mode is set up as follows::

Web edge guiding; left web edge*

Press the SENSOR LEFT key.

Web edge guiding; right web edge*

Press the SENSOR RIGHT key.

*in material running direction

Web center-line guiding

Press the SENSOR LEFT and SENSOR RIGHT buttons

simultaneously

Contrast guiding (line or edge)

Contrast transition: BRIGHT/DARK.

Contrast transition: DARK/BRIGHT.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 117/157
 Operation 7
21
7.2.3 Gain adjustment
The controller gain can be set up directly in the operating status
display or in the set-up menu.
The operating status display settings are described in the following.
The system must be in AUTO mode.

Press the SET-UP button and the parameters displayed in the line
at the bottom of the screen will change from the displayed settings
(W) to the controller gain setting (XP).
The controller gain can now be modified using the horizontal arrow
keys. The new setting will have an immediate effect on the
controller.

To enter the settings via the Set-up menu see Control Loop -
Control loop settings

7.2.4 Changing the setpoint

The setpoint can also be set up in the operating status screen or in

the set-up menu directly.
The operating status display settings are described in the following.
The system must be in AUTO mode.

The setpoint is displayed in the line at the bottom of the screen.

The setpoint can now be modified using the horizontal arrow keys.
The new setpoint will have an immediate effect on the controller.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 118/157
 Operation 7
21
7.3 Sensor positioning device

7.3.1 Using the FVG function, general

If an FVG is being used in combination with Sensor 3, the FVG

automatically retracts if the controller is switched to Sensor 3.
The requirement for this is, however, that the element which is
being used to regulate (normally a line) lies within the visual range
of Sensor 3.

7.3.2 Using the FVGPro 2MK function

When using an FVGPro 2MK, the following behaviour results:

1. Only the sensor activated for the controller carries out the
edge search. The other sensor retracts and is parked at
the home position.
2. If the guiding mode is changed during automatic operating
mode, e.g. from guiding to the right-hand edge to guiding
to the left-hand edge, the system continues the current
guiding mode until the other sensor has completed the
edge search and the norming (if necessary).

7.3.3 Arrow keys functions and

the function of the inputs
The function of the arrow keys are generally changed using the
SETUP button.
The arrow keys act upon the web position or the controller gain in
the AUTO mode of operation. The type of web adjustment
depends on the set FVG mode.
The buttons act upon the actuator in the MAN mode of operation.
They act upon the FVG after pressing the button SETUP, in the
settings Man.Sensor Positioning.

Operating Arrow keys on the keyboard Digital inputs

mode (Use the SETUP key to toggle)

AUTO Web position / controller gain Web position

MAN Manual actuator or Manual actuator or

FVG positioning FVG positioning

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 119/157
 Operation 7
21
Allocation of the change-over options to the operating modes

FVG mode Available options for the Available options for the digital inputs
keyboard arrow keys terminal 80 = Low terminal 80 = High

Operating mode AUTO

w w w
not connected
Switch over via SETUP key

xp
FVG eco w w FVG
Switch over via SETUP key
xp
Switch over via SETUP key
FVG
FVG 1MK with center-line guiding
w
Switch over via SETUP key
w (with center-line guiding) w (with center-line guiding)
xp
with web edge guiding
xp
Switch over via SETUP key FVG (with edge guiding) FVG (with edge guiding)
FVG
FVG 2MK xp FVG FVG
Switch over via SETUP key

FVG

Operating mode MAN

not connected
mot (actuator) actuator actuator
FVG eco mot actuator FVG
Switch over via SETUP key

FVG
FVG 1MK
mot (actuator) actuator actuator
FVG 2MK mot (Stellantrieb) actuator actuator
Switch over via SETUP key

FVG1
Switch over via SETUP key

FVG2

With w-setting via EFE has priority with active

electronic remote fine adjustment device.
w = setpoint
xp = gain
FVG = sensor positioning device

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 120/157
 Operation 7
21
7.4 Material set-up

7.4.1 General
Danger of cuts!

! Never touch the edges of moving material webs!

You are only allowed to set up the material when the
production machine is stopped.

The controller will be automatically optimised to match the

characteristics of the material that will be scanned during the
material set-up process.

The material set-up must be run when the following work is being
carried out in order to realise optimum controller results:
• During the initial commissioning of the web guiding control
• If infra-red sensors are being used (IR 2001, IR 2002,
IR 2005):
After changing over to a material with other contrast
characteristics (e.g. film with a different material
transparency)
• With ultrasonic sensors (US 2003, US 2007, US 2008,
US 2009):
After changing over to a material with different sound
absorption properties
• After cleaning a dirty sensor

The material set-up is the same for all three sensors.

The procedure for sensor 1 is used as the example here.

Requirement:

Material Setup > Sensor 1 The user level “Mainten” must be active.
(Sensor 2 / Sensor 3)
1. Press the MENU button to open the set-up menu.

2. Select Material set-up and confirm by pressing ENTER.

Material Setup - Sensor 1

<<<
dark 7% bright 3. Select Sensor 1 and confirm by pressing ENTER.
-2048 abs. 1775 2047 This will open the Sensor 1 material set-up window.
auto dark bri.

Material set-up can now be carried out either automatically or

manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 121/157
 Operation 7
21

7.4.2 Automatic material set-up

Use the set-up selection menu to select the set-up mode (manual
or automatic).

1. Press the F1-key.

2. Completely cover the sensor’s scanning window with the

material to be scanned for approx. 2 seconds.

3. Completely remove the material from the sensor scanning

window (no material over the sensor).

4. Press the F2-key

This completes the material set-up for this sensor. Material set-up
has been completed when the same procedure has been carried
out for any other sensors connected to the controller.

7.4.3 Manual material set-up

For the reflection sensor TW54 C5 and the line
sensor T62 D1 a special material setup is to be
carried out.

1. Completely cover the sensor’s scanning window with the

material to be scanned.

2. Press the F3-key.

3. Completely remove the material from the sensor scanning

window (no material over the sensor).

4. Press the F4-key

The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or

the light setting (steps 3 and 4) can be made first.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 122/157
 Operation 7
21

7.4.4 Special procedure with analog refelction

sensor connected as sensor 3

1. Select required guiding mode

(BRIGHT/DARK or or
DARK/BRIGHT).

Automatic material set-up:

• Press the F1-key

• Position the sensor’s light spot

on the bright contrast area
for approx. 2 seconds.

• Position the sensor’s light spot

on the dark contrast area
for approx. 2 seconds.

• Press the F2-key

Switch over to AUTOMATIC mode to check the guiding

direction. Switch over to the other relevant scanning mode if
the actuator moves in the wrong direction or if the wrong
contrast is scanned.

Manual material set-up:

ƒ Position the sensor’s light spot

on the dark contrast area.

• Press the F3-key.

The dark value will be saved.

• Position the sensor’s light spot

on the bright contrast area.

• Press the F4-key.

The bright value will be saved.

Switch over to AUTOMATIC mode to check the guiding

direction. Switch over to the other relevant scanning mode if
the actuator moves in the wrong direction or if the wrong
contrast is scanned.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 123/157
 Operation 7
21
7.4.5 Manual material set-up for
sensors T62 D1 and TW54 C5

7.4.5.1 Settings for the T62 D1

Prior to carrying out of the material setup, the zero point should be
reset for sensor T62 D1. This is different dependent on whether the
sensor is being used for line sampling or for contrast sampling.
a) Line scanning (lines of 0,5 … 5 mm)
Place the switch on the housing in “Linie” position and focus the
light spot on the primary colour of the material (that is outside of
the line), then set the “Nullpunktabgleich” (zero alignment)
potentiometer for both luminous diodes to be extinguished.
We recommend that the zero point compensation is carried out
with inclined sensor (the tilt position must be determined
empirically) when both LED´s illuminate as a result of intensive
surface reflections (e.g. metal foils).

Line
Light spot

b) Contrast scanning
The switch on the casing to be switched to “Kante” (edge) mode.
Set the sensor in a manner for ensuring that the contrast to be
scanned is in the centre of the light spot. Then extinguish both
luminous diodes by employing the “Nullpunktabgleich” (zero
alignment) potentiometer on the sensor. We recommend that the
zero point compensation is carried out with inclined sensor (the tilt
position must be determined empirically) when both LED´s
illuminate as a result of intensive surface reflections (e.g. metal
foils).

Contrast

Light spot

Adjustment elements on the T62 D1

LEDs

Changeover switch
contrast/line

Zero alignment

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 124/157
 Operation 7
21
7.4.5.2 Material set-up
For critical contrast transitions, this function enables
optimum adjustment of the reflection sensor TW54 C5 or the
line sensor T62 D1 to the properties of the material to be
scanned.
In addition to the normal material setup, the offset value and
gain for sensor 3 can also be set here.

1. Press the MENU button to open the set-up menu.

2. Select Material set-up and confirm by pressing ENTER.

Material Setup > Man. Sens. 3 3. Select Man. Sens. 3 and confirm by pressing ENTER.
This will open the window for the manual material setup of
Sensor 3.

4. Position the sensor’s light spot

centrally over the contrast transition.

5. Use function key F1 (reduce offset value) or F2 (increase

Manual Setup - Sensor 3 offset value) to change the offset such that the black bar of
50%
the upper bar indicator is located in the indicator middle.
Offset 3 Gain The current absolute offset value is shown in the Offset
0 1.00 field.
Of.- Of.+ Ga.- Ga.+

6. Position the sensor’s light spot

on the dark contrast area.

7. Use function key F3 (reduce gain) or F4 (increase gain) to

change the gain such that above the upper black bar
indicator a value of 100 % is displayed.

The target value of "100 %" must be set by

carefully increasing the value using the F4
function key, as values greater than 100 %
cannot be displayed.

The current absolute gain value is shown in the Gain field.

8. Position the sensor light spot centrally over the contrast

transition (see point 4) and if necessary readjust the offset
value (see point 5).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 125/157
 Operation 7
21
7.5 Tear-off detection

Tear-off detection enables, dependent on the selected sensing

type (edge / contrast guiding) the following functions:

1. With web edge guiding:

Detection of torn off sections on the web edge using edge
sensors IR2001/2005, US2007, …
This function is activated during web edge guiding, if during
operation of the web guiding system errors arise from the web
edge that is being scanned.
The function detects both tears into the material web (inward
tear) as well as projecting material (outward tear).

2. With guiding to a contrast:

Guiding on interrupted printed or contrast edges with contrast
sensors T62 D1 or TW54 C5.

The operating mode selection

switch on the T62 D1 contrast
sensor must be switched to
the “Kante” (Edge) position.

Interrupted printed
or contrast edge

Light spot of the

contrast sensor

Tear-off
inwards

Tear-off
outwards

If the function detects a tear, the web guiding system is

automatically blocked. Blocking of the guiding system is unlocked
again, if the sensor signal again lies above/below the set threshold
value and the set run-on time has elapsed.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 126/157
 Operation 7
21
Matching of the individual parameters of the function to the
application is implemented in the menu
Add. Functions > Tear Off Det. or
General Setup > Add. Functions > Tear Off Det..

Activate tear-off detection

1. Press the F2-key.

The function Tear-off detection is activated.

Interrupted line and web of material are displayed.

If an outward or inward tear is detected, this is indicated

in the display by an exclamation mark.

As soon as the guiding system is blocked, a lock appears

in the actuator symbol.

7.6 Oscillation
The function Oscillation enables a position displacement of the
material web within the sensor scanning area with adjustable
amplitude (size of the transverse displacement) and frequency
(speed of the displacement).
The amplitude of the oscillation can be set separately for the
operating modes Automatic and S-C.

The function is automatically switched on when changing to the

operating modes Automatic and / or S-C.

Matching of the individual parameters of the function to the

application is implemented in the menu
Add. Functions - Osc.Mode
or - Osc.Params
General Setup > Add. Functions - Osc.Params Add-on.

Activate oscillation

1. Press the F1-key.

The Oscillation function is activated.

When changing from manual operation into the mode set

for oscillation in the general setup (Auto, SC or Auto &
SC), the function is automatically switched on.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 127/157
 Operation 7
21
Deactivate oscillation

1. Press the F1-key.

The Oscillation function is deactivated.

The oscillation zero position is used as a set point for

further guiding.

7.7 Pre-positioning
You can use this function to carry out material web pre-positioning
to a position determined by a user.
Both the guiding mode on which the pre-positioning is to be used
and the target web position itself can be set.

Activate pre-positioning (FVGPro)

Select the required guiding mode in the set line (here E2) and
enter the positional value. You can also take over the actual
positional value by pressing the F4 key (set).
The system must be in the MAN or S-C operating modes to
do this.

Pre-positioning can be activated or deactivated using keys

F1 for edge 1
F2 for centre between edges 1 & 2
F3 for edge 2.
The guiding mode, the pre-positioning is activated for, is
displayed inverse (here E2).
Once the system has been switched to the AUTO operating
mode, the FVG slide(s) moves/move to the edge(s) of the web
and then slowly shift the web to the position saved in the set
line.
If the Pre-positioning function has been activated when the
AUTO operating mode is activated, the web is moved to the
predetermined position immediately.

The current positional values are displayed based on the

defined reference system.

Use of an internal FVG

The adjacent figure shows the display of the operating status.

Due to the system, the C1&2 columns and the F2 key
allocation is missing here.
All other parameters have the same meaning as described
under display for FVGPro .
Activating the functions is carried out in the same manner as
described above.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 128/157
 Operation 7
21
7.8 Pre-positioning to machine center-line
(with FVG 2MK only)

This function is used to pre-position the material to the machine

centreline.
The predefined machine centreline is calculated from the offset
value settings which were defined during the start-up procedure
(see Control Loop and example below).
Using the offset value in the operation status display, you can
define the position of the machine centre yourself without having to
carry out readjustments in the device menu.

1. Select the Preposition to center display from the

operation status display.

2. Enter the offset by which the web should be shifted from

the predefined machine centre.

3. Activate the function by pressing the F2-key.

4. Press the AUTO key.

The sensors start searching for the appropriate edge.
If the last of the two sensors has reached its edge, the
material web is shifted into the centre position by the FVGs
(working position).

Example:
Both sensors start from the home position. Measure the distance
between the centre of the sensor measurement band of each FVG.
As an example, this distance is 1070 mm.
Halve the distance!
machine center-line

1070

Now enter the value -535.0 for the

"FVG Pro slide 1 " into the offset
editing box

and the value +535.0 in the

"FVG Pro slide 2" offset editing box.

In this case, the machine centre is at 0 (zero).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 129/157
 Operation 7
21
7.9 Master-Slave guiding
This function is used to guide a slave web in relation
to a master web.
The slave web position can be guided and optimised
slave whilst running using the ekrPro Com60 horizontal
arrow-keys.
distance The default distance between the slave web and the
master web will be maintained continuously after the
function has been activated.
The distance can be set up by manually positioning
both webs from one another as well as by entering the
distance value in the menu.
master

7.9.1 Manually setting the distance

1. Set up the distance between the master web and the slave
web, e.g. by repositioning the slave web.

2. Select the operating display for the master / slave

application.

3. Press Set (F2-key) to import the distance setting.

4. Now press F1 to activate the function.

The entered distance between the master web and the
slave web will now be maintained continually.

7.9.2 Setting the distance

by entering the value
The distance setting can be also be entered directly in the
controller.

1. Select the operating display for the master / slave

application first.

2. Enter your setting under Offset E2 to E1. Press ENTER to

confirm your entry.

3. Press the F1 key to activate the function.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 130/157
 Operation 7
21
7.9.3 Using the arrow keys to
set up the distance
The arrow keys can be used to adjust the slave web whilst it is
running.

Use the SETUP button for aligning FVG2 in the master / slave
application operating display for this option.

The arrow-keys will now be applied to the slave web FVG and you
can now set up the distance.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 7

with analog sensors Date: 20.06.2011 Page: 131/157
 Remote control 8
13
8 Remote control
8.1 Remote control via CAN bus

Devices in the controller family (ekrPro Com60, ekrPro Key60) can

be interconnected via a CAN-Bus to form a networked system.
The function Unit Remote Control enables control of the control
units present in the system to be undertaken from different origins
(e.g. from another ekrPro Com60 control unit or from an ekrPro
Key60 external keyboard).
Selection of the unit to be operated is made via the menu
Remote Device.

Remote Device 1. Select menu Remote Device and press ENTER.

2. The selection window for unit remote control appears.

Select remote device After opening the option list device, all field bus devices
device this device found on the CAN bus are displayed.
To terminate remote
session press ENTER-ESC
3. Select the device that is to be remotely controlled from the
option list and press ENTER.
The displays of the remotely controlled unit now appear in

+ the display. All key operations now act directly on the

remotely controlled unit.

No remote control chaining is possible. If an

attempt is made to remotely control a further unit
via an already remotely controlled unit, this is
prevented.

4. To end unit remote control, simultaneously press the ENTER

and ESC keys.

Control function for unit remote control

The control function allows a user, to check the selection of a unit

to be remotely controlled without causing any change to the unit
settings.
Mistakes in selecting the unit to be remotely controlled, through
which an incorrect unit is remotely controlled via the CAN bus, are
avoided in this way.

1. Call up the adjoining CAN bus operating condition display.

2. Press and hold the ENTER key.

All LEDs on the operating keyboard on the remotely
controlled control unit flash, as long as the ENTER key is
pressed down.
The remotely controlled control unit can thus be
unambiguously identified.
If no other unit has been previously selected, then the LEDs
flash on the operating keyboard of the unit on which the
ENTER key is being pressed.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 132/157
 Remote control 8
13
8.2 Remote control via digital
inputs and outputs
The controller’s remote control inputs enable the functions to be
remotely controlled via external switches or PLC signals.

Attention!

! External switches block any keys on the control

panel that have counter functions.

If a remote control signal is set at the relevant terminals then you

can no longer switch over the assigned functions from the control
panel!

8.2.1 Selection of digital table and

activation of inputs/outputs
You can select from three tables in this dialog window. These
contain various assignments for the digital inputs or no predefined
assignments (Empty table).
The tables Dig.In Tabelle 1 and Dig.In Tabelle 2 are created so
that they cover most of the applications controllable using digital
inputs, which helps avoid time-consuming configurations.
Specific adjustments can, however, still be carried out if required.
The operator can set up his specific configuration based on the
Empty Table. This table is particularly suitable for use when only a
few digital inputs will be used.
The procedure for adaptation of the tables is described under
Configuration of the digital inputs.

1. Select Dig. IO in General Setup and then select the

General Setup > Dig. IO >
Configure sub-directory afterwards.
Configure Confirm the respective selection by pressing ENTER.

2. Select the required input table. The following tables are

available: Dig.In Table 1 (Default Table),
Dig.In Table 2 (Special Shifted Center)
Empty Table.
The input assignment for each table is represented in
chapter Truth Table.
Confirm the selection with the F2 (Set.) key.

3. Press the ESC button to exit the window.

Both digital inputs and outputs can be switched off for initial
startup. Please deactivate the appropriate checkboxes to do this.

Attention! Any activated Ext.Lock functionality will be cancelled

by
deactivating the IN ena. checkbox.
Thus, the actuator can carry out positioning
movements.
The controller release is, however, not influenced.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 133/157
 Remote control 8
13
8.3 Configuration of the digital inputs

When necessary the Inputs submenu permits changing of the

assignment of various functions to the digital inputs of the
controller. Moreover the respective signal pattern (bit mask), which
must be applied to the digital inputs (terminals 74 – 85) in order to
activate a particular function, can be changed.

The procedure for changing the factory-set standard configurations

of the digital inputs is explained in the following two examples,
based on the Dig.In Table 1 (Default Table).

Example 1: The function Tear-off detection is to be assigned

to the digital inputs (lines 29 and 30).
In so doing, the standard bit-pattern for lines 29
and 30 must not be changed.

General Setup > Dig. IO > 1. Select Dig. IO in General Setup and then select the
Inputs Inputs sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. The digital inputs setting window appears.

Truth Table Pattern
no. assigned function
29 Keyb.Lock ON 3. Use the function keys F1 (next line) or F2 (previous line) to
Bitmask
85 1 74 select the stored truth table.
The option list displays the factory assigned function
Ln Ln deac t.
(Keyb. Lock ON) for row 29.

Truth Table Pattern

no. assigned function 4. Select the option list using the horizontal arrow keys and
29 Tear Out ON open by pressing ENTER.
Bitmask
85 1 74 The option list contains all the available functions..
Ln Ln deac t.
5. Select the function Tear Out ON (Tear-off detection ON)
using the vertical arrow keys and press ENTER.
Truth Table Pattern
no. assigned function 6. Select line 30 using function key F2.
30 Keyb.Lock OFF The option list displays the factory assigned function (Keyb.
Bitmask
85 0 74 Lock OFF) for line 30.
Ln Ln deac t.

7. Select the option list using the horizontal arrow keys and
Truth Table Pattern open by pressing ENTER.
no. assigned function
30 Tear Out OFF
Bitmask 8. Select the function Tear Out OFF (tear-out detection OFF)
85 0 74
using the vertical arrow keys and press ENTER.
Ln Ln deac t. Assignment of the function Tear-off detection to the digital
inputs is now completed.

9. Press the ESC button to exit the window.

By pressing function key F3 (deact.) within the menu, all bits

of the selected bit pattern are set to “1”.This is only needed if
the selected line has to be deactivated.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 134/157
 Remote control 8
13
Example 2: The function Tear-off detection is to be assigned
to the digital inputs (lines 21 and 22).

The following section of the truth table shows that lines 21 and 22
belong to a bit-block with a total of 8 lines (lines 21 to 28).

Factory allocation of functions

with the corresponding standard bit-patterns
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
20 FVG stop X X X 1 1 1 X X X X X X
21 Set Lim.Sw. 1 X 1 0 X X X X X X X X X
22 Reset Lim.Sw. 1 X 0 0 X X X X X X X X X
23 Reset Lim.Sw. 1 X 1 1 X X X X X X X X X
24 Set Lim.Sw. 2 X 0 1 X X X X X X X X X
25 Reset Lim.Sw. 2 X 0 0 X X X X X X X X X
26 Reset Lim.Sw. 2 X 1 1 X X X X X X X X X
27 Set Overtemp. X 1 1 X X X X X X X X X
28 Reset Overtemp. X 0 0 X X X X X X X X X
29 Keyb.Lock ON 1 X X X X X X X X X X X

User defined allocations-

function Tear-off detection on lines 21 and 22
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
20 dig. Left/Right Stop X X X 1 1 1 X X X X X X
21 Tear Out ON X 1 X X X X X X X X X X
22 Tear Out OFF X 0 X X X X X X X X X X
23 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
24 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
25 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
26 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
27 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
28 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
29 Keyb.Lock ON 1 X X X X X X X X X X X

The procedure for changing the allocations can be divided into

three steps, which are described on the following page.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 135/157
 Remote control 8
13
Step 1: Cancel the factory allocations of functions.
As the function tear-off detection requires only lines 21
and 22 of the bit block, the factory-side allocation of
functions to the remaining lines of the block (lines 23 to
28) must be cancelled.
Accordingly the function Do Nothing is allocated to
lines 23 to 28 from the option list.
The procedure for doing this is described in example 1.

Moreover the values of all bits in the non-required lines

19 to 24 must be set to “1”.

Procedure:

1. Use the function keys F1 and F2 to sequentially

select the individual block lines.
2. Use the function key F3 to deactivate the line
selected.

Step 2: Assign new function

The function Tear Out ON (tear-off detection ON) is
assigned to the line 21 and the function Tear Out OFF
(tear-off detection OFF) is assigned to the line 22.
The procedure for doing this is described in example 1.

Step 3: Adjust bit pattern

In line 21 the bit for terminal 84 is assigned the value ”1“
(24 V signal applied to terminal 84).
In line 22 the bit for terminal 84 is assigned the value ”0“
(0 V signal applied to terminal 84).

The value for all the non-relevant bits (terminal 83) of

the two lines 21 and 22 must be set to the value "X"
(not relevant).

The procedure for changing the bit values is described

in step 1.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 136/157
 Remote control 8
13
8.3.1 Truth table

Default values for digital input allocation: Dig.In Tabelle 1

Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
1 set Auto
X X X X X X X X X 1 0 0
(Automatic mode)
2 set MAN
X X X X X X X X X 0 0 1
(Manual mode)
3 set SC
X X X X X X X X X 0 1 0
(Center positioning)
4 opmode clear
X X X X X X X X X 0 0 0
(Defined 0-state mode)
5 set Edge1
X X X X X X 0 0 1 X X X
(Edge 1)
6 set Edge2
X X X X X X 0 1 0 X X X
(Edge 2)
7 set Center1&2
X X X X X X 0 1 1 X X X
(Centre 1/2)
8 set Edge3
X X X X X X 1 0 0 X X X
(Edge 3)
9 set Edge3 Inv.
X X X X X X 1 0 1 X X X
(Edge 3 inverted)
10 guid.mode clear
X X X X X X 0 0 0 X X X
(Defined 0-state mode)
11 Motor stop
X X X 0 0 0 X X X X X X
12 Motor stop
X X X 0 0 1 X X X X X X
13 FVG stop
X X X 0 0 0 X X X X X X
14 FVG stop
X X X 0 0 1 X X X X X X
15 Motor left
X X X 0 1 0 X X X X X X
16 FVG left
X X X 0 1 1 X X X X X X
17 Motor right
X X X 1 0 0 X X X X X X
18 FVG right
X X X 1 0 1 X X X X X X
19 Motor stop
X X X 1 1 0 X X X X X X
20 FVG stop
X X X 1 1 1 X X X X X X
21 Set Lim.Sw. 1
X 1 0 X X X X X X X X X
(Limit switch 1)
22 Reset Lim.Sw. 1
X 0 0 X X X X X X X X X
(Reset Limit switch 1)
23 Reset Lim.Sw. 1
X 1 1 X X X X X X X X X
(Reset Limit switch 1)
24 Set Lim.Sw. 2
X 0 1 X X X X X X X X X
(Limit switch 2)

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 137/157
 Remote control 8
13
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
25 Reset Lim.Sw. 2
X 0 0 X X X X X X X X X
(Reset Limit switch 2)
26 Reset Lim.Sw. 2
X 1 1 X X X X X X X X X
(Reset Limit switch 2)
27 Set Overtemp.
X 1 1 X X X X X X X X X
(over-temperature)
28 Reset Overtemp.
X 0 0 X X X X X X X X X
(Reset over-temperature)
29 Keyb.Lock ON
1 X X X X X X X X X X X
(Keyboard inhibit on)
30 Keyb.Lock OFF
0 X X X X X X X X X X X
(Keyboard inhibit off)
31 - Do Nothing
1 1 1 1 1 1 1 1 1 1 1 1
60 (Reserved)

Alternative digital input allocation: Dig.In Tabelle 2

(Special Shifted Center)
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
1 set Auto
X X X X X X X X X 1 0 0
(Automatic mode)
2 set MAN
X X X X X X X X X 0 0 1
(Manual mode)
3 set SC
X X X X X X X X X 0 1 0
(Center positioning)
4 opmode clear
X X X X X X X X X 0 0 0
(Defined 0-state mode)
5 set Edge1
X X X X X 0 0 0 1 X X X
(Edge 1)
6 set Edge2
X X X X X 0 0 1 0 X X X
(Edge 2)
7 set Center1&2
X X X X X X 0 1 1 X X X
(Center 1/2)
8 set Edge3
X X X X X X 1 0 0 X X X
(Edge 3)
9 set Edge3 Inv.
X X X X X X 1 0 1 X X X
(Edge 3 inverted)
10 guid.mode clear
X X X X X X 0 0 0 X X X
(defined zero state guiding mode)
11 Shifted Center Off X X X X X 0 X X X X X X
12 Reset Prepos. Center
X X X X X 1 X X X X X X
(Reset prepositioning to center)
13 Shifted Center On X X X X X 1 X X X X X X
14 Set Prepos. Center
X X X X X 0 X X X X X X
(Prepositioning in center)
15 set Center1&2
X X X X X 1 X X X X X X
(Center 1/2)
16 FVG Left X X X 0 1 X X X X X X X
17 FVG Right X X X 1 0 X X X X X X X
18 FVG Stop X X X 1 1 X X X X X X X
19 FVG Stop X X X 0 0 X X X X X X X

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 138/157
 Remote control 8
13
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
20 Set Lim.Sw. 1 X 1 0 X X X X X X X X X
21 Reset Lim.Sw. 1 X 0 0 X X X X X X X X X
22 Reset Lim.Sw. 1 X 1 1 X X X X X X X X X
23 Set Lim.Sw. 2 X 0 1 X X X X X X X X X
24 Reset Lim.Sw. 2 X 0 0 X X X X X X X X X
25 Reset Lim.Sw. 2 X 1 1 X X X X X X X X X
26 Set Overtemp. X 1 1 X X X X X X X X X
27 Reset Overtemp. X 0 0 X X X X X X X X X
28 ext. Unlock 1 X X X X X X X X X X X
29 ext. Lock 0 X X X X X X X X X X X
30 - Do Nothing
1 1 1 1 1 1 1 1 1 1 1 1
60 (reserved)

0 = 0 V signal 1 = 24 V signal X = not relevant

Controller interlock
The controller interlock is generally activated. The function can
only be deactivated by application of a "1” signal (24 V=) to
terminal 53.
If the controller block is activated, the output of the output stage is
switched off.
The actuator will not carry out any guiding movements.
This is valid for all operating or guiding modes (AUTO, MAN, SC).

Keyboard interlock
All of the controller’s keys are locked by a “1“ (24 VDC) on
terminal 85. The controller can be controlled via the keyboard
when this signal is no longer set.

The individual lines in the truth table can each be allocated the
following meaning:

Signification Signification Signification Signification

• Do Nothing • Motor Stop • Osc. OFF • Reset Prepos. Center
• set AUTO • FVG Left • Tear Out ON • Shifted center On
• set MAN • FVG Right • Tear Out OFF • Shifted center Off
• set SC • FVG Stop • ext. Lock • Cur.pos. to Prepos.
• opmode clear • Set Lim.sw. 1 • ext. Unlock • Cur.pos. to Prepos.E1
• set Edge 1 • Reset Lim.sw. 1 • Set W. • Cur.pos. to Prepos.E2
• set Edge 2 • Set Lim.sw. 2 • Set Prepos. E1 • Cur.pos. to Prepos. C12
• set Center 1&2 • Reset lim.sw. 2 • Reset Prepos. E1 • Guiding Lock On
• set Edge 3 • Set Overtemp. • Set Prepos. E2 • Guiding Lock Off
• set Edge 3 inv. • Reset Overtemp. • Reset Prepos. E2 • Osc. Pause On
• guid. mode clear • Keyb. Lock ON • Set Prepos. C12 • Osc. Pause Off
• Motor Left • Keyb. Lock OFF • Reset Prepos. C12 • Set M-S Pos.
• Motor Right • Osc. ON • Set Prepos. Center

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 139/157
 Remote control 8
13
8.4 Display of the actual statuses
of the digital inputs

General Setup > Dig. IO > For service purposes the actual statuses of the different digital
Dig. Inp. States inputs can be displayed.

Select Dig. IO Config. in General Setup and then select the

Dig. Inp. States sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

The status is displayed in the window.

Switched inputs (24 V applied) are displayed by a black circle.
Terminals 76 and 78 are switched in this example.

8.5 Configuration of the digital ouputs

This submenu Outputs allows various messages to be assigned to

the digital outputs of the control unit (terminal 64 – 67).
The meaning of the individual messages can be taken from the
table on the following page.

General Setup > Dig. IO > 1. Select Dig. IO Config. in General Setup and then select the
Outputs Outputs sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

Dig. Outp. Cond. Low act. 2. The digital outputs selection window appears.
64 no Errors
65 W. warn nor err. min.
66 W. warn nor err. max.
67 Hyd. Lock
3. Select the option list for the desired terminal (64 – 67) using
the horizontal arrow keys and press ENTER.
def.

4. In the opened option list mark the message that is to be

allocated to the selected terminal and press ENTER.

5. Set interface conditions for the signal via the checkbox

Low act..
Signal = high active Î deactivate checkbox
Signal = low-active Î activate checkbox

By pressing F4 (def.) the allocated messages and interface

conditions are reset for all terminals (64 – 67) to the factory
settings.

6. Press the ESC button to exit the window after allocating the
messages.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 140/157
 Remote control 8
13
Signification of the messages
Message Signification
no Errors OK message output
Width err. min. Web width measurement: Web width has fallen below the lower error limit.
Width warn min. Web width measurement: Web width has fallen below the lower warning limit.
Width warn max. Web width measurement: Web width has exceeded upper warning limit.
Width err. max. Web width measurement: Web width has exceeded upper error limit.
W. warn nor err. min. Web width measurement: Web width has neither fallen below lower warning
limit nor lower error limit.
W. warn nor err. max. Web width measurement: Web width has neither exceeded upper warning
limit nor upper error limit.
Width valid Web width measurement: Valid value
Hyd. Lock Output oil blocking
Tear Off Output tear-off detection
Motor Locked Actuator is locked (the motor symbol appears in the display with a lock in it).
Current Err. The current for the selected drive has exceeded the permissible current.
Short Circ. Err. Short circuit
Mot. Temp. Err. Overtemperature
Amp. Dis. Err. Controller not released. 24 V signal on terminal 53 missing.
Limit Sw. Err. Actuator has reached a software limit switch.
Edge Search t/o Err. Sensor positioning device: Timeout for edge detection process
Norming t/o Err. Sensor positioning device: Timeout for sensor normalisation
Norming Err. Sensor positioning device: Error during sensor normalisation
Edge Search Err. Sensor positioning device: Error during edge detection
Retr. t/o Err. Sensor positioning device: Timeout during free-running process
Lock Err. Sensor positioning device: Motor output stage blocked
Width Meas. Err. Sensor positioning device: During guidance (automatic operation), a slide of
the sensor positioning device has driven into the
inner limit switch.
Width Adj. Err. Sensor positioning device: During guidance (automatic operation), a slide of
the sensor positioning device has driven into the
inner limit switch.
Low Volt Err. Collective error message
(Condition changes with a change of the error LED in the controller front plate)
opt. Logic Err. Error in the optional logic
opt. Logic Bool 1 Optional logic output 1 (Params 1)
opt. Logic Bool 2 Optional logic output 2 (Params 1)
opt. Logic Bool 3 Optional logic output 1 (Params 2)
opt. Logic Bool 4 Optional logic output 2 (Params 2)
Adj.Done Auto Operating mode AUTO - adjusted
Adj.Done SC Operating mode SC - adjusted
Lim.SW.Right Limit switch right activated
Lim.SW.Left Limit switch left activated
OpModeAuto Operating mode AUTO
OpModeMan Operating mode MAN
OpModeSC Operating mode SC

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 141/157
 Remote control 8
13
Message Signification
CLSPro 600 Bool 1
CLSPro 600 Bool 2
CLSPro 600 Bool 3
CLSPro 600 Bool 4
GuidMode K1
GuidMode K2
GuidMode K3
GuidMode C12K1
GuidMode K3Inv

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 142/157
 Remote control 8
13
8.6 Remote control using electronic
remote fine adjustment device
It might be necessary to move the position of the web away from
the actuator, depending on the machine conditions or the
production requirements.
Using the optional electronic EFE 1 (analog) remote fine
adjustment device will enable you to correct the web position from
any location near the machine.

Solely the EFE 1 potentiometer has to be used to

set up the position setting in this case.
The arrow-keys on the control panel are deactivated
in automatic mode!

8.6.1 Configuration
The EFE 1 electronic remote fine adjustment device option must
be entered in the set-up menu.

General Setup > Sensor/EFE > 1. Select Sensors/EFE in General set-up and then select the
EFE remote Adj. EFE Remote Adj. sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. Select EFE 1 from the window that has just opened up.
Press ENTER to confirm your selection.

3. The adjustment resolution can be reduced by a factor of 2

when using the EFE 1 in conjunction with a CLS Pro 600
sensor. This will give you setting up options with more
sensitive reactions. This means that you have to adjust the
potentiometer’s rotary knob by double the normal number
of steps in order to realise the same change to the set
point.
Activate the EFE high resolution function to use this
option.

4. Press ESC to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 143/157
 Remote control 8
13
8.6.2 Operation
1. Press Automatic.
The controller will switch over to automatic mode.
The LED of the button will illuminate.

2. Turn the potentiometer to set up the web set position that you
want.

Potentiometer

The current web position setting will be displayed in the

standard screen (see Chapter 7.1.1).

8.6.3 Speed dependent oscillation frequency

You can use the EFE 1 analog input to control the speed-
dependent oscillation frequency.
The production machine generates an analog machine speed
signal that can also be routed to the EFE 1 input.
The frequency setting will be realised in Osc. Params by the
maximum value (e.g. +10 V). An optimised analog signal will be
generated at a reduced machine speed an the oscillation
frequency will be reduces accordingly.
However, the normal EFE 1 remote control function will no
longer be available for use.

General Setup > Sensor/EFE > 1. Select Sensors/EFE in General set-up and then select the
EFE remote Adj. EFE Remote Adj. sub-directory afterwards.
Confirm the respective selection by pressing ENTER.

2. Select the Osc. Speed De. entry in the window that has
just opened. Press ENTER to confirm your selection.

3. Press ESC to exit the window.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 8

with analog sensors Date: 20.06.2011 Page: 144/157
 Default settings 9
5
9 Default settings
The default settings have been set up in the controller in the
factory. The following settings are set up again after a reset has
been carried out:

Menu Parameter level 1 Parameter level 2 Parameter level3 Default value Application
Change User Level Active user level Admin.
User Password 2
Actuator Type (EMS&Hydr.) EMS 17/18
Hydraulics Add-on Zero elevation [%] 0
Dither amplitude [mA] 0
Use teach table off
Specific current control off
Direction Dir. inverted off
SC Transducer Type & Dir. Type EMS Pot.
Inversion off
Pos. Limit active off
Limit left -2048
Limit right +2047
SC W & XP Setpoint 0
Gain 20.00
Man Pos. Control off
Man Speed [1/1000] 700
Sensors/ Sensor 1 IR2005
EFE Dark -2048
Bright +2047
Inv. off
Sensor 2 IR2005
Dark -2048
Bright +2047
Inv. active
Sensor 3 not connected
Dark -2048
Bright +2047
Inv. off
EFE Remote Adj. Choose EFE if present not connected
Control Gain & Offset Edge 1 w 0
loop xp 5.00
Edge 2 w 0
xp 5.00
Center 1&2 w 0
xp 5.00
Edge 3 w 0
xp 5.00
Speed control active
Adj.done Limits Auto 100
SC 25

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 9

with analog sensors Date: 20.06.2011 Page: 145/157
 Default settings 9
5
Menu Parameter level 1 Parameter level 2 Parameter level 3 Default value Application
FVG Connection Op. Mode not connected

Int. FVG Int. FVG

Homing Dir. Homing dir. inv. not reversed
For Ref. Switch inv. not reversed
internal
Offset 1 Offset [mm] 0
FVG
only! Inverted no
Offset 2 Offset [mm] 2000
Inverted yes
Range Range [mm] 5000.0
Feed Feed in μm / rev. 20088
(for 4,2:1 Gear box)

Ext. FVG 1
FVG Homing Dir. Homing dir. inv. not reversed
Ref. Switch inv. not reversed
For
Offset Offset [mm] 0
external
FVG Inverted no
only! Range Range [mm] 5000.0
Feed Feed in μm / rev. 20088
(für 4,2:1 Getriebe)
FVG 2
Range Homing Dir. Homing dir. inv. not reversed
Ref. Switch inv. not reversed
Offset Offset [mm] 2000
Inverted yes
Range Range [mm] 5000.0
Feed Feed in μm / rev. 20088
(for 4,2:1 Gear box)

FVG Retract mode Select a full retract SC & Man.

mode
General Norming mode Select a norming mode Bright/Dark
part Width Adjust. FVG width adjustment Level outer active
Width adj. lvl. [%] 75
Repositioning FVG remembers current Tear Off not active
position after:
SC or Man not active
Velocities Retract vel. [mm/s] 60
Edge push vel. [mm/s] 5
Slow man. vel. [mm/s] 1
Fast man. vel. [mm/s] 60
Norm. vel. [mm/s] 60

Special Mode after error Man.

Sensor Cover Guarding not active
Master Slave Guiding not active

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 9

with analog sensors Date: 20.06.2011 Page: 146/157
 Default settings 9
5
Menu Parameter level 1 Parameter level 2 Parameter level 3 Default Application
value
Width Ref. Width [Press “set ref”!] 0
Measure Limits Nominal width 80.0
Error E- -5.0
limits E+ +5.0
Warning W- -2.0
limits W+ +2.0
Opmodes Width measure opmodes AUTO active
MAN active
SC active
Edge Edge 1 Device This device
Sources Edge Sensor 1
Inverted off
Normed active
Edge 2 Device This device
Edge Sensor 2
Inverted active
Normed active
Edge 3 Device This device
Edge Sensor 3
Inverted off
Normed off
Src. SC Device This device
Edge SC
Inverted off
Normed active
Src. EFE Device This device
Edge EFE
Inverted off
Normed active

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 9

with analog sensors Date: 20.06.2011 Page: 147/157
 Default settings 9
5
Menu Parameter level 1 Parameter level 2 Parameter level 3 Default value Application
Add. Tear Off Det. Edge 1 Sensor none
Functions Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Edge 2 Sensor none
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Edge 3 Sensor Edge 3
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
WD Edge 3 Delay [ms] 1.0
Enabled no
Sensor value age 1 (cycle)
Center 1&2 Sensor none
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Oscillation mode Osc. Opmode off
Osc. Params. Amplit. Auto [%] 40
Amplit. SC [%] 4
Amplit. FVG [%] 10.0
Frequency [min-1] 30
Osc. Params start/stop at act.pos. active
Add-on
start osc. after restart off
Dig. IO Configure Choose default IN- Default table
Config. Table
Dig. Inputs enabled yes
Dig. Outputs enabled yes
Inputs See Section 8.3
Outputs See Section 8.4
Special Change Password User Level Admin.
Password 2
(0 displayed)
Timeout [min] 0
Dev. Config Backlight Time 0
(permanent on)
Show errors active
Confirm errors off
SW Version -
Low V cnt. 0

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 9

with analog sensors Date: 20.06.2011 Page: 148/157
 Default settings 9
5
Menu Parameter level1 Parameter level2 Parameter level 3 Default value Application
Optional Params 1 off
Logic off
0
0
0
0
Params 2 off
off
0
0
0
0
Fieldbus Status Bus type unknown
Module status 0
Data exchange not running
Last interrupt 0
Profibus Address 3
Swap Bytes off
Swap Words off
DeviceNet Address 3
Baudrate 500 kbps
Swap Bytes off
Swap Words off
CANopen NMT Master One fieldbus device active
only!
Bus off off
No Sync off
Sync Time [ms] One fieldbus device 4.0
only!
Node Id 11
Remote Select remote device This device
Device
Material Sensor 1 Dark -2048
Setup Bright +2047
Sensor 2 Dark -2048
Bright +2047
Sensor 3 Dark -2048
Bright +2047
Man. Setup – Offset 0
Sensor 3
Gain 1.00
Outputs Clamp 64 No errors
Low act. off
Clamp 65 W. warn nor
err. min.
Low act. active
Clamp 66 W. warn nor
err. max.
Low act. active
Clamp 67 Hydr lock
Low act. active

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Chapter: 9

with analog sensors Date: 20.06.2011 Page: 149/157
 Trouble shooting 10
4
10 Trouble shooting
Errors are indicated by the error LED illuminating.

You can choose to display them or suppress them. Furthermore,

the display duration of a reported error can be varied.
These settings are made in the menu
General Setup > Special > Dev. Config..

In generally we differentiate between two types of errors:

1. To acknowledge an error
The error report must be acknowledged by pressing the
‘ENTER‘ button and then the display and the error-LED will be
extinguished.
The error report will be displayed immediately after being
acknowledged if the error has not been eliminated.

2. Self-deleting errors
The error message is deleted automatically as soon as the error
is eliminated. The error LED will be extinguished.

In general, the system error that occurred last is the

one that is displayed. Any error messages that were
displayed previously are cleared automatically.

All error reports will be displayed in full on the screen immediately

after they occur.

Example: Actuator drawing excess current.

This error report must be acknowledged.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 10

with analog sensors Date: 20.06.2011 Page: 150/157
 Trouble shooting 10
4
Fault message Possible cause Solution

- Guiding device has moved - Activate into the opposite

MOTOR OVERCURRENT into a stop position or is direction.
blocking the motorised guide. Error report will be deleted
automatically.

- Actuator short circuit - Find the cause of the short

MOTOR SHORT CIRCUIT The actuator controller was circuit
switched off. - Exchange the actuator if
necessary.

- The maximum output stage - Leave the output stage to cool.

MOTOR TEMPERATURE motor operating temperature
- Determine the cause of the
has been exceeded.
error.
The actuator controller was
switched off.

- Insufficient contrast has been - Clean the sensor and repeat the
CONTRAST DIRT determined after a material material set-up.
set-up using the analog
sensors.
The setting will be imported,
but correct controlling cannot
be guaranteed.

- The actuator has reached a - Activate into the opposite

LIMIT SWITCH SET software limit switch direction.
(“Pos. Limit”).
Driving the actuator in the
corresponding traversing
direction is prevented.

- No edge was found during - Check operation of the sensor

EDGE DETECT. TIMEOUT edge detection (Search positioning unit (especially the
process timeout). slide).
No guidance is possible.
Condition:
Norming mode = „No
norming“

- No contrast transition was - Check operation of the sensor

NORMING TIMEOUT found (Search process positioning unit (especially the
timeout). slide).
No guidance is possible.
Requirement:
Norming mode = "Bright“ or
"Dark/Bright“

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 10

with analog sensors Date: 20.06.2011 Page: 151/157
 Trouble shooting 10
4
Fault message Possible cause Solution

- An error has occurred during - Check sensor.

NORMING ERROR sensor normalisation. If necessary clean sensor.
No guidance is possible.
- Insert material and repeat
sensor normalisation.

- During edge detection the - Insert material and repeat edge

EDGE DETECT. ERROR FVG slide has reached the detection.
inner limit switch.
No guidance is possible.

- Timeout during free-running - Check operation of the sensor

RETRACT TIMEOUT process of the sensor positioning unit (especially the
positioning unit. slide).
- Check the limit switch of the
The slide of the sensor
sensor adjustment unit.
positioning unit has not
reached the outer FVG limit
switch after elapsing of the
max. free-running time.

- During guidance (automatic - Check the position of the web of

WIDTH ADJ. ERROR operation), a slide of the material.
sensor positioning unit has
driven into an inner limit
switch.
The control unit changes to
manual operation.
The slide of the sensor
positioning unit moves
outwards (outer limit switch).

- The operating voltage has - Ensure the stability of the supply

VOLTAGE BELOW 16V fallen below 16 V. voltage.
Use according to regulations Operating voltage range:
is no longer guaranteed. 24 V ± 5%.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 10

with analog sensors Date: 20.06.2011 Page: 152/157
 Trouble shooting 10
4
Fault Possible cause Solution

The controller does not respond - A remote controller has been - Check terminal 85. Remove the
to any operation. connected to the control “1“ signal (24V DC) if present.
system.
It has blocked the controller
buttons.

Undefined unit response. - A program change has - Carry out a basic unit
occurred without a restart. initialisation.

A connected sensor is not - An incorrect type was - Set the correct sensor type
working entered in the set up menu (Menu General Setup >
for the corresponding sensor. Sensors/EFE).

The actuator moves to an end - The actuator direction is - Reverse the actuator direction
position and remains there in the incorrectly set. (Menu General Setup >
operating modes "manual Actuator > Direction,
operation" or "SC". Checkbox "Mot Dir. Inverted“).

- The direction of the position - Reverse the position feedback

return for the central position direction
encoder is incorrectly set. (Menu General Setup >
Actuator > SC-Transducer >
Type & Dir., Checkbox "Inv“).

Both software end switches of - The direction of the position - Reverse the position feedback
the actuator are active return for the central position direction
simultaneously. encoder is incorrectly set. (Menu General Setup >
Actuator > SC-Transducer >
Type & Dir., Checkbox "Inv“).

All the menu settings for - The gain (XP) was - Adjust the controller gain.
actuators, sensors, central inadvertently reduced to “0”.
position encoders, etc. are No guiding takes place in
correct, but the unit does not "automatic" operating mode.
control

The control unit cannot or can - Changes to the settings of the - Check the configuration of all
only be partially controlled after digital inputs have been digital inputs and if necessary
switching on. carried out (e.g. an input for adjust a possibly present
an operating mode has been external protective circuit
configured as Low-active, so (Menu General Setup >
that the operating mode can Dig. > Inputs).
no longer be changed over
the keyboard).

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 10

with analog sensors Date: 20.06.2011 Page: 153/157
 Maintenance 11
3
11 Maintenance
11.1 General

Attention!
You are only allowed to undertake maintenance or
cleaning of the controller or the control panel and of
all connected components after the mains voltage has
been switched off.

Before any maintenance or cleaning work ensure the system is

electrically isolated and at zero potential!
To this end always carry out the following measures:

1. Switch off.
2. Prevent switching back on.
3. Check the equipment is isolated.
4. Earth.
5. Cover or shield any adjacent parts that are still live.

The maintenance or the cleaning of the system can only take

place, after carrying out these steps.

The maintenance or cleaning intervals depend on the ambient

conditions at the installation site.
If the customer is processing very dusty materials then the
maintenance/cleaning intervals must be reduced accordingly.

As a matter or course, cable connectors (e.g. between controller

and actuator) should only be disconnected when the controller is
no longer connected to the mains supply. Any infringements will
result in the warranty claim being invalidated.

11.2 Controller
The controller is maintenance-free.

Cleaning of the enclosure should be carried out using a dry, clean

and soft cloth.
A commercial liquid cleaner may be used if the casing is very dirty.
Adhere to protection class IP 54!

11.3 Sensors
The sensor lenses of infrared sensors or the transmitter and
receiver capsules of ultrasonic sensors have to be kept clean to
ensure optimum guiding results.

A material setup must be run after the sensor lenses or receiver

and transmitter capsules have been cleaned
(see Material set-up).

Bahnlaufregelgerät ekrPro Com60 EDV-Nr.: MD.191.00.07/1.8.22 Kapitel: 11

mit analogen Fühlern Datum: 20.06.2011 Seite: 154/157
 Maintenance 11
3
The CLS Pro 600 sensor is classified as an optical instrument. It
must be looked after accordingly.
Cleaning of the sensor housing should be carried out using a dry,
clean and soft cloth.
A commercial liquid cleaner may be used if the housing is very dirty.
Adhere to protection class IP 54!
The measuring window’s protective lens cover must be cleaned
regularly in order to obtain optimum guidance results.
Spotted or homogeneous dirtying of the lenses can result in wrong
readings.

11.4 Electric motor-driven actuator

The electric motor-driven actuator is maintenance-free.

11.5 Hydraulic unit

You must always abide by the manufacturer’s instructions if the
hydraulic unit was supplied by the customer.
Abide by the following instructions if the hydraulic unit was supplied
by BST.
11.5.1 Safety instructions
Attention: The following safety measures must be implemented
before you undertake any maintenance work on the
hydraulic equipment:
• When all of the plant’s moving parts have been stopped, any
mechanical locks that are fitted must be activated.
• Depressurise the hydraulic system; i.e. any pressure
accumulators fitted must also be depressurised.
• Clean any parts that have hydraulic oil on them as quickly as
possible.
• Prevent your skin from making frequent and intensive contact
over a long period with the hydraulic oil.
• Thoroughly wash off any parts of your skin that get oil on them
using water and a skin-friendly cleaner.
• Abide by the legal regulations when disposing of the old oil.
11.5.2 Maintenance work
The maintenance work and the repair of any damage found must
be carried out by specialist personnel.
• Hydraulic system in general (to be undertaken during every
system inspection)
¾ Clean all deposits off of the system
¾ Inspect the outside for signs of damage
¾ Check all cable and plug connections for signs of damage and
ensure that they are seated tightly
¾ Inspect the unit and the pipelines for leaks.
¾ Check to see that all of the screw-connections are tightly
made, retighten whenever necessary.
¾ Check that the securing bolts are tight and the frame is in a
safe state.

Bahnlaufregelgerät ekrPro Com60 EDV-Nr.: MD.191.00.07/1.8.22 Kapitel: 11

mit analogen Fühlern Datum: 20.06.2011 Seite: 155/157
 Maintenance 11
3
• Hydraulic oil
¾ The 1st oil change should take place after 50 running hours at
the latest (always change the oil whilst the plant is still at its
running temperature).
¾ Other oil changes should take place after 1,500 running hours
or once a year at the latest, depending on the operating
conditions.
¾ Every oil change will provide an indication of the ageing
process, so oil samples should be taken and sent to a
laboratory on a regular basis, in order to be able to determine
the precise oil change period.
¾ The oil level must be checked at least once a week. The cause
must be found and rectified if oil loss occurs. Refill through a
suitable filter using the same type only.

• Oil filter
¾ Carry out the 1st oil filter change after the system has been
flushed out (if it is flushed out through this filter).
¾ The 2nd oil filter change should take place after the
commissioning phase has been completed.
¾ If the plant is being run continuously then the filter:
• Must be changed when the contaminated message is
displayed
• Changed at least once a year.
¾ Clean the wire-mesh insert by rinsing it in benzine. Dispose of
the paper insert and then fit a new one.

11.6 FVG stepping motor

Power is continuously applied to the stepping motor

output stage, even when stopped. Therefore any work
undertaken on the interconnections must only be
carried out with the power switched off.

The FVG stepping motor is maintenance-free.

Bahnlaufregelgerät ekrPro Com60 EDV-Nr.: MD.191.00.07/1.8.22 Kapitel: 11

mit analogen Fühlern Datum: 20.06.2011 Seite: 156/157
 Decommissioning 12
1

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

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: 12

with analog sensors Date: 20.06.2011 Page: 157/157
 Index I

Index
Actuator
Electric motor-driven EFE 1 143
Maintenance 155 Speed dependent oscillation frequency 144
Technical data 23 EFE 1 with CLS Pro 600 143
Hydraulic powered Electrical connection 33
Maintenance 155 Electro static discharge 17
Ambient conditions 27 EMC wiring 35
ATEX 15, 27 Emissions 17
Cable connections 15, 33, 34, 154 ESD 17
CAN bus ESD protection 17
Checking and setting up the unit address 37 Fault messages 151
CLS Pro 600 39
ekrPro Com60 37
Firmware
ekrPro Key60 38 Load firmware 2
FVGPro module 38 FVG eco 87
Terminator activation 40 FVG Pro 90
BST ProLogic 41 Operating mode for center line guiding 94
CLS Pro 600 42 FVG stepping motor
ekrPro Com60 40 Maintenance 156
ekrPro Key60 40
General definitions 4
FVGPro Module 41
Allocation of FVGs for a FVGPro 2MK 6
Components connectable 7
Inverting of the sensor signal 5
Control panel 7 Oscillation curves 6
Setting the device address 39 Oscillation types 6
Controller Sensor assignment 4
Ambient conditions 18 Size of the oscillation amplitude 5
Analog inputs 18 General Set-up
Analog outputs 19 Activation of the position controller 81
Assembly 27 Actuator selection 75
CAN Bus 19 Actuator settings 75
Digital inputs 18 Assignment of the sensors to the guiding
Digital outputs 19 modes 101
Dimensions built-on unit 19 Change password 109
Display 19 Commissioning sensors and EFE 82
FVG inputs 18 Configuration of the digital inputs and outputs 109
FVG ouput stage 19 Control loop settings 84
Maintenance 154 General unit settings 110
Mounting as built-on unit 27, 28 Hydraulic settings 76
Output stage 19 Selecting the servo-center component 78
Power supply 18 Sensor positioning device 86
Power supply outputs 19 Setting positioning speed for manual mode 81
Space needed to open enclosure cover 28 Setting the actuator guiding direction 77
Technical data 18 Setting the default values 74
Weight 19 Special device settings 109
Decommissioning 157 Special functions 103
Default settings 145 Oscillation 107
Digital reflectionsensor RS20/RS30 Tear-off detection 103
Installation 32 Watchdog 104
Display Web width measurement 98
Design 7 Installation 33
Screen Master-Slave guiding system 114 Installation site 27
Screen of pre-positioning 113 Intended use 3
Screen of the CAN bus status 115 Internal FVG 87
Screen pre-positioning to machine centre Keypad 7
(FVG 2MK) 114 Key functions 7
Screen when sensor 3 connected 112 Line and contrast sensor CLS Pro 600
Screen with active web width measurement 113 Installation 32
Screen with sensor positioning device connect 111
Screen without sensor positioning device 113

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Index

with analog sensors Date: 20.06.2011 Page: 1/3
 Index I
Line sensor T62
Installation 29, 30 Remote control inputs 133
Maintenance 154 Remote control via CAN bus 132
Controller 154 Truth table 133, 137
Electric motor driven avtuator 155 Safety instructions 2, 14
FVG stepping motor 156 Sensors
Hydraulic powerded actuator 155 Maintenance 154
Sensores 154 Technical data 20
Master-Slave guiding 130 CLS Pro 600 22
Manual setting of the distance 130 Fork light barrier G 53 C2/5 22
Setting the distance via arrow keys 131 Infrared sensors 20
Setting the distance via direct input of Line sensor T62 D1 21
the value 130 Opto-electronic analog sensor IRS ... 21
Reflected light measuring light barrier
Material set-up R 42 D... 22
Automatic 51 Reflection sensor TW54 C5 21
Material Set-up 121 RS20/RS30 23
Analog refelection sensor as sensor 3 123 Ultra-sonic sensors 20
Automatic 122 Settings
Manual 52, 122 Load 65
Sensors T62 D1 and TW54 C5 124 Save 65
Navigating within the system 9 Set-up menu 66
Arrow keys 13 General set-up 74
Buttons 14 Material Set-up 66
Checkbox 13 Save/load settings 66
Entries in the editing box 12 Selection of a standard system 66
Entry of a negative number 13 Selection of user level 66
Function keys 11 Sensor compensation 66
Path details 10 Software BST Tools 67
Shortcut function 11 Application with CAN interface 71
Operating manual Application with serial connection 68
Symbols used 1 Requirements 67
Utilisation 2 Special functions
Operation Oscillation 63
Changing settings during operation 116 Tear-off detection 54
Changing the setpoint 118 Watchdog 59
Changing the settings during operation Standard system
Guiding mode 117 Activating manual position control 50
Display 111 Additional functions 54
Gain adjustment 117 Commissioning 45
Sensor positioning device 119 Master set up 47
with efe Plus 46 Material Set-up 51
Oscillation 127 Selection 45
Params Add-on 65 Sensor positioning device 53
Setting parameters 64 Configuration dependet default settings 53
Password Setting center position and gain for S-C mode 49
Adjustment 42 Setting the actuator guiding direction 48
Potentially explosive areas 3 Setting the actuator path limits 48
Power pack 25 With CLS Pro 600 52
Power supply 25 With CLS Pro 600 and sensor positioning
device 52
Pre-positioning 128
With external keyboard efe Plus 46
To machine center-line (FVG 2MK) 129
Start-up 36
Protection class 16
General 36
Reflection sensor TW54
Status display 111
Installation 29, 31
Storage 26
Remote control 7, 132, 133
Configuration of the digital inputs 134
Tear-off detection 126
Configuration of the digital outputs 140 Technical data 18
Display of the actual status 140 Transport 26
EFE 1 with CLS Pro 600 143 Trouble shooting 150
Electronic remote fine adjustment 143

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Index

with analog sensors Date: 20.06.2011 Page: 2/3
 Index I
Watchdog
Deviation from the standard application 61 Parameter setting 62
Operation 62 Standard application 60

ekrPro Com60 web guide controller EDVno.: MD.191.01.07/1.8.22 Index

with analog sensors Date: 20.06.2011 Page: 3/3
 Commissioning examples A1

A1 Commissioning examples

1 Initial start-up of an actuator

with integrated position feedback

1. Wire the motor as shown in the circuit diagram.

General Setup > Actuator > 2. Select the actuator under

Type (EMS&Hydr.) General Setup > Actuator > Type (EMS&Hydr.).
Select and mark the servo-center component from the option list.

General Setup > Actuator > 3. Check the sense of rotation of the actuator:
Direction Go to General Setup > Actuator > Direction and test the
actuator movement by pressing the F2 (left) key.

4. Check the actuator positioning movement.

Does the actuator move in the direction of sensor 1?
yes = no alterations required
no = activate “Mot. Dir. Inverted“ checkbox (x)

General Setup > Actuator > 5. Set up the positioning limits – if required.
SC Transducer > Pos. Limit Go to General Setup > Actuator > SC-Transducer > Pos. Limit
and traverse to the required positions and then set them up as
the stop switch positions.

6. The function ‘servo-center position’ will no longer automatically

set to the middle between the two limit positions after the
positioning limits have been set up.
General Setup > Actuator > Go to General Setup > Actuator > SC-Transducer > SC W &
SC Transducer > SC W & XP XP
and set up the servo center position and the gain.

It only saves the last centre position setting.

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 1/7
 Commissioning examples A1

2 Start-up an actuator with

OMG 4 / OMG 7 / OMG 8
1. Wire in the motor and servo-center component as shown in the
circuit diagram.

General Setup > Actuator > 2. Go to General Setup > Actuator > Type (EMS&Hydr.) and
Type (EMS&Hydr.) select the actuator. All of the actuators present can be activated
from the options list.

General Setup > Actuator > 3. Go to General Setup > Actuator > SC-Transducer > Type &
SC Transducer > Type & Dir. Dir. and select and enter the servo-center component.

4. Check the actuator positioning movement.

Does the actuator move into the centre position?
yes = no alterations required
no = activate “Inv“ checkbox (x)

General Setup > Actuator > 5. Go to General Setup > Actuator > SC-Transducer > SC W &
SC Transducer > SC W & XP XP and set the gain for the servo-center component.

3 Start-up an actuator without

a servo-center component
1. Wire the motor as shown in the circuit diagram.

General Setup > Actuator > 2. Go to General Setup > Actuator > Type (EMS&Hydr.) and
Type (EMS&Hydr.) select the actuator.
All of the actuators present can be activated from the options
list.

General Setup > Actuator > 3. Go to General Setup > Actuator > SC-Transducer > Type &
SC Transducer > Type & Dir. Dir. and deactivate the servo-center component, i.e. select and
enter “not connected“ in the options list.

Sel Std. System

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 2/7
 Commissioning examples A1

4 Initial start-up with sensor

positoning device FVGPro 2MK
1. Carry out electrical connections as specified in the circuit
diagram.

2. Reset the parameters to the default settings.

To do this open the Sel.Std.System menu and select F1 (Def.).
The ekrPro Com60 carries out a restart.

Sel Std. System

3. Select a standard system
Now select a standard system which corresponds as closely as
possible to that you are using.
To do this, call up the Sel.Std.System menu again and select
the appropriate system from the option list. Press F2-key (set)
to activate this setting.

General Setup > Actuator > 4. Check the actuator and the servo-center component connected.
Type (EMS&Hydr.)

4.1 Check actuator connected and readjust it if necessary.

General Setup > Actuator >

Direction 4.2 Check sense of rotation.
Press the F2-key. The guiding frame must move in the
direction of sensor 1. If this is not the case, activate ‘Inv.’
and repeat the adjustment.

4.3 Check the servo-center component.

General Setup > Actuator > If a servo-center component is fitted, the value of the
SC Transducer > Type & Dir. percentage display must decrease if the actuator moves to
the
left (using key F2). If not, activate ‘Inv.’..

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 3/7
 Commissioning examples A1

General Setup > Sensor/EFE > 5. Check sensors connected and readjust it if necessary.
Sensor1 (Sensor2)

Check to ensure that the percentage display value increases

the more the sensor is covered. If not, check whether inverting
is set.

After this, the Master setup for this sensor has to be carried out.
Press the F1 („auto“) button. Then cover up the sensor
measuring window completely and then hold it free. Press key
F2 ("auto OK“) to confirm.

6. Repeat the setting for Sensor 2.

If Sensor 3 is connected, no master set up should be carried
out.

7. Check the FVG stepper motor and limit switch.

General Setup > FVG > FVG Pro > Check the FVG stepping motor’s rotational direction setting.
Slide 1 (Slide 2) > Homing Direction Press the F3-key to move the slide inwards first. If the slide
moves outwards then you must activate the “Homing dir. Inv.“
FVG Pro slide 1 Homing Dir. checkbox.
Test homing dir.using F2/F3 Now use a metallic object (e.g. a coin) to cover the outer limit
Homing dir. inv.
Ref. switch inv. switch.
outer inner The “outer“ radio button must be active ( ). The “Ref. Switch
<<>>
>><<
inv.“ checkbox must be activated if the inner limit
switch is displayed as “active”.
Check both limit switches once again afterwards for safety
purposes.

8. The settings carried out above for Slide 1 should now be

repeated for Slide 2.

Now, the FVGPro 2/MK has been made completely ready for
operation.

Additional functions such as material width measuring,

prepositioning, etc., can also be set up after the basic FVGPro
2/MK setting up has been completed.

These settings are described in the chapter entitled Start-up,

FVG – Sensor positioning device.

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 4/7
 Commissioning examples A1

5 Initial start-up wtih sensor positioning device FVGPro 2MK

and Master-Slave guiding function
1. Carry out electrical connections as specified in the circuit
diagram.

2. Reset the parameters to the default settings

Sel Std. System To do this open the Sel.Std.System menu and select F1 (Def.).
The ekrPro Com60 carries out a restart.

3. Select a standard system

Sel Std. System Now select a standard system consisting of the components
infrared sensor or ultrasonic sensor, EMS17/18 and 2MK ....
Therefore call up the menu Sel.Std.System again and select
the respective system from the option list.
Press the F2-key (set) to activate the system.

4. Activate the Master-Slave control system

General Setup > FVG > Special Select now the submenu FVG Special.
Activate the function Master-slave-guiding.

5. Carry out master set-up

General Setup > Sensor/EFE > Carry out the master set-up for both sensors.
Sensor1/Sensor2 Call up the submenu for sensor 1 und carry out the master set-
up according to point 6.4.1.2.
Don’t invert sensor 1.

After that select the submenu for sensor 2 and carry out the
master set-up for this sensor.
Activate the checkbox Inv. for this sensor

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 5/7
 Commissioning examples A1

6. Adjust the sense of rotation of the actuator

General Setup > Actuator > Check the sense of rotation of the actuator. Press the F2-key.
Direction The guiding frame must move in direction to sensor 1. If this is
not the case, activate Mot. Dir. Inverted and repeat the check
of the sense of rotation.

7. Check the effective direction of the servo-center component

General Setup > Actuator > Press the F2-key to move the actuator and observe the bar
SC Transducer > Type & Dir. indicator at the same time. The bar must decrease. If this is not
the case, activate Inv.

8. Adjust the homing direction of the FVG sensors

General Setup > FVG > FVG Pro > Check the homing direction for both FVG Pro slides
Slide 1 (Slide 2) > Homing Direction (Slide 1 and Slide 2).
Therefore open the menu Homing direction for Slide 1.
FVG Pro slide 1 Homing Dir. Press the F2-key. The respective slide must move to the outside
Test homing dir.using F2/F3
Homing dir. inv. (to the homing position).
Ref. switch inv. The outer limit switch must be activated after the free-running
outer inner
position has been reached ( ).
If, instaed of this, the FVG slide moves inwards activate the
>><<
<<>>

checkbox Homing dir. Inv.

If the inner limit switch is activated at the homing position,
activate the checkbox Ref. switch inv.
Carry out zhe same settings for slide 2.

9. Enter the position offset between both FVG Pro slides

Open the Offset menu for Slide 2.
General Setup > FVG > FVG Pro > Now enter the gap between the two FVG Pro-slides. For
Slide 2 > Offset example, the gap between the centre of the master sensor
scanning window and the centre of the slave sensor scanning
window (refer to Section 7.9 for the significance of the Offset
parameter):

Offset

Don’t activate the inversion!

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 6/7
 Commissioning examples A1

10.Setting up the actuator path limits

General Setup > Actuator > You can now set up the actuator drive’s actuator path limits, if
SC Transducer > Pos. Limit needed.
The procedure is described in Section 6.4.1.4 .

Please note that during the setting up process it is the display

bar response that is decisive and not the absolute position
display!

11.Setting up the S-C mode centre position

General Setup > Actuator > Set up the centre position for the S-C mode.
SC Transducer > SC W & XP Call up the SC W & XP sub-menu for this procedure.
The procedure is described in Section 6.4.1.4 .

12.Setting up the sensor norming mode

General Setup > FVG > The FVG Pro sensor will be automatically optimised to match
Norming Mode the characteristics of the material currently being used during
the norming process.
Call up the Norming mode sub-menu
Select a suitable mode for the application.
See Commissioning/FVG Pro/Norming mode

13.Setting the traversing range limits for the FVG Pro slides
General Setup > FVG > FVG Pro > The traversing range limits are used for displaying the traversing
Slide 1 (Slide 2) > Range range in the operating status display.
Call up the Slide 1 Range sub-menu.
Set up the Slide 1 limits.
See Commissioning/FVG Pro/Range.
Change over to Slide 2 and run the same setting up procedure.

14.Setting up the control circuit

General Setup > Control Loop > The set points and the control circuit gain can be set up via this
Gain & Offset sub-menu.
We recommend that you should use the factory default settings
for standard controllers.

The commissioning of the guiding system with FVG Pro and

master-slave control system is finished.

ekrPro Com60 web guide controller EDV-no.: MD.191.01.07/1.8.22 Chapter: A1

with analog sensors Date: 20.06.2011 Page: 7/7
 Button „Menu“ 61 Actuator 611 Type (EMS&Hydr.)
612 Hydraulics Add-on
MENU 613 Direction 6141 Type & Dir.
614 SC-Transducer 6142 Pos. Limit
615 Man Pos. control 6143 SC W & XP
1 Change User 221 Edge 1
616 Man Speed
212 Edge 2
62 Sensors/EFE 621 Sensor 1
2 Add. Functions 21 Tear Off Det. 213 Edge 3
214 WD Edge 3 622 Sensor 2
22 Osc. Mode
215 Center 1&2 623 Sensor 3
23 Osc. Params
624 EFE Remote Adj.
24 Osc. Params Add-on 6421 Homing Dir.

25 Osc. Speed Dpdcy 63 Control Loop 631 Gain & Offset 6422 Offset 1
632 Adj. done Limits 6423 Offset 2

633 Speed control 6424 Range

3 Material Setup 31 Sensor 1
634 Sens.Thresh.Warn. 6425 Feed
32 Sensor 2
635 Arrow Key Lock 6426 Special
33 Sensor 3
641 Connection
34 Man. Sens. 3
642 Int. FVG 64311 Homing Direction
64 FVG 643 FVGPro
64312 Offset
6431
Sel. Std. System 644 Retract Mode
4 64313 Range
Slide 1
65 Width Measure 651 Ref. Width 645 Norming mode
64314 Feed
652 Limits 646 Width adjust.
5 Save/Load Settings 647 Repositioning
553 Opmodes
648 Velocities 64321 Homing Direction
66 Edge Sources 661 Edge 1 649 Special
64322 Offset
6 General Setup 662 Edge 2 6432
64323 Range
663 Edge 3 Slide 2
64324 Feed
664 Src. SC
71 Params 1
7 Opt. Logic 665 Src. EFE
72 Params 2
67 Add. Functions 671 Tear Off Det.
672 Osc. Mode
673 Osc. Params

8 Fieldbus 81 Status 674 Osc. Params Add-on

82 Profibus 675 Osc.Speed Dpdcy
83 DeviceNet
68 Dig. IO Config. 681 Configure
84 Monitor
682 Inputs
85 CanOPEN
683 Outputs
684 Dig. Inp. States
9 Remote Device
69 Special 691 Change Pwd.
692 Dev. Config.
693 Reset
694 Watchdog Test Annex A2: Structure of the set-up menu
Only accessible for BST
EDV no.: MD.191.01.07/1.8.22
25 support!
695 Test Date: 20.06.2011
 Connecting plate A3

A3 Connecting plate
ekrPro Com60; version XT

Actuator (motorised/hydraulic)
Line- / contrast sensor
Sensor positioning device
Analog sensors CAN Bus connection
(not with FVGPro 2 MK)

X50 X51
X60 X100

External 24 VDC
X65

X101
X70 X71

Outputs 24 VDC Servo-center

power supply component

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A3

with analog sensors Date: 20.06.2011 Page: 1/1
 Components connectable A4
A4 Components connectable
External
BST Bus System
ekrPro Key60 Control keyboard
efe Plus

EFE1

Actuator without Electronic remote

position feedback fine adjustment
FVG 1K.../FVG 1MK...
Remote control

analog sensors

Line and
contrast sensor
Sensor positioning device with and Servo-center
without material width measurement Actuator with component
position feedback
FVG 2K.../FVG 2MK...
230 V

Line sensor Power module EMS 3/..., EMS4/...

Reflection sensor Hydraulic system

FVGPro module

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A4

with analog sensors Date: 20.06.2011 Page: 1/1
 Terminal assignment and service displays A5

A5 Terminal assignment
The below mentioned figure shows the position of the terminal
strips (X...), switches (S...) and service LEDs (H...) on the controller
processor board.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 1/11
 Terminal assignment and service displays A5

Overview terminal strips

Plug Terminal strip Function Remarks

(connecting (processor board)
plate)
X1
guiding mode
X50
Signal input analog sensor 1

X2
guiding mode
X51
Signal input analog sensor 2

X3 Signal input analog sensor 3 operating mode

servo-center component/ Namur
(position feedback EMS 17/18/
20B/ 21/22/23)

X4
Signal input analog sensor 4 operating mode
Signal input electronic remote
fine adjustment EFE 1

X6
Power supply 24 V DC input

X7
X60 Actuator

X8
X100
CAN
X101

X10
Enable and refrence switch
(FVG)

X12
X65 FVG stepper motor

X14 Digital inputs

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 2/11
 Terminal assignment and service displays A5

Plug Terminal stripe Function Remarks

(connecting (processor board)
plate)
X15
Digital outputs

X16
Analog output ± 10V and
tacho input

X17
Power supply
X70 for camera etc.
Output (24 V=)

X18
Power supply
X71 for camera etc.
Output (24 V=)

X19
Power supply for internal
Output (24 V=) auxiliary moduls

X20
PLC connection
PLC I/O (option)
options

X40
JTAG / OCDS

X41
RS232 interface Bootstrap

X42
RS232_TTL Field bus

X44
RS232_SPS PLC development

X45
Programme
Display / keyboard
update

X46
Micro-processor bus for auxiliary
8 bit parallel moduls

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 3/11
 Terminal assignment and service displays A5

A5/1 Terminal assignment

Terminal strip X1; Signal input Sensor 1

Terminal Function Remarks

X1

1 Internal connection
to terminal 8
2 IR pulse + 5 V/
Synchronisation for US sensor
3 IR pulse GND
4 + 12 V Output + 12 V
5 GND
6 - 12 V Output – 12 V
7 Analog input 4

Terminal strip X2; Signal input sensor 2

Terminal Function Remarks

X2

8 Internal connection
to terminal 1
9 IR pulse +5V/
Synchronisation for US sensor
10 IR pulse GND
11 +12V Output ±12V
12 GND
13 -12V Output -12V
14 Analog input 6

Terminal strip X3; Positron controller (SC) / servo-center component OMG 4 / Namur

Terminal Function Remarks

X3

44 +12V Output +12 V

45 GND
46 -12V Output -12 V
47 Analog input 3
48 Namur Out A link must be fitted across
49 Namur A terminals 47 and 48 if you are
using a Namur encoder
50 Namur B connected to terminals 49 and
50.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 4/11
 Terminal assignment and service displays A5

Terminal strip X4; Sensor 3 / EFE / OZ3

Terminal Function Remarks

X4

15 +5V / 1A
16 GND (+5V)
17 +12V Output +12 V
18 GND
19 -12V Output -12 V
20 Analog input 7 sensor 3
21 Analog input 1 EFE1 / OZ3

Terminal strip X6; Power supply

Terminal Function Remarks

X6

40 GND

41 +24 V

Terminal strip X7; Actuator

Terminal Function Remarks

X7
42 Actuator A
43 Actuator B

Terminal strip X8; CAN connections

Terminal Signal Remarks

X8
88 CAN_GND
89 CAN_L
90 CAN_SHLD
91 CAN_H

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 5/11
 Terminal assignment and service displays A5

Terminal strip X10; Release and reference switch FVG

Terminal Function Remarks

X10
51 GND GND for enable actuator
52 +24V +24V output for enable actuator
53 Enable actuator Enable actuator input. Link to terminal 52
if not used
54 --- ---
55 --- ---
56 --- ---
57 GND GND for reference switch 1
58 +24V +24V output for reference switch 1
59 Reference switch 1 (FVG) Reference switch 1 input (FVG)
outer stop switch
60 GND GND for reference switch 2
61 +24V +24V output for reference switch 1
62 Reference switch 2 (FVG) Reference switch 2 input (FVG)
inner stop switch

Terminal strip X12; FVG stepping motor

Plug Terminal Motor plug pin Function Remarks

X12 assignments
36 3 Winding 2A
37 4 Winding 2B Outputs are not short
38 1 Winding 1A circuit protected

39 6 Winding 1B
X65 Shield Shield The shield is not
attached. The end of
the line must be
correctly stripped back
and insulated by using
sleeves against short
circuits caused by the
screen.

Attention! The stepping motor output stages are not

protected against short circuits. Short circuits or
wrong wiring (reversed polarity) can destroy the
FVG!

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 6/11
 Terminal assignment and service displays A5

Terminal strip X14; Digital Inputs

Terminal Function Remarks

X14
72 GND
GND for inputs 0 ... 11
73 GND
74 Input 0
75 Input 1
76 Input 2
77 Input 3
78 Input 4
79 Input 5 See truth table

80 Input 6
81 Input 7
82 Input 8
83 Input 9
84 Input 10
85 Input 11
86 + 24 V Output + 24 V, max. 200 mA
87 + 24 V

Terminal strip X15; Digital outputs

Terminal Function Notes Remarks

X15
63 GND
64 OK Displayed via the H64 LED OK relay
65 Web width Displayed via the H65 LED The lower warning
too small and/or error limit
was undershot.
66 Web width Displayed via the H66 LED The upper warning
too big and/or error limit
was exceeded.
67 Oil blocking Displayed via the H67 LED Hydraulic blocking
(hydraulic) at low level

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 7/11
 Terminal assignment and service displays A5

Terminal strip X16; Analog output and tacho input

Terminal Signal Remarks

X16
68 GND GND for analog output
69 Output ±10V Analog output for external
motor output stage.
Not for direct connection of hydraulic
components SV1 …, HR 024,
HR 040, EH-St 9/3.
(see terminals 42-43)
70 Currently not used.
71 Currently not used.

Terminal strip X17, X18, X19; Power supply (output 24 V=)

Plug Terminals Function Remarks

X17,
X18,
X19
Pin 1 + 24 V
X70
Pin 2 not used
X71
Pin 3 GND

The ekrPro Com60 control unit is itself protected against

incorrect wiring (connection with reverse polarity).
If the supply voltage was inversely connected to the
control unit, this reverse polarity would also be
connected to the 24 V output socket.
This could lead to damage to components connected to
this socket.

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 8/11
 Terminal assignment and service displays A5

CAN connection assignments

The controller is connected to the CAN bus via a 5-pin M12 micro
style connector.

The maximum individual contact nominal current

is 4A.

Contact assignments in the plug connector:

View from the screw side

4 3 3 4
5 5
1 2 2 1

socket plug
(female) (male)

Pin Colour Signal Signification

1 CAN_SHLD Shield
2 Directly connected to pin 2
of the second CAN-plug
connector
3 CAN_GND
4 CAN_H Bus line (dominant high)
5 CAN_L Bus line (dominant low)

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 9/11
 Terminal assignment and service displays A5

A5/2 Service indicator displays

There are three groups of service LEDs on the processor board of
the controller. The meaning is as follows:

LED H20 – H22, H24: Power supply

LED H64 – H67: Digital outputs
LED H59, H62: FVG limit switches

LEDs Power supply

LED Name Status Significance

H20 +12V OFF Internal +12V not present

ON Internal +12V present

H21 -12V OFF Internal -12V not present

ON Internal -12V present

H22 +5V OFF Internal +5V not present

ON Internal +5V present

H24 +5PV OFF Internal +5V not present (lamp

voltage)
ON Internal +5V present (lamp
voltage)

LEDs Digital outputs

LED Name Status Significance

H64 OFF Digital output 0 OFF

ON Digital output 0 ON

H65 OFF Digital output 1 OFF

ON Digital output 1 ON

H66 OFF Digital output 2 OFF

ON Digital output 2 ON

H67 OFF Digital output 3 OFF

ON Digital output 3 ON

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 10/11
 Terminal assignment and service displays A5

LEDs FVG limit switches

LED Name Status Significance

H59 OFF Reference switch 1 (FVG)

Outer limit switch not activated
ON Reference switch 1 (FVG)
Outer limit switch activated

H62 OFF Reference switch 2 (FVG)

Inner limit switch not activated
ON Reference switch 2 (FVG)
Inner limit switch activated

ekrPro Com60 web guide controller EDV no.: MD.191.01.07/1.8.22 Chapter: A5

with analog sensors Date: 20.06.2011 Page: 11/11