Manual: Order Number Order Part Doc-ID Language 229983 WS ADS - 229983#1 - 00

Manual
Order number Order part Doc-ID Language
229983 WS ADS--229983#1--00 EN
Table of contents
Instructions: Worldwide Service Centers Safety instructions: ELGUIDER DRS, ELROLLER SRS, ELTURNER VW... Instructions: Waste disposal Instructions: EMC Info sheet Form: RMA (Return Merchandise Authorization) HIN--250139 SHS--251076 HIN--250468 HIN--234556 FOR--250764
A Systems - Operating instruction: Digital web guider WSS Guiding by edg... ANL--250945 B Operating instruction: Infra-red edge sensor FR 5001 / FR 5021 BEA--220874
D Operating instruction: Reel station WS with DC actuator AG 2571 / AG ... BEA--250206 H Operating instruction: Command station DO 2000 / DO 2001 / DO 8101... BEA--250732 H Operating instruction: Command station DO 2000 / DO 2001 Function "... BEA--250622 J Operating instruction: Control card RK 4004 BEA--250482 BEA--209283 MAS-FR_5001-057785 MAS-VA_6122-157256 MAS-AG_2671-157259 MAS-DC_03..-157872 MAS-DO_2001-157248 ERS--250372 BLO-DC_9142-002 SPM-DC_9142-001 SPM-DC_0340-005 SPM-AG_257.-001 SPM-DO_2000-001
V Operating instruction: CAN bus, serial bus Dimensioned drawing: Sensor Dimensioned drawing: Adjusting device Dimensioned drawing: Positioning drive Dimensioned drawing: Digital controller Dimensioned drawing: Operator panel X Spare parts list: Drive Unit AG 2671 Block diagram: Web guider 0-160W Circuit diagram: Web guider Circuit diagram: Web guider 0-160W Circuit diagram: Positioning drive Circuit diagram: Operator panel
Important: This documentation is part of the delivery package and must be read through carefully before beginning assembly, installation or operation of the equipment or maintenance work.
Important note
Worldwide Service Centers

When making queries about E+L devices, the Var.-Nr. / Com-Nr. must always be quoted. The Var.-Nr. / Com-Nr. is found in the following places: - on the cover of the operating manual - on the actuator typeplate - on the address stickers of the electrical components.
Typeplate Address sticker
en
Var.-Nr. / Com-Nr.
Europe, Africa, Middle East: All countries with the exception of England, France, Italy Erhardt+Leimer GmbH, Augsburg, D TCC - Technical Customer Care: Phone: +49/821/24 35-5 99 Fax.: +49/821/24 35-5 98 e-mail: service@erhardt-leimer.com England: Erhardt+Leimer Ltd., Bingley, GB Phone: +44/8707/55 97 73 Fax.: +44/8707/55 97 74 e-mail: service-uk@erhardt-leimer.com France: Erhardt+Leimer France SARL, Mulhouse, F Phone: +33/3/89 32 92 96 Fax.: +33/3/89 60 21 92 e-mail: service-fr@erhardt-leimer.com Italy: Erhardt+Leimer s.r.l., Bergamo, I Phone: +39/035/2 05 07 11 Fax.: +39/035/2 05 07 00 e-mail: service-it@erhardt-leimer.com
Service region 1
HIN--250139-EN-17
D-86136 Augsburg GERMANY Phone +49 (0)821 2435-0 Telefax +49 (0)821 2435-666 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
Erhardt+Leimer GmbH
Service region 2
North America: USA: Erhardt+Leimer Inc., Duncan, SC, USA Phone: +1/864/4 86-30 00 Fax.: +1/864/4 86-30 11 e-mail: service-us@erhardt-leimer.com Canada: Erhardt+Leimer Limited, Burlington, Ont., Canada Phone: +1/905/6 32-81 81 Fax.: +1/905/6 32-94 73 e-mail: service-can@erhardt-leimer.com Mexico: Erhardt+Leimer S. de R.L. de C.V. Mexico, D. F. Phone: +52/55/53 55 10 00 Fax.: +52/55/53 56 44 00 e-mail: service-mex@erhardt-leimer.com
Service region 3
South America: All countries Erhardt+Leimer Ind,e Com. Ltda, Guarulhos-So Paulo, Brazil Phone: +55/11/21 27-23 50 Fax.: +55/11/24 06-94 51 e-mail: service-br@erhardt-leimer.com
Service region 4
India, Sri Lanka, Bangladesh, Pakistan, Arabic countries: Erhardt+Leimer (India) Ltd., Ahmedabad, India Phone: +91/2717/39 84 00 Fax.: +91/2717/39 84 52 e-mail: service-in@erhardt-leimer.com
Service region 5
Taiwan, Indonesia, Malaysia, Philippines, Singapore, Thailand, Vietnam, Australia, New Zealand: Erhardt+Leimer GmbH Taiwan Branch, Taoyuan Hsien, Taiwan Phone: +886/3/3 81 54 52 Fax.: +886/3/3 81 37 40 e-mail: service-tw@erhardt-leimer.com China, Hongkong: Erhardt+Leimer (Hangzhou) Co., Ltd., Xiaoshan, Hangzhou, China Phone: +86/571/82 69 76 68 Fax.: +86/571/82 69 76 78 e-mail: sales@elchina.com.cn
Service region 6
Japan: Erhardt+Leimer Japan Limited, Ishikawa, Japan Phone: +81/761/51 41 61 Fax.: +81/761/51 41 62 e-mail: contact@el-japan.com
Safety instructions ELGUIDER DRS ELROLLER SRS ELTURNER VWS ELWINDER WSS
Web guiding system
EN
1. 2. 3. 4. 5.
Documentation Intended use User groups Explanation of symbols Safety instructions
2 2 3 3 4
SHS--251076-EN-02
Safety instructions
1. Documentation
Keep the documentation for the E+L system/device in a safe place and accessible for personnel at all times. The documentation is part of the scope of delivery and must be read carefully prior to starting assembly, operation or maintenance work. The documentation for an E+L system essentially comprises the higher level system description (A), the individual descriptions of the components (B, C, ... W), spare part lists (X) and the circuit diagrams (Z). Proceed in accordance with the instructions in the system description. All important processes are described in the system description. Where necessary, reference is made to the descriptions of the individual components. In the block diagram you will find a schematic illustration of your system. For digital components configured by E+L, the block diagram also contains the address settings.
2. Intended use
The web guiding system is only allowed to be used for the correction of the position of moving textile, film or paper webs. The web guiding system is only allowed to be installed in the customer's machine as defined by E+L. The web guiding system is not allowed to be modified. This action can result in additional hazards which the safety features may not be sufficient to guard against. The web guiding system is built to the state-of-the-art. Nevertheless, during operation Hazards to the user's health or Damage to property may occur. Only use the web guiding system when it is in correct working order, with due attention to safety and hazards while observing the locally applicable, statutory and customary safety regulations as well as the regulations for the prevention of accidents.
page 2
SHS--251076-EN-02
Safety instructions
3. User groups
All the activities in the documentation of the E+L system/device are only allowed to be undertaken by the user groups listed in the following with the stated qualifications.
Activities User groups Qualification Technicians, industrial mechanics, fitters etc. Electrical connection only by electricians Transport/assembly, commissioning, Specialist personnel troubleshooting/repair, maintenance, disassembly Installation, disassembly Operation Specialist personnel
Specialist personnel, unskilled personnel, Instruction by the operating organization trainees
4. Explanation of symbols
DANGER! Signifies that death or serious injury will occur immediately if the related safety measure is not taken. WARNING! Signifies that death or serious injury may occur if the related safety measure is not taken. CAUTION! Signifies that minor injury may occur if the related safety measure is not taken. NOTICE Signifies that a malfunction or damage may occur if the related measure is not taken. Jobs to be performed.
SHS--251076-EN-02
page 3
Safety instructions
5. Safety instructions
DANGER! Risk of entanglement! There is a risk of entanglement at rotating parts. Never touch or reach between moving parts. Never reach between rotating and fixed parts. DANGER! Cuts! Edges of moving webs can cause cuts. Never touch the edges of running webs. WARNING! Falling parts! Falling parts can cause injuries. Never stand under suspended loads. Only transport E+L control systems as described in the documentation. Only remove transport safety devices after assembly. WARNING! Risk of crushing! Moving parts may cause crushing. Never reach between moving and fixed parts. WARNING! Electric shock! Live parts can cause an electric shock. Never touch live parts. WARNING! Pulsed ultrasound! People sensitive to ultrasound may find the pulsed ultrasound disturbing. Wear hearing protection.
page 4
SHS--251076-EN-02
Safety instructions WARNING! Defective pneumatic lines! Defective pneumatic lines can cause injury. Regularly check pneumatic lines for damage. CAUTION! High intensity light! Camera flashes and light transmitters can temporarily affect your sight. Do not look straight into the beam. Wear safety glasses. CAUTION! Hot surface! In operation the light transmitter can become very hot. Wear protective gloves.
SHS--251076-EN-02
page 5
Erhardt + Leimer GmbH

Postfach 10 15 40 D-86136 Augsburg Phone +49 (0) 821 / 2435-0 Internet http://www.erhardt-leimer.com E-Mail info@erhardt-leimer.com
Wichtiger Hinweis
Entsorgung
Alle bei Reparatur, Wartung oder Verschrottung anfallenden Gefahrstoffe wie z.B. Altl, lschlamm oder Filter mssen vorschriftsmig nach den gesetzlichen Bestimmungen der jeweils zustndigen Landesbehrde entsorgt werden.
de
Waste disposal
Hazardous material such as used oil, sludge or lters occur whenever equipment is being repaired, serviced or scraped. This material must be disposed of in accordance with the ofcial local regulations.
en
Elimination de rsidus
Tous les matires dangereuses rsultants de rparation, dentretien ou de mise aux dchets, comme par exemple, lhuile use, la boue dhuile ou les ltres doivent tre limins de manire conforme aux rglementations de chacune des autorits nationale concerne.
fr
Smaltimento
Tutte le sostanze pericolose risultanti da lavori di riparazione, manutenzione o rottamazione, come p. es. olio residuo, morchia dellolio o ltri, devono essere smaltite secondo quanto prescritto dalle norme di legge emanate dallle autorit competenti del rispettivo Paese.
it
Eliminacin
Todas las sustancias peligrosas que se liberen durante los trabajos de reparacin, mantenimiento o destruccin y desecho, tales como aceite viejo, fangos de aceite o ltros debern ser eliminados de acuerdo con las disposiciones reglamentarias de las respectivas autoridades regionales competentes.
es
HIN--250468-DE/EN/FR/IT/ES-01
Postfach 10 15 40 D-86136 Augsburg Telefon (0821) 24 35-0 Telefax (0821) 24 35-6 66 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
EMC info sheet

Many requirements must be satised in order to assure electromagnetic compatibility. This info sheet is restricted to the principle rules that must be observed at all cost. Please contact E+L if you have any further queries on the electromagnetic compatibility of E+L systems. Grounding and chassis ground connections It is essential that grounding and chassis ground connections be performed exactly as specied in the wiring diagrams. Cables not provided by E+L must correspond to the E+L cables. It is essential that conductive connections permitting low and high frequency equipotential bonding between the individual machine parts and/or cable ducts be installed. Paint may also isolate and thus prevent connections being conductive. On screwed connections, set the toothed lock washer(s) so that a conductive connection is formed between the indented teeth and the unvarnished surface. All E+L components (command parts, controller, switch inserts, actuators and sensors) must be connected to the same chassis ground as the entire machine. Link the ground connections on the housing of E+L components to the machine frame via grounding leads (cross-section > 4 mm2).
Grounding lead Screwed connection with toothed lock washer(s) Toothed lock washer
EN
Cross section > 4 mm2
Command device DO .... in desktop housing
Machine chassis
DC .... controller
Establish a grounding contact for the actuators via the support surfaces and screw components. For the sensors, establish a good electrical connection to the machine ground via the sensor holder. If necessary, connect the sensors also to the machine ground via their own ground wires (cross section> 4 mm2). Cable paths It is essential that signal lines (sensitive to disturbance) be run separately to any potentially disruptive lines (e.g. mains or motor cables.
Metallic cable ducts
protected signal line
disruptive line
HIN--234556-EN-03
Protection with cable clamps

lacquer-free (conductive)
Establish an all-round protection contact to the relevant cable clamp. Any insulating foil featured may not be caught between the shield and cable sheath. The shield must provide a good conductive connection to the machine chassis via the cable clamp.
Cable clamp with a good grounding contact
Protection with cable screw ttings

Shield over plastic insert lacquer-free (conductive)
Variant 1 (see gure on left): Fit the shield over the cable screw tting plastic insert. Push the plastic insert into the guiding grooves of the cable screw tting. Tighten the cap of the cable screw tting. The shield must have a good conductive connection to the machine chassis via the metallic cable screw tting.
metallic cable screw tting with a good grounding contact
Variant 2:
Variant 3:
Variant 4:
Single-sheath cable
Double-sheath cable
Cable with window in the cable sheath
Screw the cables as shown in the respective gure. The shielding must have a good electrical connection to the machine ground via the metallic spring. In variant 4 it is important to note that the strands are always separated from the shielding by a sheath, mat or foil. Optionally, a self-adhesive copper strip can be wrapped around the shielding: Fold the shielding back over the cable (only in variants 2/3). Wrap a self-adhesive copper strip around the shielding.
Variant 2
Variant 4
RMA (Return Merchandise Authorization)
Postfach 10 15 40 86136 Augsburg DEUTSCHLAND Telefon +49 (821) 24 35-0 Telefax +49 (821) 24 35-324
Returns / Repairs
Dear E+L Customer, It is our intention to provide equipment that is reliable and exactly meets your requirements. If, despite our efforts, the equipment does not function correctly, we would ask you to proceed as described below to make sure your problem can be solved quickly. First check: Before returning a part or equipment, please check the operating instructions and make sure there is a defect or malfunction, not an operating error. For any further help, please call our hot line on +49-821-2435-599 or your usual contact at E+L. If the problem is still unresolved than please complete the Return Merchandise Authorization form, which accompanies the original documentation. Please note: To make sure your complaint can be treated promptly, please give a detailed description and indicate what kind of problem you have and when it occurs. Only forms lled in correctly can be dealt with! Transport/postage: Please return the equipment in the original package or equivalent to your responsible subsidiary or afliate. Please ret transport screws etc. where appropriate. As a matter of principle we cannot grant warranty where the equipment has been tampered with by a third-party, the ID numbers or type labels have been removed, mishandling or transport damage. Please return the goods free house; in the case of warranty we will send them back postage paid. Repairs: For repairs beyond the warranty period we will issue a non-binding cost estimate. If the equipment is not repaired then the charge for the estimate is 80,00 (plus freight and packing charges, if the defective equipment is returned to you). Returns: For returns beyond the warranty period we reserve the right to deduct handling costs from the credit note of a minimum of 15 % of the invoiced value of the goods. We cannot grant any credit for equipment that is not considered as new.
FOR--250764-EN-03
Werkanschrift: Leitershofen, Albert-Leimer-Platz 1, 86391 Stadtbergen
Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
RMA (Return Merchandise Authorization)

Customer No. Company Address Zip Code, City Contact name Telephone, fax, e-mail Number of original O.C./ Delivery note/ Invoice Number of exchange Order/ Delivery note/ Invoice Repair (repaired parts will be returned to customer) The following parts will be returned: Pos. Qty Mat. No. Designation 1. 2. 3. 4. 5. Reason for return wrong parts ordered (customer) wrong parts delivered (E+L) equipment on trial basis Return (parts stay with E+L Augsburg) If you have any questions, please contact Ms. Doris Helminger Tel. +49 (821) 24 35 - 649 Fax. +49 (821) 24 35 - 324 E-mail rma@erhardt-leimer.com
ID No. if available
equipment on loan basis warranty replacement spare parts for service
over delivery delivery was cancelled transport damage
equipment defective
If the reason for return is "equipment defective", please briey explain the defects of each item concerned. "Out of order" is not an adequate or helpful explanation.
FOR--250764-EN-03
Date
Completed by
Print
Thank you for lling out the form carefully and legibly and sending it with the equipment concerned.
Operating manual
Digital web guider WSS
Guiding by edge, line or color contrast with manual sensor positioning with position controller DC 03.. / DC 23.. and command device DO 200.
1. 2. 3. 4. 5. 6. 7. 8. 9. Function Assembly Installation Setup mode Commissioning with command station DO 200. Operation with command device DO 200. Optimization Maintenance Technical data 3 5 5 7 9 17 21 23 23
en
Component descriptions: Sensor Actuating element Command stations Digital interfaces (optional) Control card Electrical components (optional) CAN bus, serial bus Service manual (optional) Spare parts Parameter lists Diagrams
B D H I J U V W X Y Z
ANL--250945-EN-01
Operating instruction notes Explanation of symbols jobs to be performed important information and instructions sections of the manual due particular attention to assure the safe operation of the web guider. Operating manual structure The E+L web guider manual consists of a general system description (A), individual component descriptions (B, C, ... W), spare parts lists (X), parameter lists (Y) and diagrams (Z). Proceed according to the operating manual instructions. All important operating procedures are explained in the manual. Where necessary, reference is made to the individual component descriptions. The block diagram includes a schematic of your system. The block diagram also includes the address settings in the case of web guiders designed by E+L. See the parameter lists for explanations of the individual setup parameters. See "Setup editor" section 4 for procedure on checking/changing parameters. Type overview The operating manual applies for web guiders with the following actuating elements: - reel station WS
A page 2
Function
1. Function
1.1 Purpose The web guider positions the web in reference to the web edge, a printed line or contrast in color. It corrects deviations from the set position and prevents running off to the side. Oscillating the web around the sensor set position is possible.
1.2 Design
Unwind station
Wind station
Example: web guider WSS with reel station and sensor
Actuating element
Sensor Actuator
Actuating element
Sensor Actuator
The web guider consists of the following components: - a sensor for recording the actual position - an actuating element (reel station) with actuator and return to center switch - a digital controller DC 03.., DC 23.., DC 13.. . optionally - command station DO .. - command station NT .. - web offsetting command station RE .. - digital interface DI .. (e.g. CAN PLC, CAN ARCNET, CAN INTERBUS) 1.3 Operating principle To insert the web, center the actuating element and move the sensor manually to its outer position. Once the web is inserted, position the sensor manually at the web edge. If the web guider is set to automatic and the guider stop contact enabled, the web is guided. The sensor scans the position of the guiding criterion (edge, line or color contrast). If the guiding criterion deviates from its set position (sensor zero point) the sensor will transmit the size and direction of the deviation to the digital controller for evaluation. The position controller ensures that the guiding criterion is returned to its set position, via the actuating element.
KAP--250944-EN-01
A Page 3
Function 1.3.1 Oscillating function Use the oscillating function to offset the web to the left or right of the web set position. Use command station or setup parameters to set the oscillation time and stroke. Path-dependent oscillating is specied by the customer (reel station control). The web is still guided during oscillation.
A Page 4
Assembly / Installation
2. Assembly
2.1 Actuating element
Please observe the locally applicable and professional safety and accident prevention regulations! Mount actuating element according to attached description. See also dimensioned or set-up drawing. The sensors are pre-mounted on the actuating element (sensor support beam). In exceptional cases, see sensor and actuating element descriptions, application instructions section. The support beam is pre-mounted on the actuating element. In exceptional cases, see support beam description. The support beam must be mounted so that the sensors are located immediately after the actuating element, see also actuating element description, application instructions section. The digital controller is either mounted on the actuating element or designed for mounting in a control cabinet on-site. The connection between control board and D.C. positioning drive can run in one line up to a length of 3 m. However, if the distance is between 3 m and 10 m then the motor lead and the lead of the incremental encoder MUST run seprately.
2.2 Sensors
2.3 Support beam (optional)
2.4 Digital controller
2.5 Command stations (optional)
The command stations should be mounted in such a way that the operator actually sees the equipment he is controlling (e.g. the support beam).
3. Installation
Please observe the locally applicable and professional safety and accident prevention regultions ! Run electrical leads according to the attached wiring diagram.
3.1 Sensor
No installation work is requried for compact systems. See the sensor description for exceptions. No installation work is required for compact systems. See the description "Suppor beams" for exceptions.
3.2 Support beam (optional)
KAP--250504-EN-01
A page 5
Assembly / Installation
A page 6
Setup mode
4. Setup mode
4.1 Basic operation in setup mode
Setup settings should be performed by qualied personnel only. Basic operation in setup mode on how parameters are displayed and changed, is documented in the following diagram. In setup mode, the parameter values may be displayed and modiable parameter values also changed by each device featured in the CAN network.
Setup mode iis started via the "Acknowledge" key and, at the same time, the "Increase value" key. If a password is requested in the display, setup mode may only be started once the password has been entered .
+ +
Enter the password via the "Increase/Decrease value" keys. Press "F2" to select each individual place.
Press "Decrease value" to select the "Show Cannet" menu option.
To quit setup mode you must select the "Keyboard" menu option. Then press the "Acknowledge" key. Select the required device via the "Increase/Decrease value" keys .
The parameter value may be changed via the "Increase/ Decrease value" keys
Select the required parameter via the "Increase/ Decrease value" keys.
To change a parameter, the latter must be opened via the "Acknowledge" key .
Select the required option via the "Increase/Decrease value" keys.
A tick is set via the "Acknowledge" key . With round brackets () only one menu option may be selected, with square brackets [] several.
KAP--250211-EN-01
A page 7
Setup mode 4.2 Important additions The following two options are available to quit setup mode: 1. Jump back in the menu to the start window (as described in section 4.1 "Basic operation in setup mode"). 2. Setup mode is quit by pressing one of three "Automatic", " Center mode" or "Manual mode" keys, regardless of where one is.
Device address Device designation
CANMON may only be called up once, either via the CANMON program or command station DO 200. . A ashing device address means that two devices are featured in the CAN network with the same device address. If the device designation ashes, the device is not featured (is not identied via CANMON).
4.3 Allocate password
All settings in setup mode may be protected by a freely selected password. Settings in setup mode are only possible following password entry. To assure that no unauthorised persons may enter setup mode, we recommend that a password is dened as follows: Start setup mode. Select the "customer PIN" parameter in the device (*ZC 4070*) and enter a ve-place numerical password. The password may be freely selected between 1 and 32767. If parameter value "0" is entered, no password will be requested (status on delivery). Quit setup mode. Should unauthorised persons attempt to establish the password by entering numbers, after the third entry of an incorrect password, setup mode is inhibited and in addition, a commentary entered in the error memory. Switch off the power briey on command station DO 200. to re-enable it.
A page 8
Commissioning with command station DO 200.
5. Commissioning with command station DO 200.
There must not be anybody present in the web guider's danger area during commissioning or operation. Please observe the locally applicable and customary safety and accident prevention regulations. Check the individual connecting cables are correct. Connect all the web guider's equipment to the operating voltage. Check CAN bus connections. The light emitting diodes for the CAN bus connections on the web guider and the command stations illuminate green, i.e. ready. If a light emitting diode illuminates red, there is a malfunction on this CAN connection. Check device and CAN cabling. Position sensor, check and set if necessary (e.g. adjustment etc.), see sensor description. A prerequisite for continued commissioning is complete mechanical assembly, as well as the correct CAN addressing of the individual components.
5.1 Setting direction of web travel on the command station

Direction of web travel on the overall machine
The direction of web travel arrow in the display on the command station must match the direction of web travel in the overall machine. This setting denes the allocation of the keys. If the arrow points in the opposite direction, the value in the parameter "arrow direction" in the command station must be inverted as follows:
HELP
F1
F 2
F 3
F 4
+
System-Menu Keyboard Canmon Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply
Start Setup mode. Press "Acknowledge" key and also "Increase value". Position selection bar on "Rescan Cannet". Press "Acknowledge" key.
KAP--250943-DE-01
A Page 9

CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4...) (Center Switch) 0.8(AK 4022) 0.A(*ZC4071*) 0.B(LK4203) 0.A (*ZC4071*) ZC 4071 keyboard settings width user parameter special keys
Position the selection bar on the command station "*ZC 4071*". Press "Acknowledge" key.
Position the selection bar on the parameter heading "keyboard settings". Press "Acknowledge" key.
0.A (*ZC4071*) ZC 4071 keyboard settings keyboard usage arrow direction used sensor values used add. values width 0.A(*ZC4071*) arrow direction ( * ) Normal ( ) Inverted
Position the selection bar on the parameter "arrow direction". Press "Acknowledge" key.
Invert parameter value. The actual state of the parameter is marked by a " * " in the parameter. Position the selection bar on the value that is not in use. Press "Acknowledge" key. The " * " changes to the parameter value selected. The direction of web travel has been changed on the command station. Leave Setup mode. Press "Center mode" key.
A Page 10
Commissioning with command station DO 200. 5.2 Actuator initialization run During the initialization run the guider detects the two mechanical end points (actuator stop) and the actuator limit switches. These positions are saved in the guider. In addition the actuator's start position is saved as the center position. The actuator should therefore be in the required center position before the initialization run. Start Setup mode. Press "Acknowledge" key and also "Increase value". Position the selection bar on "Rescan Cannet". Press "Acknowledge" key.
+
CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4...) (Center Switch) 0.8(AK 4022) 0.A(*ZC4071*) 0.B(LK4203) 0.5 (RK 4...) Set Address Set Default Error List Possible Errors Properties Service Functions Reset 0.5 (RK 4...) camera cal. standard camera cal. pattern actuator calibr. 1 support calibration save back parameter save parameter device reset
Position the selection bar on the master device, address X.5. If two or more guiders are connected together on a network, at this point the required guider must be selected. Press "HELP" key.
Position the selection bar on "Service Functions". Press "Acknowledge" key.
Position the selection bar on "actuator calibr. 1". Press "Acknowledge" key.
The actuator's initialization run is performed. Leave Setup mode. Press "Center mode" key. If two or more digital guiders are connected together on a network, this chapter must be undertaken for each guider installed.
A Page 11
Commissioning with command station DO 200. 5.3 Checking effective direction for manual mode
In the "manual" operating mode the actuator must move in the same direction as the symbol on the key that is pressed. If the actuator moves in the opposite direction, the direction of rotation of the motor must be inverted:
HELP
F1 F2 F3 F4
ESC
+
Start Setup mode. Press "Acknowledge" key and also "Increase value". Position the selection bar on "Rescan Cannet". Press "Acknowledge" key.
CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4...) (Center Switch) 0.8(AK 4022) 0.A(*ZC4071*) 0.B(LK4203) 0.5 (RK 4...) RK 4004 webedge offsets webedge controller servo congurate Pos. controller
Position the selection bar on the master device, address X.5. If two or more guiders are connected together on a network, at this point the required guider must be selected. Press "Acknowledge" key.
Position the selection bar on the parameter heading "servo congurate". Press "Acknowledge" key.
0.5 (RK 4...) reserved 21 defect range servo conguration motion direction motion range total positionrange + positionrange -
Position the selection bar on parameter "motion direction". Press "Acknowledge" key.
A Page 12

0.5 (RK 4...) motion direction nb : min : def. : max :
24 0.0 0.0 1.0
Invert parameter value. Change "0" to "1", or Change "1" to "0"
0
The effective direction has been changed. Leave Setup mode. Press "Center mode" key. If the effective direction for the manual mode has been inverted, chapter 5.2 must be performed again. If two or more digital guiders are connected together on a network, this chapter must be undertaken for each guider installed.
A Page 13
Commissioning with command station DO 200. 5.4 Effec. dir. for automatic mode on an unwinder For an unwinder it is not necessary to make any settings for the automatic mode. In the automatic operating mode, the reel moves in the direction of the sensor when the sensor is clear. If the sensor's eld of view is covered, the actuator movement is reversed. On an unwinder, the parameter value for "P13 prop range " on the control card must have a positive sign (no sign).
5.5
Effec. dir. for automatic mode on a winder
On a winder the sensor is mechanically linked to the reel. The sensor is therefore positioned with the reel. In the automatic operating mode, the reel moves in the direction of the web if the sensor is clear. If the sensor's eld of view is covered, the actuator movement is reversed.
On a winder, the parameter value for "P13 prop range " on the control card must have a negative sign (no sign). Check the setting:
+
Start Setup mode. Press "Acknowledge" key and also "Increase value". Position the selection bar on "Rescan Cannet". Press "Acknowledge" key.
A Page 14

CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4...) (Center Switch) 0.8(AK 4022) 0.A(*ZC4071*) 0.B(LK4203) 0.5 (RK 4...) RK 4004 webedge offsets webedge controller servo congurate Pos. controller
Position the selection bar on the master device, address X.5. If two or more guiders are connected together on a network, at this point the required guider must be selected. Press "Acknowledge" key.
Position the selection bar on the parameter heading "webedge controller". Press "Acknowledge" key.
0.5 (RK 4...) webedge controller prop range dual-rate width dual-rate level velocity auto velocity pos velocity jog 0.5 (RK 4...) prop range nb : min : def. : max :
Position the selection bar on the parameter "prop range ". Press "Acknowledge" key. The parameter value is displayed.
Note parameter value displayed. e.g. 10.0 mm

13 -2000.0 10.0 2000.0
10.0 mm
0.5 (RK 4...) prop range nb : min : def. : max : -10.0 mm
Press "Decrease value" key until the original value with a negative sign is displayed.
13 -2000.0 10.0 2000.0
The effective direction for the winder has been changed.
If two or more digital guiders are connected together on a network, this chapter must be undertaken for each guider installed. Leave Setup mode. Press "Center mode" key.
A Page 15
Commissioning with command station DO 200. The web guider is now ready. In the majority of cases a good result will be obtained with this setting. Should this not be the case, various settings can be optimized, see chapter "Optimization". Commissioning is then complete for standard applications.
5.6 Special settings
If necessary, the settings for the following functions can be referred to in the description for the control card RK 4004: Step size for web offset using keys Oscillation Proportional range (control loop gain) Actuating speed, automatic mode Actuating speed, manual mode Actuating speed reduction on a web fault Sensor emergency guiding Adaptive gain End position pre-warning Programmable digital inputs Run-up ramp in manual mode Dynamic motor current increase
A Page 16
Operation with command device DO 200.
6. Operation with command device DO 200.
Only insert web when the web guider and processing machine are switched off. Risk of injury! If two or more digital guiders are networked, before operation each individual control loop for which the following operation sequence is to be applicable must be selected via the "multi-operation" function. Enable web guider operating voltage
6.1 Multi-operation (if featured)

HELP
F1
Select multi-operation menu Press "F 4" to start the multi-operation menu. All groups featured will be displayed.
F2
F3
F4
Select group Via the "Decrease value" key each group may now be selected by the selection bar. A tick displayed in front of a group indicates that the latter has been selected for subsequent operation. To set a tick, press "F 4" and press again to remove ticks. Select the individual groups one after another via the "Decrease value" key and make your selection. Quit multi-operation menu Press "Acknowledge" to quit the multi-operation menu.
User group
The group selected by the selection bar prior to quitting the menu is now selected as user group. The rst number indicated in the "Group" display represents the user group. The remaining numbers indicate the groups selected.
6.2 Actuating element operation

HELP
F1
F2
F3
Select center mode The web control is switched off, the web guider positions itself at the set center position. Before inserting a new web always set the actuating element to "center" mode rst.
F4
KAP--250276-EN-01
A page 17

HELP
F1
Set web offset to "0" Press the "Increase/Decrease value" keys at the same time.
F2
F3
F4
HELP
F1
F2
When using a coloured line sensor, use "F 1" to switch between light line, dark line and colour contrast. By pressing "F 1" the actuating element is always switched to "manual". How a guiding criterion is taught (light line, dark line, colour contrast), is documented in the sensor description of the coloured line sensor. Set the sensor manually to its outer position (away from the web) Insert web Positioning the sensor manually If the web/line is located at its set position, set the edge sensor at the web/line so that only the two LEDs in the center, LEDs 1 and 7, light up. If the web/line is not located at its set position or no web/line is available, set the edge sensor so that the center of the scanning range is located at the web/line set position. Select required actuating element operating mode Automatic, center position or manual mode.
F3
F4
HELP
F1
F2
- Manual mode: the actuating element may be positioned at the required location via the "Increase/Decrease value" keys.
F3
F4
HELP
F1
F2
- Automatic mode: if the guider block is not connected, the web guider will go into automatic mode immediately.
F3
F4
HELP
F1
F2
F3
F4
Set web offset Use the "Increase/Decrease value" keys in automatic mode to set a web offset.
A page 18
Operation with command device DO 200. 7.3 Oscillation

HELP
F1
F2
F3
F4
Select oscillation menu Press "F 3" to start the oscillation menu for entering the oscillation stroke and time.
Switch oscillation ON/OFF Press "Increase/Decrease value" to switch oscillation ON/OFF, the switch status is indicated on the display. Enter amplitude To enter the amplitude (oscillation stroke) the acknowledge key must be pressed. Press the "Increase/Decrease value" keys to enter the required amplitude (oscillation stroke). Enter time Press the acknowledge key again to enter the time (oscillation time for a cycle) via the "Increase/Decrease value" keys. Quit the oscillation menu Press "Acknowledge" again to quit the oscillation menu.
HELP
F1
F2
F3
F4
A page 19
A page 20
Optimization
7. Optimization
7.1 Optimization premises
Amplication too high
Amplication right Amplication too low
Amplication is correctly set if, after brief overshooting the error is corrected. If the position controller is set with too great a degree of sensitivity, the guider will overshoot as well. In the case of too little amplication the control loop will be too slow. Optimum amplication may be determined with a characteristic curve tracer. In practice, amplication may also be determined by trial and error: While the web is controlled in the automatic mode it is necessary to shortly cover up the sensor measuring range (with a piece of cardboard for ex.). A change of the web position will change the web path. The level-out behavior of the web guider provides further data on the amplication. The smaller the set proportional range at a constant maximum positioning velocity (Parameter ".1.6. velocity auto") is, the greater the amplication of the web guider will be. A negative proportional range causes negative amplication, the effective direction is thus inverted in automatic mode.
Velocity correction established correction positioning velocity depending on proportional range
Proportional range .1.3. prop range 2,0 3,5
15 mm/s 8 mm/s
control deviation Positioning velocity .1.6. velocity auto 20 mm/s
Set position (sensor measuring range center )
Control deviation of 1.5 mm
By reducing the proportional range the characteristic curve (see g.) will become steeper. The steeper the characteristic curve the greater the positioning velocity will be in the case of a control deviation and the system thus more sensitive. The positioning velocity of the actuator may be determined on the basis of the characteristic curve regardless of the control deviation.
KAP--250547-EN-01 A page 21
Optimization In this example a proportional range of 2 mm or 3.5 mm has been assumed at a maximum motion speed of 20 mm/s. If the control deviation is 1,5 mm the following positioning velocity will result: 15 mm/s for a proportional range of 2 mm 8,6 mm/s for a proportional range of 3,5 mm The values may also be calculated arithmetically: Amplication (G) = parameter .1.6. / Parameter .1.3. Correction velocity (VK) = control deviation * amplication (G) Example 1: G = 20/2 = 10 1/s VK = 1,5 mm * 10 1/s VK = 15 mm/s Example 2: G = 20/3,5 = 5,71 1/s VK = 1,5 mm * 5,71 1/s VK = 8,6 mm/s
Reduce the proportional range by small steps only. Following each change of the parameter value a web deviation should be produced manually in automatic mode so that oscillation may be detected immediately. Reduce the proportional range until the guider starts to oscillate. The increase the proportional range again until no more oscillation may be observed. 7.2 Optimizing the proportional range Select operational mode "Automatic" . Select parameter ".1.3. prop range " . Modify parameter value as required. Smaller value = web guider more responsive Bigger value = web guider less responsive Each time the parameter value is changed the web should be deviated so that oscillation is detected immediately. Leave the setup mode after setting the proportional range. If two or several digital controllers are networked it is necessary to select the equipment address of the relevant web guider before selecting the parameter, see chapter "Setup-Editor".
A page 22
Maintenance / Technical data
8. Maintenance
8.1 Sensor 8.2 Support beam (optional) 8.3 Actuating element 8.4 Converter (optional)
Maintenance may only be performed when the web guider and processing machine are switched off . See sensor description. See support beam description. See actuating element description. See converter description.
9. Technical data
The technical data depend on the devices implemented and are specied in the relevant descriptions. Technical data subject to modication without notice.
KAP--224104-EN-01
A page 23
Postfach 10 15 40 D-86136 Augsburg Phone (0821) 24 35-0 Telefax (0821) 24 35-6 66 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
Description B
Infra-red edge sensor FR 5001 / FR 5021

Software: 1. 2. 3. 4. 5. 6. 7. 8. 9. ZC 3202-0001F_ZB ZC 3202-8001F_ZD 2 2 3 5 6 7 8 11 12
en
General instructions Function Assembly Installation Commissioning Operation Parameters Maintenance Technical data
BEA--220874-EN-10
Infra-red edge sensor FR 5001/FR 5021
1. General instructions
1.1 Explanation of symbols jobs to be performed important information and instructions 1.2 Operating manual Please keep the above in a safe place and make accessible to personnel at all times. The manual is part of the package supplied and should be read carefully prior to assembly, operation and maintenance. All jobs listed in this description should be performed by qualified or suitably instructed personnel only. 1.3 Safety instructions Never touch the edges of running webs.
2. Function
2.1 Intended usage
The E+L infra-red edge sensor FR 5001/FR 5021 scans the edges of opaque materials (threads/stripes/mesh) such as paper, carpets or tightly knit textiles without touching. The Infra-red edge sensor should only be used - in perfect technical condition, - for use as intended, - in accordance with the operating instructions.
2.2 Design
Lens
LED strip display Socket
Membrane keyboard
Operational LED
Securing drill holes
B page 2
BEA--220874-EN-10
Infra-red edge sensor FR 5001/FR 5021 2.3 Operating principle The edge sensor operates on a light-sensitive barrier principle and uses an infra-red LED as light source. This infra-red LED projects light onto the micro-prism reflector located behind the web via a mirror. The reflector reflects back the light according to a retroreflecting principle, depending on how far the web covers the measuring range. The reflected light is reflected onto the CCD array via the telecentric optical unit. The CCD elements can cope with a higher signal level when thus illuminated. The signal is converted in the microprocessor into an output value proportional to the position of the web edge and conveyed to the CAN bus. This output value can be used to e.g. trigger a digital web controller. At the same time, the current web position in the measuring range is indicated on the LED strip display. If the LED beside the strip of LEDs lights up green, the edge sensor is signalling that it is operational. Edge sensor measuring range The edge sensor measuring range is 10 mm and has a resolution of 512. The edge sensor outputs the web edge position value for this range.
Edge sensor measuring range
Measuring range 10 mm
3. Assembly
3.1 Edge sensor with reflector bracket
Mount the edge sensor on the first third of the web guider exit path (see actuator description). The web must run at a 90 angle to the edge sensor (see fig. below).
Web Edge sensor
Edge sensor
Reflector bracket
The web height during travel may change to any degree with edge sensor FR 5001 but must not however touch the edge sensor or reflector. With edge sensor FR 5021 the web should be 140 -160 mm (as measured from the lens) away from it. At a distance of 0 - 140 mm, reliable web edge (narrow thread) detection is limited.
BEA--220874-EN-10
B page 3
Infra-red edge sensor FR 5001/FR 5021 3.2 Separate edge sensor and reflector Mount the edge sensor and reflector on the first third of the web guider exit path (see actuator description). Mount the edge sensor so that the web runs at a 90 angle to the edge sensor. Mount the reflector parallel to the edge sensor. To avoid any self reflection caused by the web, the edge sensor must be tilted towards the reflector by 10 to 15. The web must run parallel to the reflector .
Reflector
Edge sensor parallel to the reflector
Reflector
3.2.1 FR 5001 mounting clearances
Flat, homogenous web edge The distance between the edge sensor lens and the reflector may be 20 to 500 mm. The height at which the web travels between the edge sensor and reflector may vary to any extent but must not touch the edge sensor or reflector.
3.2.2 FR 5021 mounting clearances
Thread(stripe) or mesh-type web edge The distance between the edge sensor lens and the reflector must be 240 to 320 mm. The reflector must not be mounted in the 0 - 240 mm area. This dimensional restriction does not apply to permanently mounted E+L reflector brackets (section 3.1). The optimum web position is a clearance of 180 mm. The web height during travel may change to any degree in the shaded grey area (140 - 240 mm). The web should not be located outwith this range as otherwise reliable web edge (narrow thread) detection is limited.
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BEA--220874-EN-10
Infra-red edge sensor FR 5001/FR 5021 3.3 Clearing device (optional) The optional clearing device must be connected to the customers compressed air supply using a service unit with a submicron filter. The service unit must meet the following conditions: - Oil-free - Operating pressure 2 bar - Pore size < 5m
Clearing device
If the clearing device is mounted at the customer, the nozzle openings must be aligned with the sensor and reflector.
Nozzle openings
4. Installation
Protect signal leads and run apart from heavy current-carrying leads. Pull off the union nut on the sensor cable. These ensure that the edge sensor housing and the signal lead insulation are conductively connected. Secure the signal lead with a cable clamp. If the web is subject to a high degree of static charging we recommend you link the edge sensor housing to the machine frame.
BEA--220874-EN-10
B page 5
5. Commissioning
On compact units, no adjustment to the edge sensor is needed on first-time commissioning. If you have ordered these control components separately and wish to construct your own operable control loop or if edge sensors are supplied but not pre-mounted you must perform the steps described in section 5.1 and 5.2.
5.1 Setting group and device numbers
Edge sensor on right in web direction of travel, unit number 1 Edge sensor on left in web direction of travel, unit number 2 Direction of web travel = Processing direction for the entire system The group number depends on the digital controller (identical to the group number of the web guider to which it belongs, see block diagram). Set the controller to "center position" mode. Press the "GRP" and "DEV" buttons on the edge sensor at the same time. After about 6 seconds the group and unit numbers on the LED display will start to flash. After approx. a further 20 seconds the edge sensor switches into setup mode. The LEDs stop flashing and stay on permanently and the group number (GRP button) and unit number (DEV) can be changed. If the GRP and DEV keys are not pressed for longer than approx. 20 seconds. the group and device numbers are stored and setup mode quit again.
Edge sensor on left of web direction of travel Unit number 2 Group number 0
Processing direction for the entire system
Group number 0 Unit number 1 Edge sensor on right of web direction of travel Example: setting the group and unit numbers
B page 6
BEA--220874-EN-10
Infra-red edge sensor FR 5001/FR 5021 5.2 Calibrating the edge sensor Please observe the following when calibrating the edge sensor: - - - the sensor must be mounted mechanically correctly, clean the lens and reflector with a soft dry cloth, no web or reflector joints should be located in the sensor visual range .
Enter the edge sensor group and device numbers on the command station. Select parameter 3 and enter value 10. Select parameter 4. The edge sensor calibrating process is initiated by changing parameters. During calibration, the yellow strip LEDs 0-7 and 1-8 will flash in alternation and the "Operational" LED will light up red. When calibration is finished the "Operational" LED will light up green and the yellow strip LEDs 0-7 will go on. If the "Operational" LED lights up red there must have been a error during calibration, repeat calibration and check the error message in parameter ..9. .
6. Operation
LEDs 7 and 1 are on
Positioning the edge sensor With the help of the row of LEDs on the receiver, the edge sensor can be manually positioned at the web edge. Set the web offset on the digital controller to 0. Position the edge sensor manually: If the web is in its set position, locate the edge sensor on the web so that only the LEDs in the middle, 1 and 7, only light up. If the web is not in its set position or no web is available, locate the edge sensor so that middle of the scanning range is on the web edge set position.
Web edge set position
BEA--220874-EN-10
B page 7
7. Parameters
7.1 Parameter list
In setup mode setup parameters can be displayed and to a certain extent, changed. To enter setup mode from the edge sensor, you will need a command device DO .... or RT .... The parameter numbers are listed in the No. field of the table, in the Name field the abbreviation. The Default field indicates the standard settings, Min. and Max. are the permissible limit values respectively. The unit is indicated in the Unit field. The Description explains the parameter function. If a dot () comes after the parameter number this indicates that it is a display parameter, the value of which cannot be changed. The parameter list applies for the CAN data protocols PR 1 and PR 2. The fields indicate whether each parameter is used in the related CAN data protocols. You can see which CAN data protocol is used from the number in parameter "..4. FR 5001".
No. ..0. ..1. ..2.
Name edit device edit group reset settings
Default X.X X.X 0
Min X.1 0.X 0
Max X.F 7.X 2
Unit hex hex -
PR PR Description 1 2 X X X X X X Device number (see block diagram) Group number (see block diagram) Works setting 0 = no function 1 = E+L basic settings 2 = internal value specification (default) Starting a function 0 = no function 1 = reset 2 = save parameters 10 = perform sensor calibration Software version Software version Edge sensor mounting "0" = standard
..3.
start service
199
..4. ..4. ..5.
FR 5001 FR 5001 mounting norm/rev
1.1 4.3 0
1.0 4.0 0
1.1 4.3 1
X X
X X
"1" = scanning direction turned (edge sensor turned by 180) ..6. ..7. ..8. resolution abs. range +/position 1024 10.00 0 1024 10.00 -10.00 1024 10.00 10.00 mm mm X X X X X X Available sensor measuring range in pixels Available sensor measuring range in mm Actual edge position in mm
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BEA--220874-EN-10

No. ..9. Name error code Default 0 Min 0 Max 299 Unit PR PR Description 1 2 X X Error messages "..0" = no error "..1" = lens or reflector damaged or soiled "..2" = edge sensor under-exposed (lens or reflector soiled) "..3" = edge sensor over-exposed (direct sunlight on lens) "..4" = CCD chip error "..5" = operating temperature exceeded or not attained (temperature < 0 C or > 60 C) Calibration errors: ".4." = dark threshold too high (send in sensor) ".5." = white threshold too low (repeat calibration) ".6." = error during saving (send in sensor) 1.. = sensor not calibrated Display brightness 0 = minimum brightness 15 = maximum brightness Display mode 0 = normal display (web edge is displayed as deviation from the sensor center) 1 = web edge is displayed as illuminated band Edge sensor interior temperature in C Transmitter brightness 0 = maximum brightness 255 = minimum brightness Infra-red diode 0 = ON 1 = OFF Reverse sensor signal 0 = normal 1 = reversed Maximum brightness value Infra-red edge sensor FR 5001/FR 5021 0 = Flat, homogenous web edge 1 = Thread(stripe) or mesh-type web edge Sensitivity of thread detection 10 = sensitive 100 = insensitive Note! High sensitivity level also means a high level of sensitivity to soiling. Dirt deposits are detected as a web edge. Web guider blocking 0 = blocking OFF 1 = blocking ON. The web guider is blocked if there is no web edge in the scanning range. (invalid state signal is emitted by the CAN) Distance between sensor and reference point Entry for the support address The position of the support is added to the sensor signal and the value sent over the CAN bus. Entry for the support address The position of the support is inverted and added to the sensor signal, and the value sent over the CAN bus.
.1.0.
display brightness display mode
15
.1.1.
.1.2. .1.3.
temperature transm. brightness IR LED on/off
0 0
-60 0
150 255
X X
X X
.1.4.
.1.5.
position norm/rev maximum pixel thread detection diff. - limit
.1.6. .1.7.
0 0
0 0
255 1
X X
X X
.1.8.
30
10
100
.1.9.
invalid state flag
.2.0. .2.1.
mount position use supportadr
0 0.0
-3276.8 0.0
3276.7 F.F
mm hex
X X
.2.2.
invert support pos
BEA--220874-EN-10
B page 9

No. .2.3. Name disable expos ctrl Default 0 Min 0 Max 1 Unit PR PR Description 1 2 X X Deactivate the exposure controller If this value is set there is no automatic exposure control. This parameter will not be saved and must be set if required.
7.2 Error messages
. .9.
Error code (parameter 9) Any edge sensor errors that may occur are displayed in parameter 9. The main error messages are listed below. Error message: ..1 "Lens/reflector soiled" An alien object (e.g. grain of sand, thread, plastic splinter etc.) located in the edge sensor scanning range in addition to the web edge is represented as a dark spot on the scan. If the degree of brightness is less than 2/3 of the total brightness (<67 brightness value) and brightness contrast exceeds a width of more than 3 pixels, a "..1" error shall be emitted. What to do: clean the edge sensor lens and reflector. Error message ..1 has no function for edge sensor FR 5021.
Brightness values
Pixel Alien object
Error message 1
Brightness values
Pixel
Error message: ..2 "Edge sensor under-exposed" The transmitter brightness is regulated so that the receiver elements that are not covered by the web reach an approx. brightness value of 100. If a brightness value of 100 (parameter 16) given maximum transmitter brightness (parameter 13 = 0) is not achieved, error "..2" is output. Every second LED on the illuminated LED band flashes. What to do: clean the edge sensor lens and reflector. Error message: ..3 "Edge sensor over-exposed" If a brightness value of 100 (parameter 16) is exceeded given minimum transmitter brightness (parameter 13 = 255), error "..3" is output. Every second LED on the illuminated LED band flashes. What to do: shield the edge sensor from external light (e.g. sunlight, artificial lights).
Error message 2 and 3
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BEA--220874-EN-10

Output range for error messages Brightness values Pixel
The following applies to all error messages: For error messages to be output, error 5 s must be available and the web edge positioned within a range of 0 % to 80 % of the sensor measuring area.
Output range for error messages
8. Maintenance
Maintenance work should only be performed when the processing machine is switched off. Depending on the ambient conditions, clean the lens and reflector regularly with a dry or damp cloth. Damaged reflectors must be replaced.
BEA--220874-EN-10
B page 11

Postfach 10 15 40 D-86136 Augsburg Telephone (0821) 24 35-0 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
9. Technical data
Operating voltage Nominal value 24 VDC Nominal range 20 - 30 V DC (incl. residual ripple) Current input approx. 80 mA Scanning frequency 200 Hz Measuring range 10 mm Measuring range resolution 0,02 mm (64 pixels x 16 subpixels) Fabric and stripe thickness FR 5001 - FR 5021 min. 0,2 mm Ambient temperature +10 C to +50 C Storage temperature -20 C to +80 C Cable length max. 8 m Reflector to edge sensor distance FR 5001 20 - 140 mm / 240 - 500 mm FR 5021 240 - 320 mm Protection class max. IP 65 with suitable connector inserted Weight ca. 300 g Dimensions see attached dimensioned drawing Operating pressure clearing device 2 bar Pore size <5 m Technical data subject to modification without notice
Description D
Reel station WS
with DC actuator AG 2571 / AG 2671 / AG 4571 / AG 4671
en
1. 2. 3. 4. 5. 6.
General instructions Function Assembly Installation Maintenance Technical data
2 2 3 5 5 6
BEA--250206-EN-03
Reel station WS
1. General instructions
1.1 Description 1.2 Explanation of symbols
Keep the above in a safe place, accessible to personnel at all times. jobs to be performed important information and instructions sections of the text particularly worthy of note to guarantee the safe operation of the reel station.
2.1 Purpose
2. Function
The E+L reel station WS may only be used for web guiding on winds and unwinds. By axially offsetting the reel station, the reel is positioned correctly for feeding (unwinding) or taking off (winding) the web at the right place for the process. The only purpose of the reel station is to move the batch horizontally. The actuator should not be used for hoisting the batch. The DC actuator consists of the following components: - DC gear motor - reference switch - two mounting brackets - incremental encoder - articulated joint - and a threaded ball screw
Threaded ball screw DC actuator Articulated joint
2.2 Design
Reference switch Incremental encoder Mounting bracket
D page 2
BEA--250206-EN-03
Reel station WS 2.3 Operating principle On winding processes, the reel station is subsequently positioned according to the changing the web position. The sensor must be mechanically secured to the reel station for this purpose. On unwinding processes, the reel station and thus the web are adjusted to the set position. The sensor is mechanically secured at the machine infeed for this purpose. During normal operation, the end positions of the DC actuator are electronically limited by the incremental encoder (position transmitter), the DC actuator is switched off before the end positions are reached. In the event of a malfunction the DC actuator is automatically switched off via the current controller when it reaches the mechanical end position. The incremental encoder has a resolution of 32 pulses per revolution. The various AG .... types differ in size and technical data only. The reference switch is needed as a reference point for the digital controller and is used to re-calibrate the incremental encoder on the DC actuator.
3. Assembly
3.1 Layout conguration Unwinding Figure 1
Please observe the locally applicable and professional safety and accident prevention regulations during assembly!
Winding Figure 2 Figure 3 Figure 4
LR
Direction of production from left to right
RL
Direction of production from right to left
RL
Direction of production from right to left
LR
Direction of production from left to right
BEA--250206-EN-03
D page 3
Reel station WS The mounting reference number, which is mentioned in the order conrmation, is set-up as follows: 1 - B - - LR Direction of production (LR/RL) Drive on side (/) Sensor on side (A/B) Figure No. (1/2/3/4)
If two sensors are used, the reference number shows A/B. 3.2 Application instructions
1 2 3 4 Guide path DC actuator Guide roller Platform 5 6 7 Sensor Machine guide roller Reel
6 5
5 3
2 Unwind station
Wind station
3.3 Guide path (1)
The guide path is that from the guide roller (3) to the machine guide roller (6). The length of the guide path should be between 0.25 and 0.5 x web width. The stiffer the web, the longer the guide path should be.
3.4 Sensor (5)
Unwinds: on unwinds, the sensor or sensors must be secured to the machine. To achieve a stable control loop, the scanning point should be as close as possible to the reel station guide roller. Winds: on winds, the sensor or sensors must be secured to the reel station. To achieve a stable control loop, the scanning point should be as close as possible to the machine guide roller. Depending on the sensor used, further aspects must be taken into account during assembly. See sensor description.
3.5 DC actuator (2)
Assemble the DC actuator according to the dimensioned or setup drawing.
D page 4
BEA--250206-EN-03
Reel station WS
Axis 1
The maximum traverse of the actuator must be reached without the batch being set in motion mechanically. The DC actuator can be moved along axis 1 only. There is no movement possible along axis 2. The DC actuator must therefore be in perfect parallel alignment with respect to the servo component. The actuator should be mounted as follows: when the servo component (batch) is in its center position the DC actuator should also be in its center position (center of the traverse).
Axis 2
Parallel
Linear guide
3.6 Reference switch (8)
The reference switch reports the position of the actuator to the controller. Adjust the control rod so that it covers half the reference switch when the servo component (batch) is in its center position. The reference switch is works set to half the traverse. If the actuating elements of the reference switch touch the customer's machine mechanically, the entire reference switch with the actuating element may be turned along its axis. For this purpose loosen the fastening screws.
Reference switch
Actuating rod
3.7 Limit traverse
The traverse of the DC actuator may be limited electronically (see description chapter "Commissioning"). Alternatively, the traverse may be limited mechanically by limit switches. If the limit switches are retrotted ask Erhardt + Leimer for the connection diagram.
4. Installation
Please observe the locally applicable and professional safety and accident prevention regulations. Run the leads according to the attached wiring diagram. Depending on its mounting location, the effective direction of the DC actuator may have to be reversed on commissioning. See "Digital web controller" operating instructions.
5. Maintenance
The DC actuator does not require maintenance. If the DC actuator has to be replaced the following should be observed: Disconnect the reel station and the entire web guider from the power Loosen plugs/clamps on DC actuator AG .... .
BEA--250206-EN-03
D page 5
Postfach 10 15 40 D-86136 Augsburg Telephone (0821) 24 35-0 Telefax (0821) 24 35-6 66 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
Loosen the DC actuator securing screws. Now remove the DC actuator. Proceed in reverse order to re-assemble. Perform initialization run (i.e. adjust the center position; see "Digital web controller" operating instructions.
Incremental encoder resolution pulses per revolution
Nominal traverse, mechanic in mm
6. Technical data
Operating voltage in V DC
Nominal follow-up speed in mm/s
Nominal traverse limited electronically in mm
Ambient temperature in C
0 - 50
Nominal positioning force in N
DC actuator AG 2571
24
2,9
25 50 75 100 25 50 75 100 25 50 75 100 150 25 50 75 100 150 25 50 75 100 25 50 75 100 25 50 75 100 150 25 50 75 100 150
23 48 73 98 23 48 73 98 23 48 73 98 148 23 48 73 98 148 23 48 73 98 23 48 73 98 23 48 73 98 148 23 48 73 98 148
24
1000
8:1
32
DC actuator AG 2571
24
2,9
10
2500 20,25:1
32
0 - 50
DC actuator AG 2671
24
4,9
15
3000
16:1
32
0 - 50
DC actuator AG 2671
24
4,9
7,5
5300
28:1
32
0 - 50
DC actuator AG 4571
24
2,9
24
1000
8:1
32
0 - 50
DC actuator AG 4571
24
2,9
10
2500 20,25:1
32
0 - 50
DC actuator AG 4671
24
4,9
20
2400
11,1:1
32
0 - 50
DC actuator AG 4671
24
4,9
5300 25,14:1
32
0 - 50
Subject to technical modications without notice
Protection class in IP
54 54 54 54 54 54 54 54
Rated current in A
Transmission
Description H
Command station DO 2000 / DO 2001 / DO 8101

General part
en
1. 2. 3. 4. 5. 6. 7.
Function Assembly and installation Setup mode Commissioning Parameters Special applications Technical data
2 2 3 5 7 25 33
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Command station DO 2000 / DO 2001 / DO 8101 Explanation of symbols = jobs to be performed = important information and instructions Due to the versatile application sectors of command station DO 200. the overall description comprises a "General part" and the appropriate "Chapter description". All relevant settings that are the same for all versions are listed in this description.
1. Function
Command station DO 2000 / DO 2001 / DO 8101 is intended for the operation of a digital guider. It comprises a housing and command unit RT 4071. Command station DO 2000 with hood is for mounting in a control console or cabinet, command station DO 2001 / DO 8101 with desktop housing for eld mounting.
2. Assembly and installation
Please observe the locally applicable and professional safety and accident prevention regulations. Please ensure that insulation is not damaged, leads are properly secured, shielded and run away from heavy current-carrying leads. Shield and run signal lines. The total length of the CAN bus line must not exceed 160 meters. As far as possible mount the command station in view of the web guider. Connect CAN bus lines and power supply to the command station..
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3. Setup mode
3.1 Basic operation in setup mode
Setup settings should be performed by qualied personnel only. The following diagram documents basic operation in setup mode how parameters are displayed and changed. In setup mode the parameter values may be displayed by any device in the CAN network and the modiable parameter values also changed.
Setup mode is started by pressing "Acknowledge" and "Increase value" at the same time. If a password request is indicated on the display, setup mode may only be started once the password is entered.
+ +
Enter the password via the "Increase/decrease value" keys. F2 Use key "F 2" to select each individual place.
Select the "Show Cannet" menu option via the "Decrease value" key.
Select "Keyboard" to quit setup mode. Then press acknowledge.
Select the required device via the "Increase/decrease value" keys . The parameter value may be changed via the "Increase/decrease value" keys
F2
To enter large numbers, the units, tens, hundreds digit etc. can be selected using the "F 2" key.
Select the required parameter via the "Increase/decrease value" keys
To change the parameter the latter must be opened via the "Acknowledge" key.
Select the required option via the "Increase/decrease value" keys.
A cross is set via the "Acknowledge" key. In the case of round brackets () only one menu option may be selected, with square brackets [] several. H Page 3
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Command station DO 2000 / DO 2001 / DO 8101 3.2 Important additions Jump back to setup mode: During operation in setup mode one may "jump back" step-by-step or stage-wise.
ESC
1. Step-by-step jumping back as described in chapter 3.1 "Basic operation in setup mode". 2. Via key "ESC a stage may be jumped back by one level.
ESC
ESC
ESC
Quit setup mode: The following options of quitting setup mode are available: 1. Jump back in the menu to the entry window (as described in chapter 3.1 "Basic operation in setup mode"). 2. Setup mode is quit regardless of position via one of the three "Automatic", "Center position" or "Manual mode" keys.
Device address Device designation
Access to parameters may only be performed by one device, either via PC Canmon program or command station DO 200. . A ashing device address means that two devices are featured in the CAN network with the same device address. If the entire device designation ashes then the device is not featured (is not recognized via Canmon).
CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4004) (CenterSwitch) 0.6(RK4003) 0.7(RK4003) 0.A(*ZC4071*)
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4. Commissioning
4.1 Address setting
System-Menu Keyboard Canmon Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4004) (Center Switch) 0.8(AK 4022) 0.A(*ZC4071*) 0.B(LK4203) 0.A(*ZC4071*) Set Address Set Default Error List Possible Errors Properties Service Functions Reset
All devices in the system must be connected for commissioning purposes (supply voltage / CAN bus) and be connected to the power. On compact systems (those planned by E+L) the address of command station DO 200. is preset. Should the command station be ordered separately (e.g. as a spare part), the device address must be checked/set as follows: Work through setup mode (see section 3.1) until the "SystemMenu" window. Position the selection bar to "Rescan Cannet" then press "Acknowledge". Set the selection bar on command station (ZC 4071) and press "HELP".
Select the "Set Address" menu and press "Acknowledge". The set command station device address is now displayed. If the set address is identical to the address in the block diagram, press "Acknowledge" twice to quit the "Set Address" menu, otherwise set the device address as follows: Set the group number (Group) via the "Increase/Decrease value" keys. Press "Acknowledge". Enter the device number (Device) via the "Increase/Decrease value" keys. Press "Acknowledge" to quit the "Set Address" menu. Quit setup mode.
4.2 Device addresses of virtual command stations (with multi-command only)

virtual keyboards keyboard address 1 keyboard address 2 keyboard address 3 keyboard address 4 keyboard address 5
The device addresses of the 2 - 8 virtual command stations must be entered in the command station parameter eld as follows: Start setup mode. Select parameter "keyboard address 1" and enter the device address of the virtual command station in group 1. Select the appropriate "keyboard address 2 ... 7" parameters one after the other and enter the device addresses of the virtual command stations in groups 2 ... 7 (if featured). Quit setup mode.
1.A HEX
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Command station DO 2000 / DO 2001 / DO 8101 4.3 Allocate password All settings in setup mode may be protected by a freely selected password. Settings in setup mode are only possible following password entry. To assure that no unauthorized persons may enter setup mode, we recommend that a password is dened as follows: Start setup mode. Select the "customer PIN" parameter in the device (ZC 4071) and enter a ve-place numerical password. The password may be freely selected between 1 and 32767. If parameter value "0" is entered, no password will be requested (status on delivery). Quit setup mode. Should unauthorized persons attempt to establish the password by entering numbers, after the third entry of an incorrect password, setup mode is inhibited and in addition, a commentary entered in the error memory. Switch off the power briey on command station DO 200. to re-enable it.
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5. Parameters
The parameter abbreviation is listed in the Name eld. The Default eld indicates the standard settings, Min and Max are the respective permissible values. The unit is indicated in the Unit eld. The Description explains the parameter function. Details written in italic in the parameter lists (Description eld) are texts indicated in the command station display eld. The texts are always displayed in English, regardless of the operating language selected.
5.1 Command station DO 200. parameter list

No. ..4. ..5. ..6. Name ZC 4071 keyboard settings keyboard usage Default 1.1 0 Min. 1.0 0 Max. 1.1 7 Unit E +L Description Software version Parameter title Operating mode keyboard usage 0 = Web guider Webguider 1 = Support Keyboard Support 2 = Tension Keyboard Tension 3 = Prepositioning Keyboard Prepositioning 4 = ELSTRETCHER Keyboard ELSIS 5 = ElectroPalm Keyboard ELSTRETCHER 6 = ELSIS Keyboard 7 = Set value monitoring Target Control display direction of web travel 0 = normal (direction of web travel to right) Normal 1 = invers (direction of web travel to left) Inverted HEX Devices used (error monitoring) Support / Webguider - Keyboard: 0x0001 = Right Sensor 0x0002 = Left Sensor 0x0004 = Right Sensor1 0x0008 = Left Sensor1 0x0040 = Pivoting Frame 0x0080 = Right Support 0x0100 = Left Support 0x0200 = Right Support1 0x0400 = Left Support1 / Lengthmeter ZC5000 0x0010 = Line Sensor 0x0020 = Line Sensor1 Tension-Keyboard : (DC 6000) 0x0001 = Velocity 0x0002 = Tension Right 0x0004 = Tension Left 0x0008 = Speed 0x0020 = Sum 0x0010 = Sum1 0x0040 = Controller Output 0x0080 = Diameter Actual Tension-Keyboard : (ZC 4081) 0x0001 = Tension Right 0x0002 = Tension Left 0x0004 = Tension Right1 0x0008 = Tension Left1 0x0020 = Sum 0x0010 = Sum1
..7.
arrow direction
..8.
used sensor values
FFFF
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No. ..9. Name used add. values Default 0 Min. 0 Max. FFFF Unit HEX Description Used devices (error monitoring) 0x0001 = Mount Pos. Left 0x0002 = Mount Pos Right 0x0004 = Web Offset 0x0008 = Guide Target 0x0010 = Guide Position 0x0020 = System Mode 0x0040 = Width 0x0080 = Prepositioning 0x0100 = Web Speed Parameter title 0 0 2 Web width output 0 = no output No Width 1 = output activated Show Width 2 = inverted output Inverse Width 3 = display actual value Width Control Value HEX HEX HEX HEX CAN address of the right sensors X.1 .. X.4 0.0 ->X.1 in own group CAN address of the left sensor X.1 .. X.4 0.0 ->X.2 in own group CAN address of the right support beam X.6 .. X.7 0.0 ->X.6 in own group CAN address of the left support beam X.6 .. X.7 0.0 ->X.7 in own group Display resolution (decimal points) 0 = no decimal point No Point 1 = one decimal point One Point 2 = two decimal points Two Point Display selection 1 = only for VS 352. Only VS 352. 2 = all other support beams, cameras VS 35X.,CAN-Camera mm m Web width offset mm Web width offset m Display selection 0 = Support beam position Support Beam Pos. 1 = Web width, edge position Web Width 2X = Use mount position values Use Mount Position 4X = Monitor support beam values Check Supports 8X = Change set value Change Target Value Parameter title 0.0 0.0 7F.FF HEX Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF)
.1.0. .1.1.
width output mode
.1.2. .1.3. .1.4. .1.5. .1.6.
right sensor adr left sensor adr right support adr left support adr display resolution
0.0 0.0 0.0 0.0 0
0.0 0.0 0.0 0.0 0
7.F 7.F 7.F 7.F 2
.1.7.
number of motors
.1.8. .1.9. .2.0.
width offset width offset big use sensors
0.0 0 1
-999.9 -30000 0
999.9 30000 1
.2.1. .2.2.
user parameter parameter 1
.2.3.
parameter 2
0.0
0.0
7F.FF
HEX
.2.4.
parameter 3
0.0
0.0
7F.FF
HEX
.2.5.
parameter 4
0.0
0.0
7F.FF
HEX
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No. .2.6. Name parameter 5 Default 0.0 Min. 0.0 Max. 7F.FF Unit HEX Description Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Device parameter that may be adjusted on the operator level. (DD.PPP) DD -> Device address (01..7F) PPP -> Parameter number (04..FF) Service activation for user parameters 0x0001 = Set Address 0x0002 = Show Scan 0x0004 = Show Error List 0x0008 = Show pos. Error 0x0010 = Service Functions 0x0020 = Show Properties 0x0040 = Device Reset 0x0080 = Set Default 0x0100 = Restore Param Parameter title 0 0 FFFF HEX Special key transmit mode XXX0 send to MCP channel Mcp Channel XXX1 send to edit channel Edit Channel XXX2 send to host channel Host Channel XXX3 send to service channel Service Channel XX1X Application command for Enter Auto CMD on Auto Key XX2X Application command for Enter Center CMD on Center Key XX4X Application command for Enter Manual CMD on Manual Key XX8X Application command for Enter HELP CMD on HELP Key X1XX Application command for Enter F1 CMD on F1 Key X2XX Application command for Enter F2 CMD on F2 Key X4XX Application command for Enter F3 CMD on F3 Key X8XX Application command for Enter F4 CMD on F4 Key If the application command is not activated the key value is transmitted to the key channel.
.2.7.
parameter 6
0.0
0.0
7F.FF
HEX
.2.8.
parameter 7
0.0
0.0
7F.FF
HEX
.2.9.
parameter 8
0.0
0.0
7F.FF
HEX
.3.0.
parameter 9
0.0
0.0
7F.FF
HEX
.3.1.
parameter 10
0.0
0.0
7F.FF
HEX
.3.2.
service mode
FFFF
HEX
.3.3. .3.4.
special keys key Mode
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No. .3.5. Name enter Auto Key Default 00A9 Min. 0 Max. FFFF Unit HEX Description transmitted key code for Enter Auto 00A9 -> SetPhoto 006F -> Trace Web 0-> Disabled Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter Center Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmited key code for Enter Manual Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter HELP Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter F1 00A9 -> SetPhoto 006F -> Trace Web 0-> Disabled Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter F2 Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter F3 Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F transmitted key code for Enter F4 Application command activated: Value -> DCCP D : Target device 0 .. F CC: Application command 00 ..FF P : Parameter 0 .. F
.3.6.
enter Center Key
FFFF
HEX
.3.7.
enter Manual Key
FFFF
HEX
.3.8.
enter HELP Key
FFFF
HEX
.3.9.
enter F1 Key
00A9
FFFF
HEX
.4.0.
enter F2 Key
FFFF
HEX
.4.1.
enter F3 Key
FFFF
HEX
.4.2.
enter F4 Key
FFFF
HEX
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No. .4.3. .4.4. Name special Settings key lter 1 0 0 FFFF Default Min. Max. Unit Description Parameter title Key lter, key inhibiting 0x0001 = HELP - key 0x0002 = Cursor Up - key 0x0004 = Cursor Down key 0x0008 = Select Sensor 0x0010 = Select Support 0x0020 = Change Keyboard 0x0040 = Search Edge 0x0080 = Sensor Free 0x0100 = Oscillating 0x0200 = Change Group 0x0400 = Multi Keyboard 0x0800 = Web guider Auto 0x1000 = Web guider Center 0x2000 = Web guider Manual 0x4000 = Support Manual Key lter, key inhibiting 0x0001 = Edit PrePos 0x0002 = Set PrePos 0x0004 = Tension Mode 0x0008 = Edit Te Value 0x0010 = Fast Stop 0x0020 = Tension Auto 0x0040 = Tension Manual 0x0080 = Start Material 0x0100 = Stop Material 0x0200 = Toggle inspec. HEX HEX HEX HEX HEX HEX HEX Parameter title Address of rst virtual keyboard 0.0 -> Keyboard deactivated Address of second virtual keyboard 0.0 -> Keyboard deactivated Address of third virtual keyboard 0.0 -> Keyboard deactivated Address of fourth virtual keyboard 0.0 -> Keyboard deactivated Address of fth virtual keyboard 0.0 -> Keyboard deactivated Address of sixth virtual keyboard 0.0 -> Keyboard deactivated Address of seventh virtual keyboard 0.0 -> Keyboard deactivated Parameter title 4 0 7 Operating mode of virtual keyboard 0 = Virtual keyboard (with own CAN address) Virtual Keyboard 1 = Software keyboard (without own CAN address) Software Keyboard 2X = User-dened group designation active Keyboard Name 4X = Parameter elds are closed on opening the parameter list Closed Folder 8X = Check CAN 10X = No Group Menu 20X = Slow Scan 40X = No Param Descr.
.4.5.
key lter 2
FFFF
.4.6. .4.7. .4.8. .4.9. .5.0. .5.1. .5.2. .5.3. .5.4. .5.5.
virtual keyboards keyboard address 1 keyboard address 2 keyboard address 3 keyboard address 4 keyboard address 5 keyboard address 6 keyboard address 7 global settings keyboard mode
0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0
7.F 7.F 7.F 7.F 7.F 7.F 7.F
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No. .5.6. Name language Default 0 Min. 0 Max. 7 Unit Description User language 0 = English English 1 = German German 2 = French French 3 = Spanish Spanish 4 = Portuguese Portuguese 5 = Italian Italian 6 = Japanese Japanese 7 = Dutch Dutch Display contrast Key acknowledgement via acoustic tone 0 = tone off Off 1 = tone on On Display switching between mm and inch 0 = display in mm mm 1 = display in inch inch mm Arrow display range in web guider keyboard = 0 sensor scanning range (+/- ranges) <> 0 absolute value Customer password 0 = Password deactivated Inhibit basic functions 0x0001 = Edit parameter Parameter Edit 0x0002 = Edit parameter in extended setup mode Extended Parameter 0x0004 = Set device address Set Address 0x0008 = Set default values Set Default Values 0x0010 = Start service functions Service Functions 0x0020 = Save Can network backup Cannet Backup 0x0040 = Edit user parameter Edit User Param 0x0080 = Prepositioning parameter Preposition Para 10 ms HEX Timeout period for Canmon functions Digital output device CAN address (group lamps) -> IO Usage = 4 /0 -> function deactivated Group 0 -> Bit 0 ... Group 7 -> Bit 7 Running time meter Activated software module 0x0001 = Multi-command Multi Keyboard 0x0002 = Prepositioning Prepositioning 0x0004 = Web tenson Tension 0x0008 = ELSIS ELSIS 0x0010 = Paper Paper (ELSTRETCHER + ElectroPalm) 0x0020 = Set value monitoring Target Control Mainloop-runs per second V HEX HEX HEX Operating voltage Not assigned at present Not assigned at present Parameter title 0.0 0.0 0.0 0.0 0.0 0.0 7.F 7.F 7.F CAN address of the rst SPI module CAN address of the second SPI module CAN address of the thrid SPI module
.5.7. .5.8.
brightness sound off/on
60 1
0 0
140 1
.5.9.
mm/inch
.6.0.
arrow range
10
10000
.6.1. .6.2.
customer PIN disable services
0 0
0 0
32767 FFFF
.6.3. .6.4.
scan time *10ms digout device
12 0.0
5 0.0
100 7.F
.6.5. .6.6.
running time meter software
00
0 00
65364 0F
.6.7. .6.8. .6.9. .7.0. .7.1. .7.2. .7.3. .7.4.
main loops Input Voltage reserve 69 reserve 70 spi card address sub address 1 sub address 2 sub address 3
0 0.00 -
65364 33.00 -
The parameters of a virtual command station (parameter ..4. to .4.5.) are identical to those of the command station.
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Command station DO 2000 / DO 2001 / DO 8101 5.2 Explanation of parameters

Parameter value 1.0 1.1 1.2 1.3 1.4 1.5 etc. Software version A B C D E F
..4. ZC 4071 The current version of the command station software is displayed. The no. after the dot indicates the software version.
..5. keyboard settings Parameter block for setting the operating mode.
0.A(*ZC4071*) keyboard usage ( * ) Webguider ( ) Support ( ) Tension ( ) Prepositioning ( ) ELSIS ( ) ELSTRETCHER
..6. keyboard usage On switching on, the command station automatically detects which devices are connected and selects appropriate operating modes. Use this parameter to determine which operating mode will be displayed once operating voltage is supplied. If not operating mode is selected the command station will start with "Webguider" mode. ..7. arrow direction The web direction of travel arrow on the command station display must match the web direction of travel of the entire machine. If the arrow is pointing in the opposite direction the parameter value must be inverted.
Web direction of travel for entire machine
HELP
F1
F2
F3
F4
0.A(*ZC4071*) arrow direction ( * ) Normal ( ) Inverted
0.A(*ZC4071*) used sensor values [ * ] Right Sensor [ ] Left Sensor [ ] Right Sensor 1 [ ] Left Sensor 1 [ ] Pivoting Frame [ ] Right Support
..8. used sensor values Error monitoring of certain components (sensor, actuator, support beam etc.) is possible with the command station. For this purpose the components to be monitored must be selected here. If an error occurs on one of the components that is output on the appropriate device via the "error code" parameter, the left LED on the "HELP" key will ash. Error monitoring is possible for the following devices:
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Command station DO 2000 / DO 2001 / DO 8101 - Actuator/Support beam

Right Sensor Left Sensor Right Sensor 1 Left Sensor 1 Pivoting Frame Right Support Left Support Right Support 1 Left Support 1/ Lengthmeter ZC 5000 Line Sensor Line Sensor 1 Monitoring of the right sensor Monitoring of the left sensor Monitoring of right sensor 1 Monitoring of left sensor 1 Monitoring of the actuator Monitoring of the right support beam Monitoring of the left support beam Monitoring of the right support beam 1 Monitoring of the left support beam 1 Monitoring of the length meter (ELSIS only) Monitoring of the line sensor Monitoring of the line sensor 1
- Web tension (DC 6000)

Velocity Tension Right Tension Left Speed Sum Sum 1 Controller Output Diameter Actual Monitoring of the web velocity Monitoring of the right web tension Monitoring of the left web tension Monitoring of the reel speed Monitoring of the sum signal of the right and left web tension Monitoring of the ltered sum signal of the right and left web tension Monitoring of the positioning signal Monitoring of the reel diameter
- Web tension (ZC 4081)

Tension Right Tension Left Tension Right 1 Tension Left 1 Speed Sum Sum 1 Monitoring of the right web tension Monitoring of the left web tension Monitoring of the right web tension Monitoring of the left web tension Monitoring of the reel speed Monitoring of the sum signal of the right and left web tension Monitoring of the ltered sum signal of the right and left web tension
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0.A(*ZC4071*) used add. values [ * ] Mount Pos. Left [ ] Mount Pos. Right [ ] Web offset [ ] Guide Target [ ] Guide Position [ ] System Mode
..9. used add. values Internal device processes may be monitored as required. Here it is checked whether certain signals are transmitted to the CAN bus. If a monitored signal is no longer transmitted the left LED on the "HELP" key will ash. The following signals may be monitored:
Mount Pos. Left Mount Pos. Right Web Offset Guide Target Guide Position System Mode Width Prepositioning Web Speed Left mounting position Right mounting position Web offset Actuator target position Actuator actual position Operating mode Web width Pre-positioning Web speed
.1.0. width Parameter block for setting web width recording. .1.1. output mode "Show width" must be set in order to indicate the web position/web width on the command station display. The display is inverted (positive negative) via "inverted width" . There is no output for "No Width".
0.A(*ZC4071*) output mode ( ) No Width ( * ) Show Width ( ) Inverse Width
.1.2. right sensor adr .1.3. left sensor adr .1.4. right support adr .1.5. left support adr On standard applications the sensor/support beam is in the same device group as the command station. In this case no settings are required in these four parameters. If the sensor/support beam is located in a different device group to that of the command station, the device and group must be set in the appropriate parameter. .1.6. display resolution The display resolution may be set to a maximum of two places after the decimal point.
0.A(*ZC4071*) display resolution ( * ) No Point ( ) One Point ( ) Two Points
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0.A(*ZC4071*) number of motor ( ) Only VS 352. ( * ) VS 35X., CAN-Camera
.1.7. number of motor This parameter determines what type of support beam is concerned. For a support beam with one drive but two positioning carriages (e.g. VS 352.) the menu option "Only VS 352" must be selected, for all other types, the menu option "VS 35X., CAN-Camera" must be selected. If a camera or broadband sensor FE 80.. is used instead of a support beam "VS 35X., CAN-Camera" must be selected. .1.8. width offset .1.9. width offset big When scanning a web with two sensors the web width is displayed, in the case of only one sensor a required position value is displayed. With these two parameters "width offset" / "width offset big" the web width display may be harmonized or the position value calibrated to a required value. To calibrate the web width display (2 sensors, 1 or 2 camera/s, 2 broadband sensors FE 80..) a web must be simulated in the positioning/scanning range by a template with a pre-specied width. To calibrate the position value (1 sensor, 1 camera for scanning only one edge, 1 broadband sensor FE 80..) the edge of the simulated web must be located exactly at the position to the value of which the display is to be calibrated. When using a motor-driven support beam the sensors must be positioned at the web edge in "Search edge" mode. On a support with only one drive but two positioning carriages (e.g. VS 352.) please note that each of the two web edges is centered exactly in the middle of the respective sensor scanning range. The web may have to be offset a little to left or right.
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Command station DO 2000 / DO 2001 / DO 8101 If the display deviates from the required value (simulated web width/ position value) the offset must be corrected as follows:
Example:
Web width: Display on DO: Offset:
5015,3 mm 108,3 mm 0,0
Position value: Display on DO: Offset:
325,4 mm 365,8 mm 229,2
The offset is calculated usign the following formula: Parameter "width offset big" + parameter "width offset" + web width/position value - display = 0 + 0,0 + 5015,3 -108,3 = 4907,0 = 0 + 229,2 + 325,4 - 365,8 = 188,8
Note: If the offset exceeds the value 999,9 mm the value is entered into parameter "width offset big" from the 5th place onwards. Entry in "width offset big" parameter: 4 Entry in "width offset" parameter: 907,0 Entry in "width offset big" parameter: 0 Entry in "width offset" parameter: 188,8
Important! "Inch" values must be converted into mm (1 inch = 25.4 mm).
When using the following sensors calibration also to the web width/position value. Sensor: Display type: 1 or 2 camera/s Web width/position value 2 broadband sensors FE 80.. Web width 1 broadband sensor FE 80.. Position value .2.0. use sensors The support beam or edge position may be displayed via command station DO 200.. In the case of the support beam position (Support Beam Pos.) only the position of the positioning carriage or distance between two positioning carriages is displayed. In the case of the edge position (Web Width) the sensor signal is incorporated in the display. This means that a change of web position is displayed even if there has been no change in the location of the positioning carriage. If no web is in the scanning range, no value is displayed.
0.A(*ZC4071*) use sensors ( ) Support Beam Pos. ( * ) Web Width [ ] Use Mount Position [ ] Check Supports
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Command station DO 2000 / DO 2001 / DO 8101 The web width is calculated according to the following equations:
SR = LR = PR = PL = MR = ML = Offset = right sensor left sensor right support beam left support beam right mounting position value left mounting position value parameter ".1.8. width offset" + parameter ".1.9. width offset big"
Support Beam Pos.: Web Width.:
(PR-PL)+offset+(MR-ML) (SR-SL)+(PR-PL)+offset+(MR-ML)
The two "Use mount position" and "Check Supports" menu options are designed for special applications. In the case of "Use mount position" the mounting position values are incorporated in the display. Support beams are monitoring by "Check Supports". .2.1. user parameter Parameter block for the user parameters. .2.2. parameter 1 .2.3. parameter 2 .2.4. parameter 3 .2.5. parameter 4 .2.6. parameter 5 .2.7. parameter 6 .2.8. parameter 7 .2.8. parameter 8 .3.0. parameter 9 .3.1. parameter 10 Normally, in order to change a parameter value, the appropriate parameter must be selected in the setup editor. Several steps must be performed to access the required parameter. A quicker method is for the machine operator to be able to change certain parameters using a few keys so that he does not need to use the setup mode. In this way the risk of an unintentional parameter change can be reduced.
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display resolution number of motors width offset use sensors user Parameter parameter 1 3A.1E HEX Group number "3" (3) Device number "A" (10)
020
Any 10 parameters may be dened via parameters .2.2. to .3.1. that may be called up as required by push button and changed. Parameters required during production (e.g. error messages, guider optimization parameters etc.) in particular should be assigned here. The 10 parameters are assigned in sequence, starting with "parameter 1". Should a parameter assignment be changed or deleted the parameter value of the relevant parameter must be set to "0". The group and device number is displayed in front of the dot, the parameter number after. Each number is specied as a hex number!
Parameter number "1E" (30)
Even easier than entering in the parameter is the following method. Select the required parameter (to be determined) as in the "Basic operation in setup mode" chapter. Press "HELP". Select the "Set User Param" menu option. Press "Acknowledge". The parameter is automatically stored in the rst vacant place (from parameter ".2.2. parameter") in the user parameter list. .3.2. service mode Similarly to parameters .2.2. to .3.1. the following functions may be selected that, subsequently, may be directly called up via "HELP".
Set Address Show Scan Show Error List Show Pos. Error Service Functions Show Properties Device Reset Set Default Restore Param Swift addressing of certain components Display of the sensor or camera scan Display of the command station error messages Display of all error messages concerning the command station Call up of certain service functions Display of device properties Trigger reset Load default values Reloading of parameter values stored following a backup command
[ [ [ [ [ [
0.A(*ZC4071*) service mode ] Set Address ] Show Scan ] Show Error List ] Show Pos. Error ] Service Functions ] Show Properties
.3.3. special keys Parameter block for setting key assignments.
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Command station DO 2000 / DO 2001 / DO 8101 .3.4. key mode to .4.2. enter F4 key For service personnel only. .4.3. special settings Parameter block for inhibiting keys and functions. .4.4. key lter 1 Each command station DO 200. key may be disabled. The keys to be disabled must be selected one after the other and marked. Setup mode may be started even when all keys are disabled.
[ [ [ [ [ [
0.A(*ZC4071*) key lter 1 ] HELP Key ] Up Key ] Down Key ] Select Sensor ] Select Support ] Change Keyboard
[ [ [ [ [ [
0.A(*ZC4071*) key lter 2 ] Edit PrePos ] Set PrePos ] Tension Mode ] Edit Te Value ] Fast Stop ] Tension Auto
.4.5. key lter 2 Keys are not disabled directly but certain functions that may be triggered by keys. The following functions may be disabled:
Edit PrePos Set PrePos Tension Mode Edit Te Value Fast Stop Tension Auto Tension Manual Start Material Stop Material Toggle Inspec. Change pre-positioning values Start pre-positioning command Operating mode switch-over (web tension) Change web tension values Fast stop (web tension) Automatic (web tension) Manual (web tension) Start new material (ELSIS) Stop current material (ELSIS) Inspection interruption (ELSIS)
.4.6. virtual keyboards Parameter block for setting virtual command stations. .4.7. keyboard address 1 .4.8. keyboard address 2 .4.9. keyboard address 3 .5.0. keyboard address 4 .5.1. keyboard address 5 .5.2. keyboard address 6 .5.3. keyboard address 7 The command station features a "multi-command" function which permits the operation of a maximum of 8 groups via only one command station. The 2nd to 8th command stations are thus virtually created. Each virtual command station features its own parameter record.
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Command station DO 2000 / DO 2001 / DO 8101 To create a virtual command station the device address of the 1st virtual command station must be entered in parameter ".4.7. keyboard address 1". The 2nd virtual command station is entered in parameter ".4.8. keyboard address 2" etc. .5.4. global settings Parameter block for general settings.
0.A(*ZC4071*) keyboard mode ) Virtual Keyboard ) Software Keyboard ] Keyboard Name ] Closed Folder ] Check CAN
.5.5. keyboard mode The two "Virtual Keyboard" and "Software Keyboard" menu options are only relevant in the "Multi command" function whereby for all standard applications the multi-command of the "Virtual Keyboard" menu option is selected. The virtual keyboard occupies a xed address in the CAN network and may not be assigned a second time. In the case of special applications, the "Software Keyboard" menu option is selected. Here the address assigned the virtual keyboard is enabled. It is therefore possible to address a further device to the pre-assigned address of the virtual keyboard. As such a maximum of 7 further addresses are available for other devices. The "Keyboard Name" menu option permits displaying of a freely selected group designation. Instead of displaying "Group" a designation entered on-site is then indicated. Please refer to chapter 6.1. of this description for how to establish an on-site designation. To shorten the parameter list the menu option "Closed Folder" may be selected in which only individual parameters and parameter titles are displayed. The list is thus shortened and the search for parameters facilitated. If the selection bar is located on the required parameter block the latter is opened by pressing "Acknowledge". In the event of command station malfunctions (possibly in conjunction with a large CAN network) the "Check CAN" menu option should be selected. The menu option must not be selected in normal operation. In case of a multiple control station use menu item "No Group Menu" to switch from one group to the other with key "F 4" . Problems might occur during read-in in connection with large CAN networks. If menu item "Slow Scan" is selected, the net will be readin at reduced speed. The parameter limit values which are shown on the display for the 10 freely selectable user parameters may be blanked if necessary. To do so menu item "No Param Descr." must be selected. Only the parameter value will then be shown for parameters requiring value inputs.
( ( [ [ [
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0.A(*ZC4071*) language ( ) English ( * ) German ( ) French ( ) Spanish ( ) Portuguese ( ) Italian
.5.6. language Various languages are available for operation purposes. User-relevant displays and the help menu are displayed in the selected language. The service level is only available in English. .5.7. brightness The contrast may be adjusted if the display is difcult to read. .5.8. sound off/on On key assignment an acoustic tone is sounded in acknowledgement. If required the acoustic tone function may be switched off.
0.A(*ZC4071*) sound off/on ( ) Off ( * ) On
0.A(*ZC4071*) mm/inch ( * ) mm ( ) inch
.5.9. mm/inch All command station DO 200. (web width, web offset, oscillating stroke etc.) length displays may be indicated in mm or inch. Regardless of the display, all values in parameters (e.g. offset for web width display etc.) must be entered in mm. If only inch values are available these must be converted into mm prior to entry. .6.0. arrow range The web actual position is represented in the display as a LED bar. If the web edge is at the target position the two LEDs in the center will light up. The further away the web edge is from the target position the more LEDs will light up. The LED bar resolution may be set here. If value 0 is set the sensor measuring range will be uniformly divided over the 20 LED segments. Given a sensor measuring range of e.g. 10 mm each block will indicated 1 mm If a number value is entered, the 20 LED segments will be divided according to this value. The number specications refer to mm. If, for instance, the value 4 is entered, a web edge offset of 2 mm will effect full activation of the LED segments. .6.1. customer pin All settings in setup mode may be protected by a freely selectable numerical password. Setup mode settings are then only possible once the password has been entered. We recommend the specication of a password to prevent unauthorized persons accessing setup mode. The password may be freely selected between 1 and 32767. If parameter value "0" is entered no password is requested (delivery status).
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Command station DO 2000 / DO 2001 / DO 8101 Attempts to guess the password by entering number will be terminated after the third incorrect password entry by disabling setup mode and entering a comment in the error memory. Disabling is cancelled again by switching off the command station operating voltage briey. .6.2. disable services The following basis functions may be disabled:
Parameter Edit Extended Parameter Set Address Set Default Values Service Functions Cannet Backup Edit User Param PrePosition Param Change parameters Change parameters in extended setup mode Component address setting Load default values Service functions Storing of CAN network (backup) Change user parameters Change pre-positioning parameters
[ [ [ [ [ [
0.A(*ZC4071*) disable services ] Parameter Edit ] Extended Parameter ] Set Address ] Set Default Values ] Service Functions ] Cannet Backup
.6.3. scan time *10 ms For service personnel only. .6.4. digout device Special application .6.5. running time meter Running time meter .6.6. software Display of activated software module. .6.7. main loops Display for service personnel only. .6.8. input voltage The current operating voltage is displayed. .6.9. reserve 69 Not assigned at present. .7.0. reserve 70 Not assigned at present.
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Command station DO 2000 / DO 2001 / DO 8101 .7.1. spi card address Parameter block for setting the device addresses for SPI modules. .7.2. sub address 1 .7.3. sub address 2 .7.4. sub address 3 The command station has an SPI bus connection. It is possible to connect up to 3 modules (e.g. LK 4203, AK 4014, AK 4022, etc.) in series using this SPI bus. The addresses of these 3 modules must be entered in these parameters. The addresses must be entered one after the other starting in the parameter ".7.2. sub address 1".
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6. Special applications
In this chapter all important setting options and control settings for the command station are described. The following settings are not directly necessary for machine operation but some displays and settings are recommended. The special applications may be divided into the following two groups: 6.1 6.2 Global settings Specic device settings
6.1 Global settings

System-Menu Keyboard Canmon E+L
By "global" is meant settings that apply not just for a single device but for all devices in this group. The following menu options are started according to the following example: Work through setup mode (see chapter 3.1) until the "SystemMenu" is reached. Position the selection bar to the required menu position then press "Acknowledge". The window is opened. An arrow beside a menu means that after this point, further menu options are featured. By selecting the appropriate menu point and then acknowledging, all the remaining menu options will be opened. Jump back to user menu (quit System-Menu).
System-Menu Keyboard Canmon E+L
General introductory menu when parameters are to be displayed or changed (see also "Setup mode" chapter).
Same function as "Show Cannet" menu option only additionally a rescan of the entire network is performed. If a change has been performed on the CAN network (e.g. additional device, new software) a rescan should be performed.
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Once all settings are completed on the command station the settings should be stored in the "EEProm". This assures that settings are saved when the operating voltage is switched off and available again on restarting.
The "CAN Status" menu indicates whether any interference errors have occurred during message transmission. The following messages are hereby differentiated: Warnings : transmitting/receiving messages from command station was difcult and transmission was only possible on a further attempt. a command station message could not be transmitted/ received. the bus system was switched off due to a serious error. incoming messages to the command station have been lost. internal CAN counter for reception errors. internal CAN counter for transmission errors.
Errors Bus Off Overruns REC TEC
: : : : :
To assure perfection command station function the operating voltage must be within a certain range. Via the "Check Power Supply" menu power supply behavior may be indicated as a scan on the display. In addition, the lowest and highest measured voltage is saved and displayed in the top section. The scan is continuously updated.
Keyboard Canmon Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply Extended Info
This menu option is only intended for service engineers. Following selection of the required group and actuation of the "Acknowledge" key all values and messages transmitted for this group on the CAN bus are indicated.
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Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply Extended Info E+L Language
Various language options are available for operation purposes. Userrelevant displays and the help menu are then displayed in the required language. The service level is only possible in English.
Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply Extended Info E+L Language Keyboard Names
A group is indicated by the name "Group" in the display as standard. If required, a freely selected name may be assigned for each existing group.
Keyboard Names Group 0
Press "Acknowledge" and position the selection bar behind the appropriate group for which the name is to be assigned. Once "Acknowledge" is pressed the "Increase value" or "Decrease value" keys may be selected to assign a required name whereby letters are dened one after the other. Use key "F 2" to select place by place. The set name is saved by pressing "Acknowledge".
Save Cannet EEProm CAN Status Check Power Supply Extended Info E+L Language Keyboard Names Service
In the "Service" menu all important telephone numbers and e-mail addresses are listed according to country. In the event of problems or queries arising the required E+L branch may be contacted.
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Command station DO 2000 / DO 2001 / DO 8101 6.2 Specic device settings

CAN 0.5(ZC4081) 0.6(AK4215) 0.A(*ZC4071*)
The following settings are only relevant for service personnel. Specic device settings depend on the devices implemented. First of all the required device must be selected in the "Show Cannet" menu and then "HELP" pressed. Depending on which device has been selected, various menu options are featured. The following list indicates all possible menu options that may be displayed. The settings are only possible for the selected device. For the device selected via this menu the CAN LED will light up red. When the menu is closed a gain, the CAN LED will light up green again.
0.A(*ZC4071*) Set Address Set Default Error List Possible Errors Properties Service Functions Reset
This menu permits the fast checking/setting of the device address. This device address setting is not possible for devices with a DIP switch for the device address. In this case the device address must be checked/set directly on the DIP switch. Exception: if the device address 0 is set on the DIP switch the device address may be set.
Default values are loaded for the selected device. Any settings in the parameters of this device are thus lost during this process!
Errors occurring in this device may be viewed. The errors are displayed in reverse order. The most recent error to have occurred is displayed rst.
All error messages theoretically possible for this device are displayed whereby a differentiation is made between the following error messages: Global: Errors that may occur on any device Local: Specic device errors
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General device properties (ID number, software number etc.) are displayed.
Use the "Service Functions" menu option to call up certain unique actions, e.g. "calibrate camera", "actuator/support beam initialization run" etc. . The following list shows the most common menu options.
Menu option camera cal. standard camera cal. pattern piv frame calib. support calibration save back parameter save parameter device reset save parameter save back param. set device avail redraw keyboard user dend Function Standard camera calibration Camera pattern calibration Actuator initialization run Support beam initialization run Reload saved parameter record Save parameter record This device is reset Parameter saving Parameter saving in the backup list Start error monitoring Test function for screen refresh Numerical service input
Only triggering of the actual process may be accomplished via this menu option. The preliminary work, as explained in the appropriate descriptions, must be performed separately. It applies in principle that the entire "Commissioning" chapter for the relevant device must always be worked through.
The "Reset" menu option may be used to reset the guider. Parameter changes are stored.
Set Address Set Default Error List Possible Errors Properties Service Functions Reset Restore Parameters
Use the "Restore Parameters" menu to reload the originally stored parameter values of the selected device. The parameter record of this device is overwritten. Prerequisite to the restore command is that a "Save Cannet EEProm" has been performed once during commissioning.
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Set Default Error List Possible Errors Properties Service Functions Reset Restore Parameters Main Menu
On completion of setting work use the menu option "Main Menu" to jump back to the main menu.
0.1(OL 80XX) Set Address Set Default Show CCD-Scan Properties Service Functions Reset Main Menu
The signal progression (actual position value) of certain sensors may be indicated on the display as a scan. The scan is continuously refreshed. If several sensor scans are possible use the "F 1" key to switch back and forth between the individual scans.
6.3 Self test
During the self test a full command station hardware and software test is performed. Perform self test as follows: Switch off command station operating voltage. Press "Manual mode" and hold down. Reconnect power supply. First of all a display test is performed then all display pixels are triggered. The display darkens briey whereby it may be detected whether one or several pixels are defective or not. Release "Manual mode" key. After the display test the display indicates the following test results:
** system-check ** EEProm-Size: 32767 Power-Supply: 24.34 V boot: ZC4071-0001F_ZC soft: ZC4071-0003F_ZB test mem. at 0x027FFF 128k ext. Memory ok
"EEProm-Size" no. of EEProm memory bytes. "Power-Supply" The power supply must lie within the tolerance range (see technical data). "boot" basic software. "soft" program software. "test. mem. at" internal RAM. If the memories are o.k. the display will indicate "Memory ok" at the end. Finally a push button and LED test is performed. All LEDs on the command station light up. Press all command station keys (also keys "F 1" to "F 4"). On pressing the appropriate LED on the key goes out. Once all keys have been pressed the alarm display will also go out. On extinguishing of the alarm display the self test is completed and the command station resumes normal operation.
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Command station DO 2000 / DO 2001 / DO 8101 6.4 Activate error monitoring

- (0.A)ZC4071 Service User parameters Group 0
If the error monitoring function is activated the alarm display will optically signal the presence of an error. Error monitoring is triggered as follows: Press "HELP". Position selection bar on the line. Press and hold down "Acknowledge" and additionally press "Automatic". The network structure is now stored. First release the "Acknowledge" key and then "Automatic". The key actuation sequence is important as otherwise saving will not take place. The devices to be monitored are selected in parameter "..8. used sensor values" and "..9. used add. values". Error monitoring is deactivated when no device is selected in either parameter.
6.5 Direct parameter selection

- (0.A)ZC4071 Service User parameters Group 0
By directly selecting parameters 10 parameters may be determined in parameters ".2.2. parameter 1" to ".3.1. parameter 10", called up swiftly and changed (see also appropriate parameter explanation). The required parameters are called up according to the following procedure: Press "HELP". Position selection bar to "User parameters". Press "Acknowledge". Select the required parameter and open via "Acknowledge". Perform required parameter change and acknowledge the change by pressing "Acknowledge".
User parameters 0.8(RT4019) brightness 0.A(*ZC4071*) service mode keyboard usage
User parameters 0.8(RT4019) brightness 0.A(*ZC4071*) service mode keyboard usage
In addition, once the address is selected an option is available whereby after pressing "HELP" certain service functions may be called up that have been dened in the ".3.2. service mode" parameter.
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Command station DO 2000 / DO 2001 / DO 8101 6.6 Error interrogation via HELP key If an error occurs in the system that is detected by the command station the alarm display will light up. The error features may be interrogated as follows: Press "HELP". The device group in which one/several errors have occurred ashes. In this example "Group 0" ashes. Select the ashing device group via the selector bar and press "Acknowledge". A list of all devices monitored in this group is displayed. Run through the list with the "Increase/decrease value" keys until a ashing arrow (>) is indicated after a device. The error is displayed in text form behind the arrow. If necessary the ashing arrow may be selected by the selector bar and "HELP" pressed. Instead of the text an error number is displayed. Press "HELP" again to return to the text display. Press one of three keys, "Automatic", "Center position" or "Manual" to quit the help menu. For width measuring purposes the positions of the right and left support beams together with the respective sensor signals are evaluated. If a camera or broadband sensor is used no support beam is featured. The position values of the right and left support beams are therefore emulated. In this case an "E" for emulation is indicated after the terms "right support beam" and "left support beam" during error interrogation. 6.7 Guiding criterium photo color line sensor The color line sensor guiding criterium may also be learned automatically. The guiding criterium that is to be scanned must be located at the center orange light spot (target position). Press "Acknowledge" and "F1" at the same time. After approx. 1 second both keys may be released. The prerequisite is that "Automatic learning" is selected in the appropriate color line sensor parameter. The sensor description should be reread at the appropriate places with regard to this point.
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7. Technical data
Operating voltage Nominal value Nominal range (incl. ripple) Power input Ambient temperature Storage temperature CAN bus level CAN baud rate Weight Dimensions Protection class Command station in housing Command station as mounting kit (in built-in condition) Operation language
24 V DC 20-30 V DC 200 mA 10 C to +50 C - 25 C to +80 C 5 V (potential-free) 250 kBaud approx. 0.5 kg see dimensioned drawing IP 54 IP 54 German English French Italian Spanish Portuguese Japanese Dutch English
Parameter setting language
Technical data subject to modication without notice
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Description H
Command station DO 2000 / DO 2001

Function "actuating element" Function "support beam" Function "oscillation " Function "multi operation"
en
1. Function 2. Keys and displays 3. Operation
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Command station DO 2000 / DO 2001 Explanation of symbols = jobs to be performed = important information and instructions
1. Function
Command station DO 2000 / DO 2001 is designed to operate a digital guider. The following operations are possible with command station DO 2000 / DO 2001: - actuating element operation - support beam operation - oscillation operation - multi operation The command station consists of a housing and command unit ZC 4070. Command station DO 2000 with cover is for mounting in a control console or cabinet, command station DO 2001 with desktop housing for mounting in the eld.
2. Keys and displays
"HELP" key If necessary, press the "HELP" key to start the online help function. Special settings, e.g. address setting, are also started using this key. If the green LED lights up in the key, a help request or special setting is possible. A ashing yellow LED indicates a warning, although the guider is still operational, the "HELP" key should be pressed to initiate an error query. Alarm display If a system error occurs (e.g. temperature error, defective CAN line etc.), the alarm display lights up and the error may be queried via the "HELP" key (see "Operation" section). Text display The text display can display letters, numbers and symbols. Menu guidance is performed, to some extent, in the required foreign language.
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Command station DO 2000 / DO 2001 Function keys "F 1", "F 2", "F 3", "F 4" Depending on the devices used, the following functions may be selected via the "F 1" to "F 4" keys: F 1 Switch between sensors or between drives Switches between left sensor, right sensor and both sensors on the operating panel for the web guider. When using a colored line sensor, use "F 1" to switch between light line, dark line and color contrast. On the operating panel for the support beam it is possible to switch between left drive, right drive and both drives. F 2 Switch between operating panels The "F 2" key can be used to switch between the existing operating panels. F 3 Oscillation The oscillation stroke (amplitude) and time are set here. F 4 Multi-operation Using the multi-operation function, key "F 4", up to 8 control loops may be operated by just one command station DO 200. . The groups that are to be operated simultaneously are selected in menu "F 4". Values (web offset, web width etc.) may be displayed by one of these selected groups.
"Increase value" / "Decrease value key A web offset may be set via these keys in automatic mode. In manual mode, the actuating element or positioning carriage may be shifted to the left/right. Variable numbers, e.g. parameters, parameter values etc. may be changed. Shortly before reaching the end position, the display in the appropriate key ashes, once the actuating element reaches its end position, the display lights up. Simultaneous pressing effects a reset of the web offset to "0" in automatic mode, a jump back to the start of the parameter list or in the parameter itself, the parameter value will be set to 0. "Acknowledge" key The entered values are adopted (stored) via the "Acknowledge" key. With regard to the function of the key, it is comparable to the ENTER key on a PC.
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Command station DO 2000 / DO 2001 "Automatic" key If the "Automatic" key is pressed, the green display will light up on the key. If the display ashes, the guider block signal is supplied and automatic mode inhibited. The function of the "Automatic" key depends on the setup settings in parameters ".9.9. >operatorkey cong" and ".1.1. >osc. trigger mode" of device X.5 (master device). Amongst others, automatic mode may mean: a. Guiding by the web center, an edge, line or colour contrast If the automatic key is pressed, the web guider controls according to the signals of the selected sensors. Both sensors must be selected for guiding by the web center. b. Hybrid (machine center) If the automatic key is pressed, all support beams and sensors are selected, the web guider controls according to the machine center (automatic hybrid mode). c. Oscillation The "Oscillation" function must be set in parameter ".1.1. >osc. trigger mode" in the master device address X.5 and may be selected in addition to operating modes a. and b.. In oscillation mode, the web is moved in parallel to the left and right. "Center mode" key If the "center mode" key is pressed, the actuating element moves itself to the stored center position. While advancing to the center position, the display ashes. Once the center position is reached, the display on the push button lights up. "Manual mode" key If the "manual mode" key is pressed, the display on the push button lights up, the actuating element may be moved to the left or right via the "Increase/Decrease value" keys. In "Support beam" mode the positioning carriage may be moved to the left/right via the "Increase/Decrease value" keys.
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3. Operation
Operation depends on applied equipment combination and is described in basic terms only below. Detailed system operation is specied in the system operating manual, operation section. Only insert the web when the web guider and processing machine are switched off. Risk of injury! When networking two or more digital controllers each individual control loop for which the following operation sequence is to be valid must be selected via the "multi-command" function prior to operation. If only one controller is featured, omit section 3.1. Enable web guider operating voltage If the message (can net load error bad device list) is being displayed when the device is switched on, acknowledge by pressing key "Acknowledge" and the command station will change to the normal operating mode. The procedure as listed in sub-chapter "Storing parameter values" of commissioning should now be repeated. The renewed storing of the parameter values should keep the device from displaying this message when it is switched on.
3.1 Multi-command (if featured) Select multi-operation menu Press "F 4" to start the multi-operation menu. All groups featured will be displayed.
Select group Via the "Decrease value" key each group may now be selected by the selection bar. A tick displayed in front of a group indicates that the latter has been selected for subsequent operation. To set a tick, press "F 4" and press again to remove ticks. Select the individual groups one after another via the "Decrease value" key and make your selection. Quit multi-operation menu Press "Acknowledge" to quit the multi-operation menu.
User group
The group selected by the selection bar prior to quitting the menu is now selected as user group. The rst number indicated in the "Group" display represents the user group. The remaining numbers indicate the groups selected.
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Command station DO 2000 / DO 2001 3.2 Actuating element Select actuating element menu Press "F 2" until the following symbol displayed beside the key.
(actuating element) is
Select center mode The web control is switched off, the web guider positions itself at the set center position. Before inserting a new web always set the actuating element to "center" mode rst. Set web offset to "0" Press the "Increase/Decrease value" keys at the same time.
Select guiding mode Use "F 1" to switch from web edge (left/right edge sensor) to web center (both sensors). The web edge (left/right edge sensor) depends on the direction of web travel.
Both sensors (web center) Left sensor Right sensor
By pressing "F 1" the actuating element is always switched to "manual". When using a coloured line sensor, use "F 1" to switch between light line, dark line and colour contrast.
Web direction of travel
The specication of the set position in the case of camera/wide band sensors is performed by pressing "Acknowledge" and "Automatic" at the same time. If only the left/right web edge is to be specied as set position, rst of all press "F 1" to select the required web edge (left/right) and then press "Acknowledge" and "F 1" at the same time. Set operating mode - Center mode: the actuating element moves into the stored center position.
- Manual mode: the actuating element may be positioned at the required location via the "Increase/Decrease value" keys.
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- Automatic mode: if the guider block is not connected, the web guider will go into automatic mode immediately.
Set web offset Use the "Increase/Decrease value" keys in automatic mode to set a web offset.
3.3 Support beam Select support beam menu Press "F 2" until the following symbol played next to the key. (support beam) is dis-
Both support beam drives
Support beam drive left / right
Select support beam drive Use "F 1" to select both drives or the left/right drive after one another. The left/right drive depends on the direction of web travel.
Direction of web travel
Manual mode Once manual is selected the positioning carriage (s) may be moved to the left/right via the "Increase/Decrease value" keys. Park sensors To park the sensors "Center position" mode must be selected. The sensors are parked. The frame around the "Park sensor" symbol, located next to the "Increase value" key, ashes while the sensors are being parked. Insert web Edge search Use the "Automatic" key to start the edge search. Once the sensors have found the web edge they will follow it. The frame of the "Search edge" symbol, located next to the key, ashes while the edge search is being performed.
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Command station DO 2000 / DO 2001 By triggering the edge search, the actuating element operating mode selected is cancelled. Edge searching remains active until an operating mode is selected for the actuating element. Exception: if, during the actuating element automatic mode, an edge search is performed without rst parking the sensors, the actuating element will be blocked during the search routine. Once the sensors have found the web edge, the edge search is stopped and the actuating element re-enabled. The selected "Automatic" mode is resumed. Quit support beam menu Press "F 2" until the following symbol displayed next to the key.
(actuating element) is
Select required actuating element operating mode Automatic, center position or manual mode. 3.4 Oscillation
Select oscillation menu Press "F 3" to start the oscillation menu for entering the oscillation stroke and time. Switch oscillation ON/OFF Press "Increase/Decrease value" to switch oscillation ON/OFF, the switch status is indicated on the display. Enter amplitude To enter the amplitude (oscillation stroke) the acknowledge key must be pressed. Press the "Increase/Decrease value" keys to enter the required amplitude (oscillation stroke). Enter time Press the acknowledge key again to enter the time (oscillation time for a cycle) via the "Increase/Decrease value" keys. Quit the oscillation menu Press "Acknowledge" again to quit the oscillation menu.
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Command station DO 2000 / DO 2001 3.5 Direct parameter selection Using the direct parameter selection option, the 10 parameters specied during commissioning may be quickly retrieved and edited. Press "HELP". Position the selection bar to "user parameter". Press "Acknowledge". Select the required parameter and open via "Acknowledge". Perform the required parameter editing. Parameter editing is identical to that described in the "Basic operation in setup mode" section. 3.6 Error query via the HELP key If a system error occurs that is identied by the command station, the alarm display will light up. The error may be queried as follows: Press "HELP". The device group in which one/several errors have occurred ashes. In this example, "Group 0" ashes. Select the ashing device group via the selection bar and press "Acknowledge". A list of all the monitored devices in this group is displayed. Scan the list via the "Increase/Decrease value" key until a ashing arrow (>) is displayed behind a device. The error is displayed in text form behind this arrow. If necessary, the ashing arrow may be selected via the selection bar and the "HELP" key pressed. Instead of the text, an error number is displayed. Press "HELP" again to switch back to the text display. Press one of the three "Automatic", "Center" or "Manual" mode keys to quit the help menu. When width measuring, the positions of the right and left support beam, together with the relevant sensor signals, are evaluated. When using a camera or wide band sensor no support beam is featured. The position values of the right and left support beams are therefore emulated (created articially). In this event, an "E" for Emulation is indicated after the terms "right support beam" and "left support beam" in the error request display.
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3.7 Guiding mode adoption colour line sensor
Additionally, the guiding criterion of the colour line sensor may be automatically taught. The guiding criterion to be scanned must be located at the middle orange light spot position (set position). Press the "Acknowledge" and "F1" keys simultaneously. After approx. 1 second both keys may be cancelled. The prerequisite here is that "Automatic teaching is selected in the relevant colour line sensor parameter. At this point, the relevant points in the sensor description should be reread.
Description J
Digital controller RK 4004

Software: 1. 2. 3. 4. RK 4004-0403 F_ZD V 1.4 RK 4004-8403 F_ZC V 4.2 2 7 7 8 9 10 13 13 22 62 64 67
en
Function Type overview Assembly Installation 4.1 Terminal assignments X 1 to X 21 4.2 Setup operation 5. Parameters 5.1 Parameter list 5.2 Explanation of parameters 5.3 "Three position controller" upgrade 6. Setting values 7. Technical data
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Digital controller RK 4004 Explanation of symbols = jobs to be performed = important information and instructions
1. Function
1.1 Purpose
Controller card RK 4004 is used to control a DC actuator with speed and position feedback. For this purpose a current controller, speed controller, position controller and motor output stage are integrated on the card. Appropriate sensors may be attached via a CAN bus for the position controlling of running webs and following-up of tools. Operation is via a command device with text display and/or a digital input-output card.
1.2 Design
The controller card consists of the following modules: - a processor with data memory - several JST plug sockets - several terminals - a green LED for "output stage on stand-by" - a red LED for the "overcurrent" display - three segment displays - and three keys (setup, increase value, decrease value)
Segment displays Keys: "Setup" "Decrease value" "Increase value"
Green LED
Red LED
JST plug sockets
Data memory
JST plug sockets JST plug sockets Terminals
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Digital controller RK 4004 1.3 Operating principle The operating principle depends on the mode selected. The following operating modes are possible: Actuator manual: In manual mode the actuator may moved to the left or right to a required position. The speed may be set in the appropriate parameter. Actuator center position: The actuator is positioned at the set center whereby first of all it is moved to the reference switch and the internal position controller is adjusted. The actuator is then moved to the set center position. The reference switch should be mounted so that when the actuator is in its center position the switching point of the reference is crossed thus assuring that the actuator may be center-positioned without any major positioning movement. Automatic mode: In automatic mode the web or tool is guided to the set position. Prerequisite to guiding is that guider lock is released. Guider lock in automatic mode: Guider inhibiting is only effective in automatic mode and may be activated on controller card RK 4... or via an interface. Web offset: A web offset may be set in automatic mode. A web offset means that the set position value may be changed positively or negatively. In the case of fixed sensors or a single motor support beam with two positioning carriages, web offsetting is limited to 75 % of the sensor measuring range. On the remaining applications with support beams the web offset may be extended to include the entire support beam position range. Oscillation: In automatic mode an oscillating set value is additionally added to the set position value. The oscillating mode, period and path may be set in the appropriate parameters or via a command station. In the case of fixed sensors oscillation is only possible within 75 % of the measuring range. Park sensor: When using a support beam the positioning carriage along with the sensor/tool located on it are moved (outwards) to the outer end position.
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Digital controller RK 4004 Search for edge: The sensor searches for and follows the web edge until the operating mode is changed by, e.g. a guider enable. 1.4 Control structure with constant controlling for proportional actuators In a control structure for proportional actuators the web or tool actual position value is compared with the required set position value and, in the event of a deviation, it is transmitted to a P position controller as a control difference. The resultant set speed value is compared with the actual speed value and transmitted to the PI speed controller. The latter emits a pulse width-modulated signal at the output stage. The following are available as proportional actuators: DRS pivoting frame, VWS turning rod, SRS steering roller, WSS winding station, SVS push roller SVS and VSS positioning and follow-up controller.
Control structure legend 1 Operating mode 2 Actuator position controller 3 Max. variable actuating speed in manual 4 Speed controller 5 Variable current controller 6 Power output stage 7 Gearing with spindle 8 Right end position 9 Center position 1 0 Left end position 1 Right offset 1 1 2 Left offset 1 3 Actual position memory 1 4 Actual speed value recording
1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 23 24 25
Counter Incremental encoder Web position controller Max. variable actuating speed in automatic Memory command at stop Right edge sensor Left edge sensor Sensor selection (right web edge, left web edge, web center) Web offset Oscillation generator Current controller
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Digital controller RK 4004 1.5 Control structure with constant controlling for support beams In a control structure for a support beam a set speed value is determined on the basis of the sensor signal via the P position controller that is transmitted to the speed controller. The resulting set speed value is compared to the actual speed value and transmitted to the PI speed controller. The latter emits a pulse width-modulated signal at the output stage. In "search for edge" or "hybrid" modes the sensor is driven to follow-up the web edge. Available as proportional actuator: Support beam VSS
Control structure legend 1 Operating mode 2 Sensor 3 Counter 4 Web offset 5 Edge sensor position controller 6 Support beam speed controller 7 Power output stage 8 Sensor zero point detector 9 Memory for edge position 1 0 Park position
1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8
Support beam position controller Actual speed value recording Incremental encoder Max. variable actuating speed in search for edge mode Variable current controller Current controller Variable actuating speed during positioning Oscillation generator
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Digital controller RK 4004 1.6 Control structure with constant controlling for integral actuators In the case of a control structure for integral actuators the web actual position value is compared to the required web set position value and, in the event of a deviation, it is transmitted as a control difference to a P position controller. The latter provides the necessary set position value for the actuator. The current actual actuator position value is compared to the required set position value and transmitted as a control difference to the actuator position controller. The latter generates the set speed value which is compared to the actual speed value, the difference being fed to the PI speed controller which emits a pulse width-modulated signal at the output stage. Available integral actuators: SWS segmented roller guider, VGA pivoting roller, BCS edge and width spreader
Control structure legend 1 Operating mode 2 Actuator position controller 3 Max. variable actuating speed in manual 4 Speed controller 5 Variable current controller 6 Power output stage 7 Gearing with spindle 8 Right end position 9 Center position 1 0 Left end position 1 Right offset 1 1 2 Left offset 1 3 Actual position memory
1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5
Actual speed value recording Counter Incremental encoder Web position controller Max. variable actuator speed in automatic Memory command at stop Right edge sensor Left edge sensor Sensor selection (right web edge, left web edge, web center) Web offset Oscillation generator Current controller
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2. Type overview
The following table provides an overview of the most common digital controllers. The individual digital controllers (DC) are listed in the vertical column. The crosses mark the components belonging to them (AK ...., LK ...., etc.).
AK 4002 X X X X X X X X X X X X X LK 4203 RT 4019 DO 2000 AK 4014
Type DC 0310 DC 0311 DC 0340 DC 0341 DC 0360 DC 0361 DC 1310 DC 1340 DC 2340 DC 2341
RK 4004 X X X X X X X X X X
3. Assembly
Controller card RK 40.. is usually mounted in a sheet steel housing or E+L device. If the controller card is supplied on its own it should be mounted in a control cabinet away from heavy current-carrying modules. The maximum distance to the DC actuator must not exceed 10 m.
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4. Installation
Connect electrical leads according to the attached wiring diagram. Shield and run signal lines away from heavy current-carrying leads. The connection line between the controller card and DC actuator may be run in one lead up to a length of 3 m. From a distance of 3 m to 10 m the motor and incremental encoder lines must be run separately. The CAN bus must not exceed a total maximum length of 160 m and the SPI bus a total maximum length of 0.2 m.
X 5 X 15 Fan Right digital sensor X 6 Left digital sensor X 12 CAN connection without LED display for internal device networking X 7 CAN connection with LED display for CAN device connector
X 21 Supply voltage for further E+L modules X 13 Supply voltage for further E+L modules X 1 Operating voltage
X 11 SPI bus X 9 serial bus
X 8
Analogue card AK 4002 (only when analogue sensors are used)
X 14 External configuration adapter X 10 Optical incremental encoder
X2
DC actuator and incremental encoder
X 3
Command station for web offset RE .... or signal for path-dependent oscillation
X 4
Reference switch, guider lock and end position signal
X 20 End switch
RK 40.. terminal assignments
The wiring diagram indicates which connectors are assigned. The guider lock is intended for on-site requirements where the actuator is to be stopped in its current position. If the guider lock is closed (make contact) the actuator remains in this position until the contact is open again.
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Digital controller RK 4004 4.1 Terminal assignments X 1 to X 21

Terminal X 1 No. 1 2 3 1 2 3 4 5 6 1 2 Input X X X X X X X X Output Assignment +24 V DC supply voltage 0 V Ground DC actuator DC actuator Incremental encoder on DC actuator track A Incremental encoder on DC actuator track B +24 V DC 0 V +24 V DC Programmable input (default "Web offset or path-dependent") or ("Oscillation signal") or ("automatic mode signal (for minimum operation only)") 0 V Sensor range limit or range limit for D.C. actuator (possible only in combination with web offset RE 1721) Programmable input (default "Guider lock") 0 V potential 0 V for controller lock +24 V DC reference switch Programmable input (default "Reference switch signal") 0 V reference switch +24 V DC Programmable input (default "Actuator end position signal") 0 V CAN High CAN Low LED + LED GND (0 V) (Index) Track A +5 V Track B CAN High CAN Low free free +24 V / I max 1,0 A GND 0 V +12 V Switch output for additional fan +24 V Programmable input (default "Actuator 2nd end position signal") 0 V Programmable output (default System on stand-by) +24 V / I max 1,0 A 0 V
X 2
X X
X 3
3 4 X 4 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 5 1 2 3 4 1 2 1 2 1 2 3 4 1 2 X X X X X X X
X X
X X X X X X X X X X X X X X X X X X X X X
X 7
X 10
X X X X X -
X 12
X 13 X15 X 20
X 21
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Digital controller RK 4004 4.2 Setup operation The three keys and the displays are used as the setup control panel. The key assignment (setup, decrease/increase value) is indicated in the illustration opposite. The following applications are possible: 4.2.1 Setting the controller card device address 4.2.2 Current error display 4.2.3 Setting parameters
4.2.1 Set controller card device address
Prior to commissioning the device address of controller card RK 4004 must be checked and changed as necessary. Press both keys "decrease value" and "increase value" at the same time. The group number is indicated via the "decrease value" key and the device number via the "increase value" key. If both keys are held down for longer than approx. 4 seconds the device address will start to flash. If the device address deviates from the required address it may be changed via the keys. If none of the keys are actuated the device address will be saved after approx. 20 seconds have elapsed and a software reset is triggered.
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Digital controller RK 4004 4.2.2 Current error display In normal circumstances the display on the controller card indicates only three dots. These three dots signal that no errors are present. A flashing number signals an error. The number indicates the error code. If several errors are present at the same time, the error with the highest priority will be indicated. If this error is no longer present, the display will indicate the next error. Below is a list of possible errors:
No. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 23 Error display in CANMON UDC-power low UDC-power high I motor high Temp case high encoder fault encoder invers sensor R fault sensor L fault gearconstant fault Motorline fault powerstage defect Motor blocked ref. switch error end switch error 24 V ext. fault motor protect Description 19.5 V DC operating voltage not attained 30.5 V DC operating voltage exceeded set maximum cut-off current exceeded heat sink over 70 oC incremental encoder motor fault incremental encoder motor inverted no message from right sensor no message from left sensor calculated gear constant produces impermissible value motor line interrupted motor power stage defective motor blocked due to overloading (I = max. & n = 0) Attention! output is set after 5 seconds only several reference switch errors detected. end position proximity switches incorrectly configured ext. supply voltage overloaded. motor protection Output at terminal X 20.4 0 0 0 0 0 0 0 0
4.2.3 Output X 20.4
In the case of certain errors (see table) output X 20.4 is switched to "0". The internal switch on the controller card that furnishes a connection to ground is opened. The following circuit variants are recommended:
Lamp "ON" = system on stand-by Lamp "OFF" = error
PLC "1" = system on stand-by PLC "0" = error
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Digital controller RK 4004 4.2.4 Parameter setting All parameters in the CAN network may be selected and changed by the three keys. The following flow diagram illustrates basic operation with the setup editor:
Basic operation in setup mode:
Para- Parameter meter value Start setup mode

+
Start setup mode: press the setup and additionally the increase value key (press the setup key first). The green LED on the setup key will flash . Enter device number: press and hold down the setup key and select parameter 0 via the increase value key. Release the setup key again and enter the device number via the increase or decrease value keys (device number is specified in the block diagram) Enter group number: press and hold down the setup key and select parameter 1 via the increase value key. Release the setup key again and enter the group number via the increase or decrease value keys (group number is specified in the block diagram) Select and change parameters: press and hold down the setup key and select the required parameter via the increase value key. Release the setup key again and enter the required parameter value via the increase or decrease keys. Incorrect parameter changes may impair the function of the entire system !
Enter device number
+ or
Enter group number
+ or
Select parameter Change parameter value
or
May parameter value be changed no

Select expanded setup mode: select device number X.5, then press and hold down the setup key and select parameter 3 by pressing the increase value key. Release the setup key again and enter parameter value 42 via the increase or decrease value keys.
yes
Expanded setup mode

or
Select further parameters no
yes
Quit setup mode: select device number X.5, then press and hold down the setup key and select parameter 3 by pressing the increase value key. Release the setup key again and enter parameter 1 by pressing the increase or decrease value key. Press and hold down the setup key and press the increase value key once. Release the setup key again.
Quit setup mode
or +
X is used as a place retainer
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5. Parameters
In setup mode parameters may be displayed and to some extent changed as well. In order to access the controller card setup mode a command station DO .... , a operating panel RT .... or an E+L CANMON program is required. The parameter numbers are listed in the No. field of the table, in the Name field the abbreviation. The Default field indicates the standard settings, Min. and Max. are the permissible limit values respectively. The unit is indicated in the Unit field. The Description explains the parameter function. If a dot () comes after the parameter number this indicates that it is a display parameter, the value of which cannot be changed. The parameter list applies for the CAN data protocols PR 1 and PR 2. The fields indicate whether each parameter is used in the related CAN data protocols. You can see which CAN data protocol is used from the number in parameter "..4. RK 4004". To make reading easier, standard display is a reduced parameter record only. The bold faced parameters are part of this reduced parameter record. The following options are available for displaying all parameters: - enter value 42 (extended setup mode) into parameter "..3. start service" - special section on command station DO 2000 resp. in the CANMON-Programm.
5.1 Parameter list
5.1.1 Parameter list "Standard"

No. ..0. ..1. ..2. Name edit device edit group reset settings Default 5 0 0 Min. 1 0 0 Max. F 7 2 Unit hex hex PR PR Description 1 2 X X X X X X Select device number See block diagram for device number Select group number See block diagram for group number Works settings 0 = no function 1 = perform customer settings 2 = perform internal default setting
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No. ..3. Name start service Default 0 Min. 0 Max. 199 Unit PR PR Description 1 2 X X Starting a function 0 = no function 1 = reset controller 2 = save parameter 10 = actuator initialisation run (device X.5) 11 = support beam initialisation run (device x.6, x.7, x.8, x.9, x.10, x.11) 12 = actuator initialisation run, with specification of the gear constants (device x.5) 13 = actuator guiding criterion photo (for integral controller only) 15 = calibrate system offset 20 = calibrate the zero point for the motor current measurement 22 = save application parameters 23 = save the calibration data from the RK 4004 30 = preset for general web guider parameters 31 = preset for sensor support beam VS 35 parameters 32 = preset for 3-position controller parameters 33 = preset for DR 11../DR 12.. parameters 34 = preset for support beam VS 50.. parameters 42 = select expanded setup 44 = save customer settings 55 = delete reset counter and running time meter 56 = delete maximum temperature 57 = set calibration values to default 98 = delete error memory 99 = delete data memory Software version Software version Parameter title Web offset Step width for web offset Oscillation amplitude +/Oscillation cycle time cycle-dependent = sec/ cycle path-dependent = pulse/ cycle Oscillation progression 5% = square wave 50% = trapezoidal wave 95% = delta wave Oscillation operation 0 (4) = operation via keyboard 1 (5) = operation via AUTO key 2 (6) = oscillation OFF 3 (7) = oscillation ON Values in () for path-dependent oscillation Parameter title Guider proportional range Web offset in mm at which the DC actuator runs at maximum speed. Decrease value in case of inaccurate guiding! Increase value in case of uneven guiding!
..4. ..4. ..5. ..6. ..7. ..8. ..9.
RK 4004 RK 4004 webedge offset weboffset step width osc. amplitude osc. cycl. time
1.4 4.2
1.0 4.0
3.0 5.5
X X
X X X X X X
0.00 0.10 0.0 20
-325.00 0.01 0.0 1
325.00 10.00 500.0 700
mm mm mm sec.
X X X X
.1.0.
osc. wave form
95
95
.1.1.
>osc. triggermode
.1.2. .1.3.
webedge controller prop range +/10.0 -2000.0 2000.0 mm
X X
X X
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No. .1.4. Name dual-rate width Default 30 Min. 10 Max. 90 Unit % PR PR Description 1 2 X X Window width in % related to proportional range ".1.3." This value is used to establish the switch point for determining the dual rate characteristic curve. Positioning velocity reduction This value is used to determine % motion speed at the switch-over point. Max. positioning velocity speed in automatic mode Positioning velocity speed in positioning mode Positioning velocity speed in jog mode Positioning velocity when exceeding the set threshold Display of velocity limited by internal functions (only active for selecting in parameter 1.1.8.) Not assigned at present Range for detecting a web fault If not attained switching to the set "velocity defect" speed will be performed Parameter title Motion effective direction 0 = normal 1 = inverted Depends on mounting position and web direction of travel Total motor position range on calibration AG positioning path must be entered prior to calibration Positive motor position range Negative motor position range Limit value for end position early warning Hybrid support beam offset Adjustment of hybrid support beam center to machine center. Is set in device X.7. Reference switch offset Distance between reference switching point and AG- positioning range center Centring offset Distance between actuator positioning range center and required actuator 0-position in center position mode. System offset Distance between set actuator 0-position and the reference point (e.g. machine center). Motor gear constant Encoder resolution Entry of rev encoder resolution pulse/rev (without 4-fold evaluation) Gear transmission on motor Entry of gear transmission
.1.5.
dual-rate level
100
200
.1.6. .1.7. .1.8. .1.9. .2.0. .2.1. .2.2.
velocity auto velocity pos velocity jog velocity defect derated velocity reserved 21 defect range
20 50 10 1
0 0 1 1
1000 1000 1000 1000 1000
mm/ s mm/ s mm/ s mm/ s mm/ s mm
X X X X X X
X X X X X X X
10.0
0.0
2000.0
.2.3. .2.4.
servo configuration motion direction 0 0 1
X X
X X
.2.5. .2.6. .2.7. .2.8. .2.9.
motion range total positionrange + positionrange alarm limit % hybrid offset
0.0 0.0 0.0 75 0.0
0.0 0.0 -3270.0 0 -3270.0
3270.0 3270.0 0 100 3270.0
mm mm mm % mm
X X X X X
X X X X X
.3.0.
reference offset center offset
0.0
-3270.0
3270.0
mm
.3.1.
0.0
-3270.0
3270.0
mm
.3.2.
system offset
0.0
-3270.0
3270.0
mm
.3.3. .3.4.
total resolution encoder resolution rotation gear
0.0 8
0.0 8
3270.0 9999
Imp/ mm Imp/ U
X X
X X
.3.5.
8.0
0.1
100.0
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No. .3.6. Name linear gear Default 4.0 Min. 0.1 Max. 250.0 Unit mm/ U X 0.0 5.0 0.0 0.0 00 100 0 0.0 0.1 -3270.0 -3270.0 00 0 -2000.0 200.0 200.0 3270.0 3270.0 7F 2000.0 2000.0 mm mm mm mm mm mm X X X X X X X X X X X X X X X PR PR Description 1 2 X X Linear gear transmission Entry of transmission ratio from rotational to linear movement Mechanical ratio Filtering of encoder impulses Parameter title Position controller dead zone Position controller proportional range Actual position (display only) Set position (display only) Master address Address from which the master set position is received Actuator correction path in the event of a web fault of (.1.3. prop range +/-) Actuator offset between set center and set operating point during automatic mode is set for <SETUP>+<AUTO>. Only if function is activated via Configuration SYS. Parameter title Motor speed characteristic value Value is required for speed limiting Current motor speed (display only) P component for speed controller I component for speed controller Acceleration time Current I-PWM-value (display only) Current motor set speed (display only ) Parameter title Cut-off current of motor output stage Max. permissible nominal motor current Dynamic motor current rise Motor is overloaded briefly by the variable factor Thermal time constant for brief motor current excess Current permissible motor current Actual measured motor current P component for current controller I component for current controller Set motor current display Not assigned at present Superimposed a.c. component for minimizing the breakaway torque
.3.7. .3.8. .3.9. .4.0. .4.1. .4.2. .4.3. .4.4. .4.5. .4.6.
mech. gearfactor encoder filter pos. controller death zone pos prop act position set position pos source adress prop stroke foto auto offset
1.00 4
0.10 2
5.00 16
.4.7. .4.8. .4.9. .5.0. .5.1. .5.2. .5.3. .5.4. .5.5. .5.6. .5.7. .5.8. .5.9. .6.0. .6.1. .6.2. .6.3. .6.4. .6.5. .6.6.
speed controller max. motor speed act. speed speed_P speed_I accel. time I-PWM set speed current controller cut-off current motorcurrent dyn. currentfactor therm. timeconst. limited current act. current current_P current_I set current reserved 65 current dither 0.00 0.00 1.00 A 8.0 1.0 150 60 2.6 0.4 0.0 0.0 100 1 -7.00 -20.00 0.0 0.0 10.0 7.0 200 200 7.00 20.00 100.0 50.0 A A % sec. A A U/ min 2.00 0.10 0.0 0.01 0.01 0.1 10.00 5.00 10.0 sec. 1250 100 4000 U/ min U/ min
X X X X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X X X
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No. .6.7. .6.8. .6.9. Name dither cycletime diagnostics system error xx Default 0 Min. 0 Max. 200 Unit ms PR PR Description 1 2 X X X X X X Dither cycle time The reciprocal value corresponds to the frequency Parameter title Error display 1 = supply voltage < 20 V DC 2 = supply voltage > 30 V DC 3 = cut-off current exceeded 4 = heat sink temperature > 70 C 5 = incremental encoder defective 6 = incremental encoder inverted 7 = no message from right sensor 8 = no message from left sensor 10 = motor line interrupted 12 = motor output stage defective 13 = motor blocked 14 = reference switch has several switching points 15 = end pos. proximity switches incorrectly configured 16 = external voltage output overloaded 23 = motor protection Not assigned at present Reset counter Running time meter Operating voltage Heat sink temperature Maximal heat sink temperature reached Not assigned at present Not assigned at present For internal evaluation only Parameter title Display of current digital inputs Use of output X20.4 Use of input X4.1 Use of input X4.4 Use of input X4.7 Use of input X20.2 Use of input X3.2 Parameter title
.7.0. .7.1. .7.2. .7.3. .7.4. .7.5. .7.6. .7.7. .7.8. .7.9. .8.0. .8.1. .8.2. .8.3. .8.4. .8.5. .8.6. .8.7.
reserved 70 reset counter running time meter supplyvoltage 24DC temperature case temp. case max. reserved 76 reserved 77 mainloops/sec. I/O configuration >digi input status >usage output X20.4 >usage input X4.1 >usage input X4.4 >usage input X4.7 >usage input X20.2 >usage input X.3.2 guide config. 1 2 3 4 00 0 -10 -10 -10 -10 -10 FF 7 23 23 23 23 23 hex 0 32000 Hz x xx.x xx xx h V C C
X X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X
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No. .8.8. .8.9. .9.0. .9.1. .9.2. Name guide target reserved 89 reserved 90 system config. >controller type 0 0 3 Default 0.0 Min. -3000.0 Max. 3000.0 Unit PR PR Description 1 2 X X X X X X X X X X Display of the set web position via an external data master (CoGuideTarget) Not assigned at present Not assigned at present Parameter title Controller type 0 = proportional actuators 1 = integral actuators 3 = 3 position controller Control mode Automatic setting of the sensor addresses to 0 = display only of sensor addresses 1 = automatic setting of the sensor addresses to x.1/x.2 2 = setting of the sensor addresses to those set in parameters .95. and .96. Address of the sensor at the right slot Address of the sensor at the left slot System configuration1 [X] framelimit Check [ ] N~ / M control [ ] Center direct [ ] ref on Power on [ ] watch webedge R [ ] watch webedge L [ ] enable AG-Foto [ ] sens. err. > Center [ ] MCP active [ ] Apl. deactive [ ] support 2 motor [X] weboffset 1/10 mm [ ] weboffset invers [ ] defect detection [ ] ext. system mode [ ] RE 1721 invers
.9.3. .9.4.
controller operate >auto address
0 0
0 0
99 2
X X
X X
.9.5. .9.6. .9.7.
CAN connector Right CAN connector Left >function config 1
0.0 0.0 0801
0.0 0.0 0000
7.F 7.F FFFF
X X X
X X X
0x0001 0x0002 0x0004 0x0008 0x0010 0x0020 0x0040 0x0080 0x0100 0x0200 0x0400 0x0800 0x1000 0x2000 0x4000 0x8000 0x0000 0x0001 0x0002 0x0003 0x0004 0x0005 0x0008 0x0010 0x0020 0x0040 0x0080 0x0100 0x0200 0x0400 0x0800 0x1000 0x2000 0x4000 0x8000
.9.8.
>function config 2
0040
0000
FFFF
System configuration 2 (*) no Controler output ( ) N-target -> CAN ( ) delta N -> CAN ( ) Pos-target -> CAN ( ) delta Pos -> CAN ( ) I-target -> CAN [ ] disable I-controle [ ] Pos-TXD: targetpos [ ] lock webspeedlim [X] AUTO: start slow [ ] AUTO: Clear I-part [ ] Pos-TXD: 50->10ms [ ] AG-Foto with sens. [ ] deselect all sen. [ ] pos-CMD: no photo [ ] trigger control [ ] high prior Manual [ ] no weboffset limit [ ] list-res 0.1 mm -> 1 mm
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No. .9.9. Name >operatorkey config Default 0000 Min. 0000 Max. FFFF Unit PR PR Description 1 2 X X Operatorkey [ ] Auto: sel. all sens [ ] sel. valid sensor [ ] force support free [ ] Center -> sup. free [ ] unused sup. free [ ] no edge -> sup. free [ ] sens sel. direct [ ] emergency sensor L [ ] emergency sensor R [ ] Foto @ Auto [ ] Foto @ Auto + Setup [ ] Foto @ host command [ ] no Foto @ Centered [ ] unused sup. search (*) lost web: ---- ( ) lost web: Center ( ) lost web: Manual System configuration 3 [ ] desel. VSxx to sensor 0x0001 0x0002 0x0004 0x0008 0x0010 0x0020 0x0040 0x0080 0x0100 0x0200 0x0400 0x0800 0x1000 0x2000 0x0000 0x4000 0x8000 0x0001
1.0.0. 1.0.1. 1.0.2. 1.0.3. 1.0.4. 1.0.5. 1.0.6.
>function config 3 delaytime 1 delaytime 2 subsystem 0 adress subsystem 1 adress subsystem 2 adress subsystem 3 adress calib. UDC offset. I-act calib. I-act template position
0000 1.0 1.0 00 00 00 00
0000 0.0 0.0 00 00 00 00
FFFF 10.0 10.0 7F 7F 7F 7F s s hex hex hex hex
X X X X X X X X
X X X X X X X X X X X X X X
Delay time 1 (for switching to emergency sensor) Delay time 2 (for switching to main sensor) Serial bus card 0 address Serial bus card 1 address Serial bus card 2 address Serial bus card 3 address Parameter title Operating voltage calibration Motor current measurement offset Motor current measurement calibration Absolute edge position for a system offset calibration Parameter title Normalization of web speed recording Value corresponds to the input pulse figure per running meter of the web Maximum web speed Web speed limit Current measured web speed Parameter title
1.0.7. calibration 1.0.8. 1.0.9. 1.1.0. 1.1.1. 1.00 0 1.00 0.0 0.80 -50 0.80 -3270.0 1.20 50 1.20 3270.0 mm
X X X X
1.1.2. webspeed config. 1.1.3. webspeed constant webspeed max. webspeed limit 10 10 1000 I/m
1.1.4. 1.1.5.
0 0 0
0 0 0
4000 4000 4000
m/ min m/ min m/ min
X X X X
X X X X
1.1.6. actual webspeed 1.1.7. adaptive control
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No. 1.1.8. Name adaptive function Default 0 Min. 0 Max. 3 Unit PR PR Description 1 2 X X Selection of the adaptive amplification functions 0 = no intervention in the proportional range 1 = proportional range depends on an external CAN signal 2 = proportional range depends on the web speed 0 = no intervention in the positioning velocity 4 = positioning velocity depends on an external CAN signal 8 = positioning velocity depends on the web speed 0 = no intervention in the positioning path 16 = the positioning path depends on an external CAN signal 32 = the positioning path depends on the web speed Display of the current control loop amplification Adaptive factor in % at maximum web speed Adaptive factor in % at web speed limit Not assigned at present Not assigned at present 0.000 0 0 0.000 0 0 1.000 1 9 1/s Additional I-part for integral actuator Parameter title Switching on service mode ! For service personnel only ! (*) Square current controller test ( ) Delta current controller test ( ) Square speed controller test ( ) Delta speed controller test ( ) PWM square bridge signal ( ) PWM delta bridge signal ( ) Square position set value ( ) Delta position set value % % s 2 3 4 5 6 7 8 9
1.1.9. adaptive ratio 1.2.0. 1.2.1. 1.2.2. 1.2.3. 1.2.4. 1.2.6. 1.2.7. max webspeed ratio lim webspeed ratio reserved 122 reserved 123 position I-Part service off/on >service mode
0 0 0
0 0 0
409.6 409.6 409.6
% % %
1.2.5. !! Service !!
1.2.8. 1.2.9. 1.3.0.
testvalue 1 testvalue 2 testcycletime
0 0 0.01
-100 -100 0.01
100 100 10.00
Test value 1 for service mode ! For service personnel only! Test value 2 for service mode ! For service personnel only! Test cycle time for service mode ! For service personnel only !
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Digital controller RK 4004 5.1.2 Parameter list "Extended DCS" (only on RK 4004-8003)
No. ..0. ..1. ..2. Name edit device edit group reset settings Default 5 0 0 Min. 1 0 0
The following parameters can only be edited using a CANMON program.

Max. F 7 2 Unit hex hex Description Select device number See block diagram for device number Select group number See block diagram for group number Works settings 0 = no function 1 = restore customer settings 2 = restore internal basic settings Software version hex Configuration [ ] check workspace [ ] emergency guide Limit for web offset Rate of change of reference variable 0x0001 0x0002
..4. ..5.
Add. DCS Config. >function config
4.1 0000
4.0 0000
5.5 FFFF
..6. ..7. ..8.
mid target limit auto offset limit target change speed
0.0 0.0 0
-3250.0 -3250.0 0
3250.0 3250.0 120
mm mm mm/s
Limit for reference variable during lamination
If the following sign ">" is set in front of the parameter it may be edited with the help of a parameter value list (selection list) in CANMON or DO 200. . Editing with Canmon: Select the "Value" field and open the parameter list via the enter key. Select the required parameter value with the cursor keys, to mark the parameter value press the space bar . Editing with command station DO 200.: Select the required parameter value via the "increase value"/ "decrease value" keys, to mark the parameter value press the acknowledge key.
Parameter value list (selection list)
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Digital controller RK 4004 5.2 Explanation of parameters 5.2.1 Explanation of parameters "Standard"
..0. edit device ..1. edit group The device address consists of the device and group numbers. Each device with a CAN connection (serial or parallel) possesses its own device address that may only be assigned once in the entire CAN network . In order for a specific device to be addressed in the control loop the device number must be set in parameter "..0. edit device" and the group number in parameter "..1. edit group". The device and group numbers are specified in the block diagram for each device with a CAN address. ..2. reset settings In the event of incorrect functioning or parameter entries, the E+L basic settings or default values may be reloaded. The following settings are possible: 1 = perform customer settings. This customer setting is only possible on compact systems set by E+L prior to delivery where all parameter settings were saved in a backup list. The setting values are thus reloaded. 2 = perform basic settings. The default values specified in the parameter list are loaded. The default values are however only loaded for the currently selected device. No parameter values are changed on the remaining devices. ..3. start service Use this parameter to start various processes that are particularly required on commissioning the system. The following functions are possible: 1 = Reset guider In this reset all parameter values for the selected device are saved and a restart performed. Every time parameter values are changed setup mode should always be quit via 1 to assure that all changed parameter values are saved. 2 = Save parameters Function 2 is identical to function 1, the only difference is that no restart is performed for the selected device. 10 = Actuator initialisation run (with specification of the motion path) Prior to the initialization run the actual positioning path must be established and entered in parameter ".2.5. total motion range". The actuator initialization run is started by entering the value 10. Prior to starting the actuator should be located in its center position for this start position is saved as the new center position. The latter may also be corrected manually at any time via parameter ".3.1. center offset".
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Digital controller RK 4004 11 = Initialisation run support beam By entering value 11 the initialization run for all support beams featured in this group is performed. 12 = Initialisation run actuator (with specification of motor and gear data) In this initialization run by first entering the motor and gear data (parameter .3.4./.3.5./.3.6. and .3.7.) the maximum positioning path is established and entered in parameter ".2.5. total motion range". 13 = Capture of guiding criterion photo On follow-up control systems the position of the actuator/tool is controlled according to the detected web position. In order to calibrate the offset, a guiding criterion photo of the actuator must be taken. To this end, the actuator is moved to the required location manually. While the actuator guiding criterion photo is being taken, the offset is calculated on the basis of the current actuator position and the web position and entered in parameter ".4.6. foto auto offset". 15= Calibrate system offset (only with data protocol PR 2) If the control card is used for a support beam, the system offset must be calibrated. During the calibration of the system offset, the support beam position is calibrated to the middle of the machine (reference line). The parameter "1.1.1. template position" must be set before the calibration can be performed. 20 = Calibrate the zero point for the motor current measurement A zero calibration for the motor current measurement is performed. The offset determined during this process is saved in parameter 1.0.9. 22= Save system parameters The parameter values of certain parameters are additionally stored and not deleted in the case of possible data memory deletion. The following parameters are saved: .8.2. / .8.3. / .8.4. / .8.5. / .8.6. / .9.2. / .9.7. / .9.8. and .9.9. . 23= Save the calibration data for the controller card RK 4004 The values saved are displayed in parameter 1.0.8. to 1.1.0. . 30 = general web guider basic parameter setting 31 = VS 35 .. support beam basic parameter setting 32 = 3 position controller basic parameter setting 33= Basic parameter setting for DR 11.. / DR 12.. 34 = VS 50.. support beam basic parameter setting The device-specific parameters are preset for the specified devices by entering the appropriate value.
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Digital controller RK 4004 42 = Expanded setup-mode In setup mode all existing parameters may be selected and the parameter values viewed. Some of the parameter values may be changed immediately. The protected parameters may only be changed once value 42 has been entered. This entry furnishes access to what is known as "expanded setup-mode". In expanded setup mode all parameters that can be changed, may be changed. 44 = Save customer settings In this form of saving all parameter settings are stored in a backup list. If necessary, all customer-specific settings may be reloaded using parameter "..2. reset settings" . 55 = Delete reset counter and running hours meter The internal reset counter and running hours meter are reset to zero. 56 = Delete maximum temperature The maximum heat sink temperature saved is deleted. 57 = Set calibration values to default The calibration values are reset to the default values. 98 = Delete error memory This command should only be used by E+L service personnel. The controller card can store up to 100 errors that have occurred. If the number of errors exceeds the 100 mark, the error messages are pushed out at the back of the error memory and are thus deleted. 99 = Delete data memory This command should be used by E+L service personnel. The entire data memory of the controller card is deleted. Once the controller card is switched on the default values are automatically loaded. No commands are performed until a parameter change has been executed!
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Number 1.X to 3.X 4.X to 6.X 7.X to 9.X Number 1.0 1.1 etc. 1.9 2.0 2.1 etc. CAN data protocol PR 1 PR 2 PR 1 + PR 2 Software version A B etc. J K L etc.
..4. RK 4004 The actual CAN data protocol and the software version are displayed. The number before the point indicates the CAN data protocol used by the software. The number after the point indicates the software version.
..5. webedge offset Parameter block for setting the web offset. ..6. weboffset The web offset permits the displacement of the set web position to the left or right during automatic mode. The offset is set directly in this parameter by a command station or via a digital interface. The step width for web offsetting may be set in parameter "..7. step width". The offsetting of the set position is displayed on the command station in mm. A set web offset is preserved, even when the operating voltage is switched off, until a new entry is saved. In the case of fixed sensors or a single motor support beam with two positioning carriages the web offset is limited to 75 % of the sensor measuring range. For the remaining applications with support beams and cameras the web offset may be increased to the maximum parameter value . ..7. step width The step width of the web offset per key push may be set in 1/ 100 mm. The web offset is changed by this set value by pressing a key on the command station. ..8. osc. amplitude During the oscillation stroke it is determined by how far to the left and right the actuator will swing in oscillation mode. The oscillation stroke may be entered directly in this parameter or via a command station with oscillation feature. Entering is performed in 1/10 mm.
Oscillation stroke
Sensor zero point
Web offset to the right in the direction of web travel
In the case of fixed sensors or a single motor support beam with two positioning carriages the oscillation stroke is limited to 75 % of the sensor measuring range.
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Digital controller RK 4004 ..9. osc. cycl. time Cycle-dependent: The cycle time (oscillation time tc) for an oscillation period is established here. The longer the period, the slower the actuator oscillates. Entry may be directly in the parameter or via a command station with oscillation function.
Oscillation time tc
Path-dependent: In path-dependent oscillation the oscillation period is determined by path-dependent, external pulses. The oscillation period is divided up into n-sections. The maximum number of pulses must not exceed 20 pulses per second. The number of pulses to be set may be calculated as follows: 1. Establish path length per oscillation period
n-sections web length s
s = web length per oscillation period
2. Establish maximum oscillation frequency fc max = s x 60 Vmax fc max = maximum oscillation frequency (1/s) Vmax = maximum web speed (m/min) s = web length per oscillation period (m)
3. Establish no. of pulses The maximum number of pulses per period is limited by the maximum input frequency of fe max 20 Hz. fe max n = fc max fe max = maximum input frequency 20 Hz fc max = oscillation frequency (Hz) n = no. of pulses per period
The no. of pulses n is entered in the parameter. Dimensioning of the external pulse generator may be determined as follows: n fa max = s fa max = maximum pulse generator output frequency (Hz) s = web length per oscillation period (m) n = no. of pulses per period
The external pulse generator must emit the calculated no. of pulses fa max at maximum web speed.
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Digital controller RK 4004 .1.0. osc. wave form

s
"5" s "95" s
Oscillation mode determines the oscillation course. By entering a value of between 5 and 95 oscillation progression may be changed from square to delta wave. 5 = Square-wave (steep rise/drop of the oscillation signal, long dwelling period in the oscillation end position 95 = Delta-wave (shallow rise/drop of the oscillation signal, short dwelling period in the oscillation end position
.1.1. >osc. triggermode Depending on the command station featured, oscillation may be started in different manners. In addition, the differentiation must be made of whether cycle or path-dependent oscillation is concerned. In the case of cycle-dependent oscillation the duration of an oscillation cycle depends on the set time and in the case of path-dependent oscillation on the external pulses (see parameter "..9. osc. cycl. time"). On switching-off oscillation the cycle in progress is continued to the next zero pass. In the case of path-dependent oscillation the corresponding pulses must be supplied up to the zero pass. For path-dependent oscillation the digital input X 3.2 must be programmed to "web speed measuring" (see parameter .8.6.). The following table illustrated the various setting options:
Parameter value: Cycle dependent 0 1 Path dependent 4 5 Oscillation is switched on together with automatic mode or off via a command station with oscillation key or digital interface (command code), independently of the automatic key. If no command station with oscillation key is featured, oscillation may in this case be switched on or off via the automatic key. After starting automatic mode, by pressing the automatic key oscillation is started or stopped while the actuator always remains in "automatic" mode. Oscillation is generally switched off. Even if an oscillation key is featured, oscillation cannot be started. Oscillation is always active. Automatic mode without oscillation is not possible. Oscillation is started together with automatic mode! Explanation:
2 3
6 7
.1.2. webedge controller Parameter block for setting the web guider.
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Digital controller RK 4004 .1.3. prop range +/ On proportional actuators the amplification of the position controller is set via the two parameters ".1.3. Prop range " and ".1.6. velocity auto". On integral actuators amplification is set via the two parameters ".1.3. Prop range " and ".4.5. prop stroke". With regard to the following considerations please always take into account that a change to one of the two parameters will always influence amplification.
Amplification too high
Amplification right Amplification too low
Amplification is correctly set if, after brief overshooting the error is corrected. If the position controller is set with too great a degree of sensitivity, the guider will overshoot as well. In the case of too little amplification the control loop will be too slow. Optimum amplification may be determined with a characteristic curve tracer. In practice, amplification may also be determined by trial and error. Proportional actuator: The smaller the set proportional range at a constant maximum positioning velocity (Parameter ".1.6. velocity auto") is, the greater the amplification of the web guider will be. A negative proportional range causes negative amplification, the effective direction is thus inverted in automatic mode.
Velocity correction established correction velocity depending on proportional range Proportional range .1.3. prop range 2,0 3,5
15 mm/s 8 mm/s
Control deviation Positioning velocity .1.6. velocity auto 20 mm/s
Set position (sensor measuring range center)
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Digital controller RK 4004 By reducing the proportional range the characteristic curve (see fig.) will become steeper. The steeper the characteristic curve the greater the positioning velocity will be in the case of a control deviation and the system thus more sensitive. The positioning velocity of the actuator may be determined on the basis of the characteristic curve regardless of the control deviation. In this example a proportional range of 2 mm or 3.5 mm has been assumed at a maximum motion speed of 20 mm/s. Given a control deviation of 1.5 mm the positioning velocity is 15 mm/s for a proportional range of 2 mm and 8.0 mm/s for a proportional range of 3.5 mm. The values may also be calculated arithmetically: Amplification (G) = parameter .1.6. / Parameter .1.3. Correction velocity (VK) = control deviation * amplification (G) Example 1: G = 20/2 = 10 1/s VK = 1.5 mm * 10 1/s VK = 15 mm/s Proportional actuator optimisation: Reduce the proportional range by small steps only. Following each change of the parameter value a web deviation should be produced manually in automatic mode so that oscillation may be detected immediately. Reduce the proportional range until the guider starts to oscillate. The increase the proportional range again until no more oscillation may be observed. Example 2: G = 20/3.5 = 5.71 1/s VK = 1.5 mm * 5.71 1/s VK = 8.6 mm/s
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Digital controller RK 4004 Integral actuator: The smaller the set proportional range is for the maximum correction path of the actuator (parameter ".4.5. prop stroke "), the greater the amplification of the web guider. A negative proportional range causes negative amplification, the effective direction in automatic mode is thus inverted.
Correction positioning path established correction path depending on proportional range Proportional range .1.3. prop range 2.0 3.5
18 mm 10,5 mm
Control deviation Correction path .4.5. prop stroke 25 mm
Set position (Sensor measuring range center)
By reducing the proportional range the characteristic curve (see fig.) becomes steeper. The steeper the characteristic curve the greater the positioning path of the actuator given a control deviation and the more sensitive the system becomes. The correction path of the actuator may be established on the basis of the characteristic curve independently of the control deviation. In this example a proportional range of 2 mm or 3.5 mm has been assumed with a correction path of 25 mm. Given a control deviation of 1.5 mm the correction path amounts to approx. 18 mm with a proportional range of 2 mm and with a proportional range of 3.5 mm approx. 10.5 mm .
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Digital controller RK 4004 The values may also be calculated arithmetically: Amplification (G) = parameter .4.5. / parameter .1.3. Correction path (SK) = control deviation * amplification (G) Example 1: G = 25/2 = 12.5 SK = 1.5 mm * 12.5 VK = 18.75 mm Integral actuator optimisation: Reduce the proportional range by small steps only. Following each change of the parameter value the a web deviation should be produced manually in automatic mode so that oscillation may be detected immediately. Reduce the proportional range until the guider starts to oscillate. The increase the proportional range again until no more oscillation may be observed. .1.4. dual-rate width .1.5. dual-rate level
Window width .1.4. dual-rate width Positioning velocity reduction .1.5. dual-rate level
Example 2: G = 25/3.5 = 7.14 SK = 1.5 mm * 7.14 VK = 10.71 mm
If the web edge is subject to certain fluctuations (uneven edges) these two parameters may be used to determine a range in which, given a deviation from the set position, the correction velocity of the actuator is reduced in the case of proportional guiders. Given a web edge progression as illustrated opposite, the actuator would normally try to correct the deviation according to the broken line. The actuator would only oscillate and the control result would not be satisfactory. The broken line represents the controller amplification (parameter .1.3./.1.6.). Within the set window width ".1.4. dual-rate width" the positioning velocity is reduced in the case of a control deviation. The positioning velocity reduction is set in parameter ".1.5. dual-rate level". Potential oscillation due to edge errors may thus be reduced. If the edge error exceeds the set window width range the positioning velocity is increased (see fig. on left). Both parameter values are % entries and are related to the set values of parameter ".1.3. prop range " and ".1.6. velocity auto" Example: The following values are set in the parameters.
Set position
Error of uneven edge
.1.3. prop range .1.6. velocity auto
: :
10.0 mm 20 mm/s
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Digital controller RK 4004 .1.4. dual-rate width : .1.5. dual-rate level : 50 % 70 % = 5 mm = 14 mm/s
Window width = 10.0 mm * 50 % / 100
Reduced pos. velocity = 20 mm/s * 70 % / 100
Within 5 mm of the set web position a web error is corrected at a maximum motion speed of 14 mm/s. This function is being deactivated when value "100" is entered into parameter ".1.5. dual-rate level". .1.6. velocity auto The greater the set maximum positioning velocity is given a constant proportional range (parameter ".1.3. prop range "), the greater the amplification of the web guider will be in automatic mode.
Correction velocity established correction velocity depending on the positioning velocity Proportional range .1.3. prop range 2.0
15 mm/s 11 mm/s
Control deviation
Positioning velocity .1.6. velocity auto 15 mm/s 20 mm/s
By increasing the maximum positioning velocity the characteristic curve becomes steeper (see fig.). The steeper the characteristic curve the greater the positioning velocity will be given a control deviation and the more sensitive the system will become. The positioning velocity with which the actuator tries to correct the error may be deduced from the characteristic curve.
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Digital controller RK 4004 In this example a maximum positioning velocity of 15 mm/s or 20 mm/s has been assumed with a proportional range of 2 mm. Given a maximum positioning velocity of 15 mm/s the positioning velocity amounts to approx. 11 mm/s with a control deviation of 1.5 mm and approx. 15 mm/s with a maximum positioning velocity of 20 mm/s. The values may also be calculated arithmetically: Amplification (G) = parameter .1.6. / parameter .1.3. Correction velocity (VK) = control deviation * amplification (G) Example 1: G = 15/2 = 7.5 1/s VK = 1.5 mm * 7.5 1/s VK = 11.25 mm/s Example 2: G = 20/2 = 10.0 1/s VK = 1.5 mm * 10.0 1/s VK = 15.0 mm/s
If the positioning velocity is too high the web guider will begin to oscillate. The maximum positioning velocity must be set higher than the maximum error velocity, yet must not exceed the nominal positioning velocity the DC actuator. .1.7. velocity pos The positioning velocity is determined in this parameter for the following operating modes: - actuator "center position" - support beam "park sensor" - actuator / support beam positioning commands" The step width of the speed setting is 1 mm/s. .1.8. velocity jog The positioning velocity with which the actuator or support beam is positioned in "manual" mode may be set in this parameter with a step width of 1 mm/s.
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Digital controller RK 4004 .1.9. velocity defect

".2.2. defect range " Switching threshold for reducing the positioning velocity
".1.9. velocity emergence" Value of the reduced positioning velocity
So that, in the event of a web displacement (e.g. seam joint) the actuator no longer follows up at maximum positioning velocity in "automatic" mode, the positioning velocity may be reduced to a required value. From which degree of control deviation (web offset) onwards the reduction is activated, must be set in parameter ".2.2. defect range " . In the case of a support beam this velocity setting is determined in "search for edge" mode. This parameter is only active if "defect detection" is selected in parameter .9.7..
Web edge progression in the sensor
.2.0. derated velocity Not assigned at present. .2.1. reserved 21 Not assigned at present. .2.2. defect range If the set value is exceeded, the positioning velocity will be reduced to the value set in parameter ".1.9. velocity defect". In the event of a sudden web displacement (seam joint) this prevents the actuator following up at maximum positioning velocity which might lead to a web tear. This parameter is only active if "defect detection" is selected in parameter .9.7. . .2.3. servo configuration Parameter block for setting the motor data.
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Digital controller RK 4004 .2.4. motion direction The positioning direction of the DC actuator drive may be inverted via this parameter. Following inversion of the positioning direction an initialization run must be performed. .2.5. motion range total The actual positioning path (dimension K) covered by the actuator at the outfeed (transfer roller) must be entered in this parameter. As on certain actuators (e.g. pivoting frames) the actuator positioning path is not identical to that of the DC actuator drive, the exact value must be entered. The mechanical ratio (".3.7. mech. gear factor") is determined via this setting during the initialization run and the motor gear constant calculated. The latter effects the normalization of the positioning speed and path. .2.6. positionrange + .2.7. positionrange Via the position range limit the DC actuator drive is prevented from reaching its mechanical spindle stop or the actuator its mechanical stop. On compact systems the maximum actuator positioning path (see parameter ".2.5. total motion range") is shortened at the factory by approx. 2 mm. In the case of on-site mounting of the DC actuator drive the position range limit must be set by the customer. Especially in the case of large moved masses, please ensure that the actuator does not come to a standstill at once. The positioning range must be reduced accordingly. The set values are always in relation to the set center. The positioning path must entered for both sides (right/left) of the center position in parameter .2.6. and .2.7. of the positioning range. These position range limits must not be used as safeguards for persons or appliances. For the safety of persons or appliances the end position limits must be fitted with additional limit switches or a suitable mechanical stop. .2.8. alarm limit % If necessary a range may be defined that, once exceeded, triggers the output of a limit alarm. The value is entered in % and is in relation to the two parameters ".2.6. positionrange +" and ".2.7. positionrange -". If the actuator exceeds this calculated value the "End position early warning" message is output. The End position reached message is only output at the two end positions. The limit for "End position early warning" always relates to the center of the actuating range set. The warning is output for both sides (positive and negative).
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Transfer roller
Digital controller RK 4004 Example: Entered value in parameter .2.8. Entered value in parameter .2.6. / .2.7. 15 mm * 75 / 100 = 11.25 mm
.2.6. = 15 mm .2.7. = 15 mm
= =
75 % 15 mm
11.25 mm end position early warning in relation to theoretical center
If the actuating range of 11.25 mm is exceeded, the End position early warning message is output. If the actuating range of 15 mm is reached, the "End position reached" message is output.
If the values differ in parameters .2.6. / .2.7. a theoretical center will be deduced from the sum of the two values. The end position early warning is in relation to this center. Example: Entered value in parameter .2.8.
.2.6. = 15 mm .2.7. = 10 mm
= = =
75 % 15 mm 10 mm
Entered value in parameter .2.6. Entered value in parameter .2.7. (15 mm + 10 mm) / 2 * 75 / 100 = 9.375 mm
9.375 mm end position early warning in relation to theoretical center
.2.9. hybrid offset If a support beam is operated with two drives in what is termed hybrid mode the two positioning carriages move symmetrically to the support beam center. This support beam center (center of the guided web) should match the machine center. The support beam center may be matched to the machine center via this parameter (.2.9. hybrid offset). In the case of mechanically coupled support beams (one drive, two positioning carriages) this offset is not possible. This parameter is only necessary on a two-motor support beam in device X.7. .3.0. reference offset In this parameter the distance between the reference switch switching point and the center of the DC actuator drive is set. To calibrate the internal position counter the actuator moves first to the reference switch, then center position (neutral position) in "center position" operating mode . To assure that the positioning movement is as slight as possible in "center position" mode the reference switch switching point should be the same as neutral position. This parameter is automatically determined and entered during the actuator initialization run.
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DC actuator drive center Center offset
.3.1. center offset What is termed the "center offset" is the difference between the DC actuator drive center and the actuator neutral position. If this neutral position deviates from the positioning path center the former may be changed by entering the "center offset". In the case of a pivoting frame, neutral position means that the positioning roller is parallel to the guide roller. If the guider is in "center position" mode while the "center offset" is changed, the change of parameter value will be performed immediately by the DC actuator drive. Checking of the actuator neutral position is possible at once. .3.2. system offset If the DC actuator is located in the center of its positioning range the actual position value "0" will be transmitted via the CAN bus. For special applications an offset value may be set in this parameter which is added to the transmitted actual position value. .3.3. total resolution The motor gear constant is displayed in this parameter. It is calculated on the basis of the following four parameters: .3.4. encoder resolution, .3.5. rotation gear, .3.6. linear gear, .3.7. mech. gear factor; .3.4. encoder resolution .3.5. rotation gear .3.6. linear gear .3.7. mech. gearfactor The motor gear constant is calculated via these parameters.
DC actuator drive securing point Outfeed point
Actuator neutral position
Center of rotation .3.4. encoder resolution .3.5. rotation gear .3.6. linear gear .3.3. total resolution .3.7. mech. gearfactor S 2/S 1
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Digital controller RK 4004 The values for the three parameters .3.4./.3.5./.3.6. must be determined using the table in chapter 6. The mechanical ratio is specified in parameter ".3.7. mech. gear factor". The ratio may be established as follows: Measure distance S 1 between the center of rotation and DC actuator drive securing point. Equally, measure distance S 2 between the center of rotation and the outfeed point. These two values are set in relation to one another and the value calculated produces the mechanical ratio (parameter .3.7.). Example: measured distance S 1 measured distance S 2 850 mm / 450 mm = 1.89 In this example the entry in parameter .3.7. is 1.89. During the initialization run (parameter ..3. / value 10) parameter ".3.7. mech. gearfactor" is established automatically. .3.8. encoder filter For a dynamic speed control the encoder impulses should be filtered as little as possible. Too small a filter value will cause an unsteady motor speed. .3.9. pos. controller Parameter block for setting the positioning control loop. 450 mm 850 mm
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Digital controller RK 4004 .4.0. death zone

s (mm) Set position
25 20 15 10 5 1 2
Actual position without dead zone
If, in applications with a stiff mechanism or large moved masses, there are problems with the position control loop (e.g. oscillation around the set position), a dead zone can be set taking into account the necessary positioning accuracy. There is no actuating movement within the range set.
t (s)
s (mm) Set position
25 20 15 10 5 1 2
Actual position with dead zone
.4.0. death zone
t (s)
.4.1. pos prop

Positioning velocity
Position error
If the position error is greater than the set "position controller proportional range" the correction velocity will thus correspond to the maximum positioning velocity. If the position error is within the set "position controller proportional range" a lesser positioning velocity according to the one of the characteristic curves is produced. Via this parameter the P component of the actuator drive position controller is indirectly set. Example:
Position controlMaximum positioning velocity ler proportional range in automatic (Parameter .4.1.) (parameter .1.6.)
A web set position deviation of 1 mm produces an actuator set position of 15 mm based on the set values (parameter .1.3. and .4.5.). The DC actuator drive covers the first 10 mm at maximum positioning velocity as these values are outwith the grey range. Once the 10 mm are passed, only 5 mm remain. These 5 mm lie within the grey range and the velocity is thus reduced linearly to 0 until the 15 mm position range is reached. In the case of uneven edges (textile) this parameter may be increased to dampen the DC actuator drive position controller. The static precision of the web guider is hereby preserved. The value of parameter .4.1. should amount at most to half of the sensor scanning range.
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Digital controller RK 4004 .4.2. act position The actual position of the actuator at the outfeed, in relation to the set center, is displayed. .4.3. set position The set position of the actuator at the outfeed, in relation to the set center, is displayed. .4.4. pos source adress In the case of follow-up controlling (master/slave) a second actuator (slave) without sensor scanning precisely follows up a freely selectable actuator (master). The device address of the master's guider must be entered on the controller card of the second actuator (slave). Example: The master's address is The slave's address is 1.5 2.5
Master address 1.5
Slave address 2.5
Value 15 (address 1.5) must be entered in parameter .4.4. of the slave controller card (address 2.5).
.4.5. prop stroke In the case of integral actuators the correction path is set in relation to the set proportional range (parameter ".1.3. prop range "). This parameter has no function for proportional actuators. The greater the set correction path is for a constant proportional range (parameter ".1.3. prop range "), the greater the amplification (steep characteristic curve) of the web guider in automatic mode. The steeper the characteristic curve the longer the correction path in the event of a control deviation and thus the more sensitive the system will become. The correction path used by the actuator to try to correct an error may be seen in the characteristic curve.
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Correction path established correction path depending on the correction path Proportional range .1.3. prop range 2,0
15 mm 11 mm
Control deviation
Correction path .4.5. prop stroke 15 mm 20 mm
In this example a maximum correction path of 15 mm or 20 mm was set with a proportional range of 2 mm. Given a correction path of 15 mm (20 mm) the correction path is approx. 11 mm (15 mm) given a control deviation of 1.5 mm. The values may also be calculated arithmetically: Amplification (G) = parameter .4.5. / parameter .1.3. Correction path = control deviation * amplification (G) Example 1: G = 15/2 = 7.5 VK = 1.5 mm * 7.5 VK = 11.25 mm Example 2: G = 20/2 = 10.0 VK = 1.5 mm * 10.0 VK = 15.0 mm
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Digital controller RK 4004 .4.6. foto auto offset During the actuator initialization run the offset is set to zero. A default offset value can only be set with controller type 1 (parameter ".9.2. >controller type"). With a follow-up control/tool control the actuator follows up the actual web position proportionally. To specify the required set position of the unwinder/tool the offset between the "center" position and the required set position must be entered. Manual offset specification: The entry of the offset value is in 1/10 mm. Depending on the presign of the entry the set position of the actuator will be displaced to the right or left of the center position. For the manual default setting parameter "1.2.4. position I-Part" must show value "0". Automatic offset specification: In the case of automatic specification the web must be located in the sensor scanning range and the actuator manually moved to the required set position. The offset is calculated and saved via the "setup" and "automatic" key combination. For the automatic default, the function "enable AG Foto" must be selected in parameter ".9.7. >function config 1". Automatic offset adjustment: In the automatic mode the offset is adjusted automatically if the value in parameter "1.2.4. position I-part" is >0. If an adjusting support is used this values corresponds to the edge position after the search run. This is possible only with a CAN-Dataprotocol PR 1 .4.7. speed controller Parameter block for setting the speed controller. .4.8. max. motor speed The motor speed at maximum terminal voltage (22 V) is set here. The speed value may be found in the table in chapter 6. The speed value is set at 22 V motor voltage. .4.9. act. speed The actual motor speed of the DC actuator at that moment is displayed .
Center position
.4.6. foto auto offset Center position Actuator set position
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Digital controller RK 4004 .5.0. speed_P .5.1. speed_I Please refer to the table in chapter 6 for the P and I components of the various device types. The values must not be changed. They have already been optimized at the factory. A change to these 2 parameters impairs the optimum function of the guider. A change to these values may range from guiding impairment to the system ceasing to function. .5.2. accel. time
Positioning velocity Positioning velocity without ramp function
This function is only possible in "manual offset" mode. In manual mode the actuator is positioned with the positioning velocity set in parameter ".1.8. velocity jog". With this ramp function ".5.2. accel. time" an acceleration time of 0 to the maximum motor speed may be entered. The actuator drive thus reaches its maximum motor speed after a set time. The motor speed is increased linearly. Equally, the actuator comes to a standstill after the same ramp function. In the fig. opposite the motion speed progression of an actuator is displayed with a set ramp function of 3 seconds. The key for the manual offset has been pressed for 5 seconds in this example. The broken line progression indicates the positioning velocity progression without ramp function. .5.3. I-PWM The actual I-PWM value (pulse-width-modulated) is displayed. The display is only of significance for internal tests. .5.4. set speed The actual motor set speed is displayed. .5.5. current controller Parameter block for setting the current controller. .5.6. cut-off current Once the set value is exceeded the motor output stage is switched off. This value should be twice as much as the motor nominal current (parameter ".5.7. motorcurrent"). Error display 3 is output as error in parameter ".6.9. system error". If the current fails to reach the set value the motor output stage will be re-enabled.
Time Positioning velocity with ramp function
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Digital controller RK 4004 .5.7. motorcurrent The motor nominal current specified on the DC actuator drive type plate should be set here. If set too high the motor current may overload or even destroy the DC actuator drive. Please also refer to the table in chapter 6 in order to establish the current value. .5.8. dyn. currentfactor .5.9. therm. timeconst. .6.0. limited current This time-limited excess current is used to increase the dynamics of the DC actuator drive (shorter acceleration time)
Current in mA
Pos. 1
Pos. 2 internal current limit actual permissible motor current nom. motor current motor current Time in s
For a short time a DC actuator drive may be operated with a higher motor current. The factor is determined here. The internal current limit is calculated on the basis of the nominal motor current in parameter ".5.7. motorcurrent" and the factor from parameter ".5.8. dyn. currentfactor". The duration of the excess current is set in parameter ".5.9. therm. timeconst.". Excess current functions according to the following principle: If the motor current input is less than the nominal motor current the permissible motor current will be increased within the set time (.5.9. therm. timeconst.) to the internal current limit. This actual permissible motor current is displayed in parameter ".6.0. limited current". If the motor current input (pos. 1) is greater than the nominal motor current (.5.7. motorcurrent) the permissible motor current will then be reduced again within the set time (.5.9. therm. timeconst.) to the nominal motor current. As soon as the motor current is again drops below the nominal motor current (pos. 2) increasing of the current limit is resumed.
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Digital controller RK 4004 Once the operating voltage is supplied the permissible motor current begins at the nominal motor current. The current limit is upwardly limited by the maximum output stage current (see technical data). If a support beam VS 50.. / VS 60.. is operated using the control card, a current increase must not be set. The value in the parameter ".5.8. dyn. currentfactor" must be 100.
.6.1. act. current The actual motor current of the DC actuator drive is displayed. .6.2. current_P .6.3. current_I The P and I components of the current controller may be found in the table in chapter 6. The values may not be changed. The values are already optimized at the factory. Changing these 2 parameters impairs optimum guider operation. Changing these values may result in guiding impairment to loss of system function. .6.4. set current The current internal set current is displayed. Only of significance for E+L service personnel. .6.5. reserved 65 Not assigned at present.
I (A)
.6.6. current dither An a.c. component may be superimposed on the motor current. The motor breakaway torque is thus reduced and the actuator responds with greater sensitivity. Guiding in the lower speed range is improved.
t (ms)
.6.7. dither cycletime Entry of the cycle time for the a.c. component. .6.8. diagnostics Parameter block for displaying the system status.
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Digital controller RK 4004 .6.9. system error The following error messages are possible: 1 = 2 = 3 = 4 = 5 = 6 = 7 = 8 = 10 = 12 = 13 = 14 = 15 = 16 = 23 = supply voltage under 20 V DC supply voltage over 30 V DC the guider cut-off current has been exceeded the heat sink temperature is over 70 C the incremental encoder is defective the incremental encoder is inverted (signal lines confused) no message from the right sensor no message from the left sensor the motor line is interrupted the motor output stage is defective the motor is blocked at maximum motor current several reference switch switching points the end position proximity switches are confused the external voltage supply of the control card is overloaded for further attached devices. If the motor blocks longer than for 10 seconds the motor current for this direction of rotation is switched off and the defect display "13" changes to "23". If the direction of rotation is reversed the motor protection will be cancelled.
.7.0. reserved 70 Not assigned at present. .7.1. reset counter The number of control card starts is displayed. .7.2. running time meter The operating hours of the control card are displayed here. .7.3. supplyvoltage 24 DC The current supply voltage of the controller card is displayed. .7.4. temperature case The current temperature of the controller card case is displayed here. .7.5. temp. case max. The controller card stores the highest measured temperature of the heat sink. This stored temperature is displayed.
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Digital controller RK 4004 .7.6. reserved 76 .7.7. reserved 77 Not assigned at present. .7.8. mainloops/sec. For internal evaluations only. .7.9. I/O configuration Parameter block for programming the digital inputs. .8.0. >digi input status The current status of the digital controller card inputs is displayed here. .8.1. >usage output X 20.4 The following functions can be assigned to the digitale output (see connection diagram).
Value 1 2 4 Application sytem o.k. motor limits sensor limits Signal at active output System operational The actuator has reached the limit of the positioning range. The web edge is outside of the sensor measuring range.
.8.2. >usage input X 4.1 .8.3. >usage input X 4.4 .8.4. >usage input X 4.7 .8.5. >usage input X20.2 .8.6. >usage input X 3.2 The digital inputs (see wiring diagram) may be assigned functions. Each function may only be assigned once. The following table illustrates the possible function options:
Value 0 1 -1 2 -2 3 -3 4 -4 Application no usage Motor lock Motor unlock Automatic lock Automatic unlock Reference with speedReference with speed+ Speed lock Speed unlock Signal at active input no function of this input motor is stopped in each operating mode motor is enabled in each operating mode motor is only stopped in automatic mode motor is only enabled in automatic mode reference switch switches at negative motor direction of rotation (see example 1) reference switch switches at positive motor direction of rotation (see example 1) at signal 1 the motor direction of rotation is blocked. Which direction of rotation is inhibited is only determined in conjunction with the reference switch. (see example 1) at signal 0 the motor direction of rotation is blocked. Which direction of rotation is inhibited is only determined in conjunction with the reference switch. (see example 1)
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Value 5 -5 6 -6 7 -7 8 -8 9 910 -10 11 12 13 14 15 16 Application Speed + lock Speed + unlock Speed - lock Speed - unlock Auto <-> Center Center <-> Auto Oscilation ON Oscilation Off Weboffset Remote Webspeed Measure Manual Key Right Key Left Key Auto Key Center Key Latch weberror Signal at active input at signal 1 the positive motor direction of rotation is stopped (see example 2) at signal 0 the positive motor direction of rotation is stopped (see example 2) at signal 1 the negative motor direction of rotation is stopped (see example 2) at signal 0 the negative motor direction of rotation is stopped (see example 2) switching-over between automatic and centering switching-over between centering and automatic oscillation ON oscillation OFF external web offset RE 1721 (only possible on terminal X 3.2!) not assigned web speed measuring (only possible on terminal X 3.2!) not assigned "Manual" key "Right" key "Left" key "Auto" key "Center" key Only possible with "integral" type of control. The current web position deviation is saved at signal "1" and an appropriate correction position added to the current AG position at signal "0". This guiding mode is required if the web position is only available at certain times as a valid value (e.g. label scanning, broken lines etc.). In case of a 1 signal the positive actuating movement is suppressed and a change made to the opposite negative actuating movement. The actuating speed for the negative actuating movement is set in parameter ".1.9. velocity defect". In case of a 1 signal the negative actuating movement is suppressed and a change made to the opposite positive actuating movement. The actuating speed for the positive actuating movement is set in parameter ".1.9. velocity defect". "Edge Search" key "Sensor Free" key Trigger get guiding set point Reset of the start of the guiding process to "0" All sensoren in this equipment group will be deselected. The color line sensor is select for control (only with data protocol PR 2) The "guide target" (set position of the web) is set to 0 (only with data protocol PR 2)
17
ATL switch R
18
ATL switch L
19 20 21 22 23 24 25
Edge Search key Sensor Free key Foto key Foto zero key Desel. all sensors Sel Line Sensor Zero Guide Target
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Digital controller RK 4004 Example 1: The positioning range is to be limited by two series-connected break contacts. The inputs X 4.4 (reference switch) and X 4.7 (end positions) should be assigned as follows: Input X 4.4 is assigned the value -3. The switching point is reached via the positive motor direction of rotation. Input X 4.7 is assigned the value -4 (break contact). Example 2: The positioning range is to be limited by two separate break contacts. The inputs X 4.4 and X 4.7 should be assigned as follows: Input X 4.4 is assigned the value -6. At signal 0 the negative motor direction of rotation is stopped. Input X 4.7 is assigned the value -5. At signal 0 the positive motor direction of rotation is stopped. If the circuit is set up with make contacts, value 5 or 6 must be set. .8.7. guide config. Parameter block for external guiding specification. .8.8. guide target The external data master transmits the set web position. The set position value is displayed here. .8.9. reserved 89 Not assigned at present. .9.0. reserved 90 Not assigned at present. .9.1. system config. Parameter block for application adaptation.
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Digital controller RK 4004 .9.2. >controller type This parameter is used to determine which type of guider will be used. Proportional actuator
Pivoting frame Steering roller Turn rod Winding station Push roller Pivoting roller Segmented guide rollers Edge spreading device Spreading device Positioning control Follow-up control
Integral actuator
Three-level mode
n nist nsoll S S Sist Sset
= speed = actual speed = set speed = web set position = web deviation = actual position = set position
nist nsoll Ssoll Stellglied Sist Stellglied S Sist Bahn Ssoll Bahn
= actual speed = set speed = actuator set position = actuator actual position = web deviation = actual web position = set web position
S = web deviation Sist = actual position Ssoll = set position
0= on a proportional guider a specific motion speed is output to correct the guiding difference in the event of a deviation of the actual position from the set position. 1= on an integral actuator a specific actuator position is output to correct the guiding difference. 3= for applications with an actuator with three-level action (e.g. reversing contactor).
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Digital controller RK 4004 .9.3. controller operate In the case of web center guiding systems with motor-driven sensor following-up (hybrid) value 1 must be set. .9.4. >auto address The controller card features automatic sensor addressing. Sensor addressing is only performed after a reset and is only possible for sensors that are directly connected to the controller card at connectors X 5/X 6. Furthermore, the sensors must feature the appropriate software for automatic sensor addressing. The following sensor addressing options are possible. 0 = The sensor address/es is/are only displayed in parameters "connector X5" and "connector X6". The address is manually set on the sensor or via the command device. 1 = Device number 1 is automatically assigned to the sensor at terminal X5 and device number 2 to the sensor at terminal X6. The sensor device group is identical with the controller card group. Address setting according to the sensor description is thus unnecessary. 2 = The sensor at terminal X5 (X6) is assigned the address set in the "connector X5" ("connector X6) parameter. In the event of sensor replacement (defective sensor) the new sensor is automatically assigned the right address. .9.5. CAN connector Right .9.6. CAN connector Left The address setting of the sensor at terminal X5 (X6) is displayed. .9.7. >function config 1 Certain functions may be activated or deactivated. The following table indicates the possible functions:
Function [X] [ ] [ ] [ ] framelimit Check N~ / M control Center direct ref on Power on Value 0001h 0002h 0004h 0008h 0010h Description Monitors both position range limits. This function must be switched of on actuators without end positions (e.g. tube slitters)! No function at present In this case moving to center position is performed without additional calibration of the position counter in "center position" operating mode. Once operating voltage is supplied the reference switch is first of all approached in order to calibrate the position counter. Then the operating mode is selected that was set before the operating voltage was switched off. In the motor-driven positioning of fork-type sensors the right web edge is monitored. If the sensor scanning range is fully covered, motor-driven positioning is interrupted. Damaging of the web edge by the fork-type sensor is thus prevented.
[ ]
watch webedge R
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Function [ ] watch webedge L Value 0020h 0040h 0080h 0100h 0200h 0400h 0800h 1000h 2000h 4000h 8000h Description In the motor-driven positioning of fork-type sensors the left web edge is monitored. If the sensor scanning range is fully covered, motor-driven positioning is interrupted. Damaging of the web edge by the fork-type sensor is thus prevented. The actual motor position is saved as the set position for automatic mode. Displaying is in parameter ".4.6. foto auto offset". This function can only be used with controller type 1 (integral actuator), see also parameter ..3./value 13. In the case of an invalid sensor signal the actuator is moved to the stored center position. If this function is not activated the actuator will only be blocked in the event of an invalid sensor signal. Activation of the MCP (MasterControleProcessor). If no controller card is featured in a group with the address x.5 (master) this function must therefore be set. Switching-off of all web guider applications. If on one support beam, two positioning carriages are featured that are to be moved independently of one another, this function must be selected for the purpose of collision monitoring. This function is automatically set during support beam initialisation. On predecessor controller cards the web offset is always transmitted in 1/10 mm. Controller card RK 4004 transmits in 1/100 mm. To assure that controller card RK 4004 is compatible to older models this function must be set. The effective direction of the web offset is inverted. This inversion is only possible if the signal for the web offset is received over an interface (e.g. Profi-Bus, Interbus-S, etc.). If the edge error exceeds the set proportional range (e.g. due to web displacement, adhesive point, web tear etc) the motion speed is reduced to the set motion speed in parameter ".1.9. velocity emergence". The system mode is expanded for future applications. Various operating modes may then be performed simultaneously with the modified command stations. Turning the potentiometer in a clockwise direction (to the right) must also effect a web offset to the right. If the web offset is in the opposite direction (to the left) this function is used to invert the effective direction of the command station.
[ ]
enable AG-Foto
[ ]
sens. err.> Center
[ ] [ ] [ ]
MCP active Apl. deactive support 2 motor
[X]
weboffset 1/10 mm
[ ]
weboffset invers
[ ]
defect detection
[ ] [ ]
ext. system mode RE 1721 invers
The functions may be directly selected with a CANMON program or command station DO 200.. If these two options are not available the sum of the required functions must be formed and this sum value entered in this parameter. Sum formation must be performed in the hexa-decimal system. Example 1: The "Watch webedge R" and "Watch webedge L" functions are required. Sum value = 0010h + 0020h = 0030h Parameter value = 30 Example 2: The "enable Photo" and "Sens. err.> Center" functions are required. Sum value = 0040h + 0080h = 00C0h Parameter value = C0
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Digital controller RK 4004 .9.8. >function config 2 Certain functions may be activated or deactivated. The following table illustrates the functions: In the case of the curved brackets () only one function may be selected.
Function (*) no controler output ( ) N-target -> CAN ( ) delta N -> CAN ( ) Pos-target -> CAN ( ) delta Pos -> CAN ( ) I-target -> CAN [ ] disable I-controle [ ] POS-TXD: targetpos Value 0000h 0001h 0002h 0003h 0004h 0005h 0008h 0010h 0020h 0040h Description None of the following 5 values is output via the CAN channel Output of the set speed value Output of the speed difference Output of the set position value Output of the position difference Output of the set current value If no motor is connected to the controller card, this setting must be used to switch off the current circuit. Instead of the DC actuator drive actual position the set position of the DC actuator drive is transmitted as a CAN message. The following losses with a follow-up controlling system are thus reduced. If the set web speed fails to be reached (parameter 1.1.5.) automatic mode is blocked If the web is outside of the proportional range when the operating mode "automatic" is selected, the positioning speed will be reduced to the positioning speed set for the manual mode. This reduction will be made only once and it will be made after the "automatic" mode has been selected. On selecting "Automatic" mode the set I-part of parameter "1.2.4. position I-part" is reset to 0. The cycle time for transmitting the actual position to the CAN-bus may be reduced from 50 ms to 10 ms . This minimizes the lag error for the chasing system. The current motor position is saved as set position for automatic mode. The sensor value is also taken into account during calculation in addition to the set position. Automatic mode is performed without taking the sensor signals into account (e.g. oscillation without sensor). In the case of motor positioning commands via interface no guiding criterion photo is triggered. Each time a new actual position of the web is received, the actual web position is saved and a corresponding correction position added to the current AG position. This type of guiding is required if the actual position of the web is sent with t > 5 ms. Attention! The "latch weberror" function for the programmable inputs must not be selected. In the "Automatic" mode, the actuator can be moved using the "web offset" keys. When the key is released, the web guider returns to the "Automatic" operating mode. The "web offset" function cannot be used. The web offset limit on the sensor measuring range is removed. Changes the parameter resolution. With paths greater than 3200.0 mm the values can no longer be displayed or entered in the related parameters. For this reason the resolution must be changed from 1/10 mm to 1 mm. Attention! A reset and a rescan must then be performed.
[ ] lock webspeedlim [X] AUTO: start slow
[ ] AUTO: Clear I-part [ ] Pos-TXD: 50->10ms [ ] AG-Foto with sens. [ ] deselect all sens. [ ] pos-CMD: no photo [ ] trigger control
0080h 0100h 0200h 0400h 0800h 1000h
[ ] high prior Manual
2000h 4000h 8000h
[ ] no weboffset limit [ ] list-res 0.1 mm -> 1 mm
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Digital controller RK 4004 The functions may be directly selected with a CANMON program or command station DO 200. . If these two options are not available the sum of the required functions must be formed and this sum value entered in this parameter. Example : The "I target-> CAN" and "Disable I Loop" functions are required. Sum value = 0005h + 0008h = 000Dh Parameter value = 000D .9.9. >operatorkey config This parameter is used to activate or deactivate certain functions. The table below lists the functions:
Function [ ] AUTO: sel. all sens [ ] sel. valid sensor Value 0001h 0002h Description In "automatic" mode all edge sensors featured in this group are selected. It is only possible to select sensors with a valid sensor signal (sensor status gltig/ valid) via a corresponding command station. This setting is of significance in the case of a camera or color line sensor, as these sensors support the status gltig/valid or ungltig/invalid. When the "park sensor" key is pressed or signal supplied to the input of the same name on a digital interface the sensors are moved to their outer position and main mode set to "SystemLocked". The system is only enabled once the "park sensor" key is released or signal no longer supplied to the input of the same name on a digital interface. In "center position" mode the positioning carriages/sensors are moved to their outer position. In "automatic" mode the positioning carriages/sensors move to their origin position or in "hybrid" mode so that they are symmetrical to the machine center. In "automatic" mode non-selected sensors mounted on a motor-driven positioning carriage, are moved to their outer position (not active at present). If, during "search for edge" mode the inner end position of the positioning carriage is reached, "park sensor" mode is automatically switched to. This value must be set in the controller card X.5 (Master). If no controller card with address X.5 is featured, the function must be set on the controller card with activated MCP (MasterControlProcessor) (see parameter .9.7. function config 1/value 0100). Without this setting "manual" mode will always be switched to when a sensor is selected. If this function is set the selected operating mode is retained when a sensor is selected. Emergency guiding with left sensor Emergency guiding with right sensor The guiding set point is obtained using the "automatic" key The guiding set point is obtained using the "automatic" and "setup" key The guiding set point is obtained using a Host command The guiding set point is not obtained in the "center position" operating mode If, on a two-motor support beam, only one support beam is selected, the second (not selected) support beam continuously follows the web edge. As a result it is possible to measure the width of the web despite single-sided edge operation. On the loss of the web edge no change to the operating mode is performed. On the loss of the web edge "center position" mode is switched. On the loss of the web edge "manual" mode is switched.
[ ] force support free
0004h
[ ] Center -> sup. free
0008h 0010h 0020h
[ ] unused sup. free [ ] no edge -> sup. free
[ ] sens sel. direct
0040h 0080h 0100h 0200h 0400h 0800h 1000h 2000h 0000h 4000h 8000h
[ ] emergency sensor L [ ] emergency sensor R [ ] Foto @ AUTO [ ] Foto @ AUTO + Setup [ ] Foto @ hostcommand [ ] No Foto @ CENTERED [ ] Unused sup. search
(*) lost web ---( ) lost web: Center ( ) lost web: Manual
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Digital controller RK 4004 The functions may be selected directly with a CANMON program or command station DO 200.. If these two options are not available the sum of the required functions must be formed and this sum value entered in this parameter. Example 1: The "Auto: use all sens" and "force support free" functions are required. Sum value = 0001h + 0004h = 0005h Parameter value = 5 Example 2: The "Sens sel. direct", "emergency sensor L" and "emergency sensor R" functions are required. Sum value = 0040h + 0080h + 0100h = 01C0h Parameter value = 1C0 1.0.0. >function config 3 The following functions are possible:
Function [ ] desel. VS XX to sensor Value 0001h Description If a color line sensor is used in conjunction with a motorized support beam, the Search for edge, Web offset using support beam etc. functions are not possible. On the selection of the color line sensor, the selection of all support beams in this device group is cleared automatically. The support beam can only be positioned using corresponding commands from an interface.
1.0.1. delaytime 1 1.0.2. delaytime 2 On the loss of the guiding criterion when a color line sensor an option is available of switching to what is termed an emergency sensor. Emergency guiding is activated in parameter ".9.9. operatorkey config". The periods after which switching-over takes place are set via the two "delaytime" parameters.
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Digital controller RK 4004 Switching-over is performed according to the following principle:
Main sensor (Color line sensor)
Emergency sensor (Edge sensor) Time Status Color line sensor Parameter Operating mode Sensor selection automatic valid .1.0.1 delaytime 1 blocked right edge sensor invalid 1.0.2. delaytime 2 automatic dark line valid
dark line
At this point the color line sensor loses its guiding criterion. The web guider is blocked and the delay time set in parameter "1.0.1. delaytime 1" started. On expiry of the set time switching to the emergency sensor takes place and the web guider is enabled. Automatic mode is continued. At the same time the controller card adopts the current actual web position as the set position for the emergency sensor. The guiding criterion is available again and the delay time in parameter "1.0.2. delaytime 2" starts. Guiding is still performed by emergency sensor. Once the set time has elapsed the system switches back to the color line sensor.
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Digital controller RK 4004 1.0.3. subsystem 0 adress 1.0.4. subsystem 1 adress 1.0.5. subsystem 2 adress 1.0.6. subsystem 3 adress Controller card RK 40.. features a serial bus connection. Up to 4 modules (e.g. a command station, several logic cards etc.) may be serially connected via this serial bus. The addresses of the serial devices are entered automatically in ascending order beginning in parameter 1.0.3., (1st slot = address in parameter 1.0.3., 2nd slot = address in parameter 1.0.4. etc). In the event of double addressing, the address must be changed in the appropriate parameter. The place in front of the dot specifies the group number and the place after the dot the device number. Example: Device number: Group number: Entry in parameter 1.0.7. calibration Parameter block for calibrating the controller card. 1.0.8. calib. UDC Scaling of operating voltage measuring and display. This parameter is automatically set during the test run at E+L. 1.0.9. offset. I-act Motor current offset measuring. This parameter is automatically set during the test run at E+L. 1.1.0. calib. I-act Scaling of motor current measuring and display. This parameter is automatically set during the test run at E+L.
Template
A 0 0.A
9 0 0.9
F 3 3.F
C 7 7.C
1.1.1. template position This parameter is only relevant for a support beam. For the automatic calibration of the system offset using parameter "..3. start service, value 15", the distance between the middle of the machine (reference line) and the edge of the template must be entered. The sign for the entry is dependent on the direction of travel of the web. If the edge of the template is to the left of the center of the machine (reference line) in the direction of travel of the web, a negative value must be entered. The value determined is given in parameter ".3.2. system offset" after the calibration.
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Center of machine/reference line
Digital controller RK 4004 1.1.2. webspeed config. Parameter block for setting web speed measuring. 1.1.3. webspeed constant In order to calibrate the web speed measuring function in the controller card the no. of pulses that are generated per running meter of the web must be entered here. 1.1.4. webspeed max. 1.1.5. webspeed limit 1.2.0. max webspeed ratio 1.2.1. lim webspeed ratio These parameters are only significant if one of the four functions is activated in parameter "1.1.8. adaptive function".
% factor
The guider proportional range or actuator speed may be influenced depending on the web speed. The two vertices for the characteristic curve are determined via the following parameters. Depending on the current web speed, a per cent factor is produced on the basis of the characteristic curve with which the proportional range or motion speed may be influenced. 1.1.4. = 1.2.0. =
m/min
1.2.1. 1.2.0.
Entry of the maximum web speed Entry of the accompanying per cent value Entry of the minimum web speed Entry of the accompanying per cent value
1.1.5.
1.1.4.
1.1.5. = 1.2.1. = Example 1:
1.2.1. 1.2.0.
The set proportional range (.1.3.) should be 200% at minimum web speed and 50% at maximum web speed. The minimum web speed is 15 m/min, the maximum web speed 60 m/min. The corresponding per cent factor for the proportional range at a specific web speed may be deduced from the characteristic curve opposite. Example 2:
1.1.5. 1.1.4.
1.2.0.
1.2.1.
The maximum positioning velocity in "automatic" mode (.1.6.) should be 25% at minimum web speed and 100% at maximum web speed. The minimum web speed is 5 m/min, the maximum web speed 20 m/ min.
1.1.5. 1.1.4.
The corresponding per cent factor for the positioning velocity at a specific web speed may be deduced from the characteristic curve opposite .
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Digital controller RK 4004 The reduction of the positioning velocity does not have any effect on the sensitivity of the control loop. 1.1.6. actual webspeed The actual web speed is displayed in m/min. 1.1.7. adaptive control Parameter block for process-dependent setting of the control parameters. 1.1.8. adaptive function An adaptive guider setting is available for adapting the web guider control loop to changing process variables (e.g. web speed). Which guider setting is to be influenced by which process variable must be set with one of the following values. 0 = Adaptive controlling without function. 1 = The guider proportional range (.1.3.) is influenced depending on an external CAN signal. 2 = The guider proportional range (.1.3.) is influenced depending on the web speed. 4 = The motion speed in automatic mode (.1.6.) is influenced depending on an external CAN signal. 8 = The motion speed in automatic mode (.1.6.) is influenced by the web speed. 16 = The correction path (.4.5.) is influenced by an external CAN signal. 32 = The correction path (.4.5.) is influenced by the web speed. 1.1.9. adaptive ratio Display of the current control loop amplification. 1.2.0. max webspeed ratio See parameter 1.1.4. . 1.2.1. lim webspeed ratio See parameter 1.1.5. . 1.2.2. reserved 122 Not assigned at present.
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Digital controller RK 4004 1.2.3. reserved 123 Not assigned at present. 1.2.4. position I-part If, in the case of integral actuators (e.g. segmented guider roller) controller type 1 (parameter .9.2.) is used, a permanent guiding deviation results due to technical guiding reasons. To reduce or avoid this guiding deviation an automatic offset of the operating point may be set via parameter "1.2.4. position I-part". The larger the value set, the faster the guiding deviation will be compensated. There is however a danger that the actuator may begin to oscillate. In this case the value must be reduced. To assure that the operating point is reset to "0" on selecting automatic mode, the "AUTO clear I-part" must be selected in parameter ".9.8. function config 2". 1.2.5. !! Service !! This parameter serves only as a parameter title for the following parameters that are grouped together due to their function. The parameter itself has no function. 1.2.6. service off/on For E+L service personnel only. Service mode is started via value "1". Following a reset the value is automatically reset to "0". 1.2.7. >service mode For E+L service personnel only. 2 = 3 = 4 = 5 = 6 = 7 = 8 = 9 = Square current controller test Delta current controller test Square speed controller test Delta speed controller test PWM square bridge signal PWM delta bridge signal Square position set value Delta position set value
1.2.8. testvalue 1 For E+L service personnel only. 1.2.9. testvalue 2 For E+L service personnel only. 1.3.0. testcycletime For E+L service personnel only.
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Digital controller RK 4004 5.2.2 Explanation of parameters "Extended DCS" (only for RK 4004-8003) ..0. edit device ..1. edit group ..2. reset settings ..4. Add. DCS Config. See parameter explanation "Standard" ..5. >function config The following functions are possible:
Function [ ] check workspace Value 0001h Description If in the web center control type the web leaves the field of view of a camera (sensor status ungltig/invalid), the automatic operating mode in a standard control system is interrupted and the controller inhibited. If this function is selected, the controller is not inhibited in the situation stated above. The set position of the web is changed via the controller such that the web is brought back into the field of view of the camera. When the web is back in the field of view of both cameras, the original set position for the web is adopted. If in the web center control type a camera loses its guiding criterion (sensor status ungltig/invalid), the web edge control type is selected and the existing guiding criterion used for control. The position of the existing guiding criterion at this moment is cached as the set position until the lost guiding criterion is available again.
[ ] emergency guide
0002h
..6. mid target limit Limit for the set position of the web, for the slave controller. In the case of lamination, the set position of the web for the slave controller is defined by the master web. In some circumstances this set position can vary to such a large amount that the slave controller can no longer mechanically follow this position. Using this parameter the set position for the slave controller is limited to the value set.. With the value "0" the limit is deactivated. ..7. auto offset limit The web offset is limited to this value set. With the value "0" the limit is deactivated. ..8. target change speed If a new set position for the web is defined via an interface, a step change may result in a web tear. To prevent this situation, a web set point ramp can be set using this parameter. With the value "0" the ramp is deactivated.
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Digital controller RK 4004 5.3 "Three position controller" upgrade For control card applications as a three position controller the value 32 must be entered in parameter "..3. start service" during control card commissioning. This loads the three position controller parameter record. The three position controller parameters that differ from the norm are described below.
Min. 0.0 0.0 0.0 0.0 0.0 0.0 0 0 Max. 2000.0 2000.0 2000.0 2000.0 10.0 10.0 1 7F hex Unit mm mm mm mm sec. sec. Description Switching threshold for transition Stop at pulse output Switching threshold for transition Pulse output to permanent signal Switching threshold for transition Permanent signal to fast signal Hysteresis of the individual switching thresholds Switch-on time of pulse signal Switch-off time of pulse signal Jog mode with fast signal Address of digit. output card for the positioning signals Display of the current positioning signal
No. .1.3. .1.4. .1.5. .1.6. .1.7. .1.8. .1.9. .2.0. .2.1.
Name puls range slow range fast range hysteresis pulse ON-time pulse OFF-time jog with fast dig. I/O adress act. control out
Default 2.0 4.0 6.0 1.0 1.0 1.0 0 0
.1.3. pulse range (switching threshold 1)

Address X.X .2.0. dig. I/O address
.1.4. slow range (switching threshold 2) .1.5. fast range (switching threshold 3) The three position controller software features 3 switching thresholds.
Usage 15
Switching threshold 1 Switching threshold 2 Switching threshold 3 Output: "right" "left" "fast"
pulsed "Right" or "Left" "Right" or "Left" output "Fast" output
output duration duration
The "Fast" output is switched to threshold 2. The switching thresholds should be entered in the appropriate parameters. The entered value corresponds to the unit mm . If a switching point is not required, the value "0" must be set in the appropriate parameter.
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No hysteresis set: on and off switching point at 0.4 mm
.1.6. hysteresis A hysteresis may be set for the three existing switching thresholds (pulsed, continuous and fast). The hysteresis allows the switching-off point to lie below the switching-on point by the amount of the hysteresis. The set value is applicable to all three switching thresholds. The hysteresis must not be set higher than the smallest distance between two switching thresholds or from one switching threshold to "0".
Hysteresis of 0.1 set: Switch-on point at 0.4 mm and switch-off point at 0.3 mm
Switch-on duration parameter .1.7.
.1.7. pulse ON-time .1.8. pulse OFF-time The switch-on and off duration may be set separately for switching threshold 1 (parameter ".1.3. pulse range "). The switch-on duration is entered in parameter .1.7. and the switch-off duration in parameter .1.8. . .1.9. jog with fast In jogging mode the fast output may be additionally switched to the left or right output. The value "1" must be entered in order to activate the fast output. .2.0. dig. I/O address The device address of logic card LK 4203 must be entered here to the output signals "Left", "Right" and "Fast". The address is specified in the block diagram. In logic card LK 4203 the value 15 (3 position controller) must be set in parameter "..5. >IO card usage". .2.1. act. control out The current positioning signal is displayed for internal purposes.
Switch-off duration parameter .1.8.
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6. Setting values
Typ Mat. No. Watts motion range total .2.5. AG 2491 AG 2491 AG 2491 AG 2491 AG 2497 AG 2497 AG 2497 AG 2497 AG 2571 AG 2571 AG 2571 AG 2571 AG 2571 AG 2571 AG 2571 AG 2571 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2591 AG 2593 AG 2593 AG 2593 AG 2593 AG 2595 AG 2596 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 AG 2671 J Page 64 201444 204474 210667 341637 361305 361306 361308 361309 311963 311941 311964 311942 311965 311966 311804 311943 229159 210896 323301 210897 217908 210898 227057 230119 219860 344426 230661 300587 234536 310696 226921 227183 311967 311946 311944 311947 310208 311948 311945 311949 311807 311950 20 20 20 20 20 20 20 20 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 120 120 120 120 40 40 80 80 80 80 80 80 80 80 80 80 24 50 100 150 24 50 100 150 50 50 100 100 150 150 200 200 30 50 50 100 100 150 150 200 200 350 24 50 100 150 150 80 50 50 100 100 150 150 200 200 300 300 encoder rotation resolugear tion .3.4. 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 100 100 100 100 8 8 8 8 8 8 8 8 8 8 8 8 .3.5. 8:1 8:1 8:1 8:1 15:1 15:1 15:1 15:1 8:1 20,25:1 8:1 20,25:1 8:1 20,25:1 8:1 20,25:1 8:1 8:1 20,25:1 8:1 20,25:1 8:1 20,25:1 20,25:1 8:1 8:1 1:1 1:1 1:1 1:1 8:1 8:1 16:1 28:1 16.1 28:1 16:1 28:1 16:1 28:1 16:1 28:1 linear gear .3.6. 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 max. motor speed .4.8. 3300 3300 3300 3300 3300 3300 3300 3300 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 1228 1228 1228 1228 2750 2750 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 speed P .5.0. 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 1,0 1,0 2,0 1,0 2,0 1,0 2,0 2,0 1,0 1,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 speed I .5.1. 0,02 0,02 0,02 0,02 0,02 0,02 0,02 0,02 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,02 0,02 0,10 0,02 0,10 0,02 0,10 0,10 0,02 0,02 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 motorcurrent .5.7. 0,86 0,86 0,86 0,86 0,86 0,86 0,86 0,86 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 1,6 2 2 2 2 2,9 2,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 dyn. current factor .5.8. 150 150 150 150 100 100 100 100 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150
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Typ Mat. No. Watts motion range total .2.5. AG 2671 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 2691 AG 4081 AG 4081 AG 4081 AG 4081 AG 4091 AG 4451 AG 4451 AG 4451 AG 4451 AG 4451 AG 4451 AG 4497 AG 4571 AG 4571 AG 4571 AG 4571 AG 4571 AG 4571 AG 4571 AG 4571 AG 4591 AG 4591 AG 4591 AG 4591 AG 4591 AG 4591 AG 4591 AG 4591 AG 4591 AG 4671 AG 4671 AG 4671 319780 224526 212610 229098 212609 228765 312204 217808 212325 234946 228283 214554 208615 208616 226862 208618 209822 322010 322011 323398 323399 344055 344910 361457 311968 311952 311805 311953 311951 311954 311806 311955 230566 232466 319709 307757 230567 230568 229330 229329 230136 311969 311958 311956 80 80 80 80 80 80 80 80 80 80 80 80 9,5 9,5 9,5 9,5 9,5 9 9 9 9 9 9 20 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 80 80 80 400 100 100 100 150 150 200 200 200 350 350 350 50 12 100 12 12 24 60 24 60 60 24 50 50 50 100 100 150 150 200 200 50 50 50 100 100 150 150 200 200 50 50 100 encoder rotation resolugear tion .3.4. 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 500 500 500 500 500 500 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 .3.5. 16:1 4:1 16:1 28:1 16:1 28:1 34,5:1 16:1 28:1 4:1 28:1 16:1 6,25:1 6,25:1 6,25:1 6,25:1 6,25:1 1:1 1:1 1:1 1:1 1:1 1:1 15:1 8:1 20,25:1 8:1 20,25:1 8:1 20,25:1 8.1 20,25:1 8:1 20,25:1 4,5:1 20,25:1 8:1 8:1 20,25:1 8:1 20,25:1 11:1 25,14:1 11:1 linear gear .3.6. 5 5 5 5 5 5 5 5 5 5 5 5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 max. motor speed .4.8. 3070 3070 3070 3070 3070 3070 2750 3070 3070 3070 3070 3070 2778 2778 2778 2778 2778 1746 1746 1746 1746 1746 1746 3300 2750 2750 2750 2750 2750 2750 2750 2750 2750 2750 3070 2750 2750 2750 2750 2750 2750 3070 3070 3070 speed P .5.0. 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 0,4 0,4 0,4 0,4 0,4 1,0 1,0 1,0 1,0 1,0 1,0 0,5 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 speed I .5.1. 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,01 0,01 0,01 0,01 0,01 0,02 0,02 0,02 0,02 0,02 0,02 0,02 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 motorcurrent .5.7. 4,9 4,9 4,9 4,9 4,9 4,9 7,5 4,9 4,9 4,9 4,9 4,9 0,71 0,71 0,71 0,71 0,71 0,9 0,9 0,9 0,9 0,9 0,9 0,86 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 2,9 4,9 4,9 4,9 dyn. current factor .5.8. 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 100 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 J Page 65
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Typ Mat. No. Watts motion range total .2.5. AG 4671 AG 4671 AG 4671 AG 4671 AG 4671 AG 4671 AG 4671 AG 4691 AG 4691 AG 4691 AG 4691 AG 4691 AG 4691 AG 4699 BC 1103 BT 25 DR 1272 DR 1275 DR 2272 DR 2275 DR 2399 DR 2472 DR 2472 DR 2472 DR 52 SW 95.. VE 5016 VG 1403 VG 1404 VG 1404 VG 1404 VG 1404 VG 1404 VG 1404 VG 1404 VG 18 VS 35 VS 36 VS 50 VS 60 VS 90 326900 220745 219700 216764 305383 332835 335093 307742 311959 311808 311960 311957 311961 311809 311962 230562 230563 231350 230564 230565 230135 309000 80 80 80 80 80 80 80 80 80 80 80 80 80 80 40 80 20 20 20 20 36 80 80 80 40 40 40 40 20 20 20 100 100 100 40 80 20 20 35 30 80 100 150 150 200 200 300 300 50 100 100 150 200 200 38 20 20 20 20 40 20 30 40 34-50 150 700 50 100 150 200 150 100 74 100 110 encoder rotation resolugear tion .3.4. 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 500 500 500 500 100 500 500 500 8 8 8 8 8 8 8 8 8 8 8 8 10 10 8 8 8 .3.5. 25,14:1 11:1 25,14:1 11:1 25,14:1 11:1 25,14:1 11:1 11:1 25,14:1 11:1 11:1 25,14:1 11:1 8:1 16:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 8:1 8:1 8:1 20,25:1 8:1 8:1 8:1 16:1 16:1 16:1 8:1 64:1 48,2:1 48,2:1 64:1 288:1 16:1 linear gear .3.6. 5 5 5 5 5 5 5 5 5 5 5 5 5 6 5 100,0 2,5 2,5 2,5 2,5 2 2 2 2 5 5 5 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4 77 77 125 300 5 max. motor speed .4.8. 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 3070 2750 3070 1746 1746 1746 1746 1925 3475 3475 3475 2750 2750 2750 2750 3300 3300 3300 3070 3070 3070 2750 1897 2750 2750 3300 3300 3070 speed P .5.0. 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 1,0 1,0 1,0 1,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 0,5 0,5 0,5 2,0 2,0 2,0 1,0 2,0 0,5 0,5 2,0 2,0 2,0 speed I .5.1. 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,02 0,02 0,02 0,02 0,10 0,10 0,10 0,10 0,10 0,10 0,10 0,1 0,02 0,02 0,02 0,10 0,10 0,10 0,02 0,10 0,02 0,02 0,10 0,10 0,10 motorcurrent .5.7. 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 4,9 2,9 4,9 0,9 0,9 0,9 0,9 1,65 3,3 3,3 3,3 2,9 2,9 2,9 1,9 0,9 0,9 0,9 4,9 4,9 4,9 2,9 2,95 1,0 1,0 2,7 2,7 4,9 dyn. current factor .5.8. 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 100 100 150
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7. Technical data
Operating voltage Nominal value Nominal range (including ripple) Power input without motor/sensors with motor (maximum) Current input without motor/sensors with motor (maximum) Output voltage at motor terminal Maximum output current without additional fan with additional fan Ambient temperature Protection class CAN bus CAN bus level CAN baud rate
24 V DC 20 - 30 V DC
4,8 W 180 W 0,2 A 7.2 A 22 V (PWM) (PWM=pulse width-modulated) 5 A 7 A maximum 50 C IP 00
+ 5 V (potential-free) 250 KBaud
Sound level digital inputs terminal X 4.1 / 4.4 / 4.7 / 20.2 / 3.2 Low "0" 0 to 3 V DC High "I" 10 to 30 V DC Incremental encoder frequency maximum 5 kHz Digital output terminal X 20.4 Output current maximum 0.1 A PNP Sensor connector X 5/X 6 Output voltage 24 V DC Output current maximum 0.5 A Technical data subject to modification without notice
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Postfach 10 15 40 D-86136 Augsburg Telephone (0821) 24 35-0 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
Description V
CAN bus, serial bus
CAN bus, serial bus

1. Safety 2. Type overview 3. Function 3.1 CAN bus networking 3.2 CAN bus organisation 3.3 Serial bus 3.4 Application examples 3.5 CAN bus adapter EK 4... 3.6 CAN bus gateway 4. Technical data 2 2 3 3 3 4 5 7 7 7
en
ARCNET
/ Interbu
sS
Bus SPS PC CAN CAN CAN
S CAN-BU
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CAN bus, serial bus Explanation of symbols jobs to be performed important information and instructions
1. Safety
Intended usage The bus systems (CAN bus and serial bus) are designed for connecting individual E+L control components and networking control loops. Description Keep the above in a safe place, accessible to personnel at all times. Installation Run bus lines away from noisy or heavy current carrying cables (e.g. motor cables). Please ensure when running bus lines that the insulation is not damaged and lines correctly secured and protected. The CAN bus must not be longer than 160 m, the serial bus 0.5 m.
2. Type overview
CAN bus cards CAN bus gateway (Connection to other bus systems ) Serial bus cards Expansion cards
Control card RK 4.... Central unit ZC 4... Digital interface DI .... Operator panel RT.. Logic card LK 4... Analog card AK 4... Power unit PK 40..
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CAN bus, serial bus
3. Function
3.1 CAN bus networking Individual CAN bus cards are connected together by the CAN bus (see type overview). The CAN bus must not exceed a total length of 160 meters. A terminating resistor connector must be attached to both ends of the CAN bus. The CAN bus operates on the multi master principle.
CAN bus connection example Web guider Command station DO..
RK..
RK.. ZC.. ZC.. ZC..
PLC LK..
Terminating resistor connector
CAN bus line
Web guider
Main drive Command station DO..
RK..
RK..
ZC..
ZC..
CAN bus line
3.2 CAN bus organisation
Device no.DIP switches 1 - 4 Group no. DIP switches 5 - 7 Example: 5 0 1 2 3 4 5 6 7 8

ON OFF
In order to distinguish between the different CAN bus cards in a CAN bus system, each CAN bus card must have its own address. Setting is via a DIP switch on all CAN bus cards. The address is specified in the block diagram (on systems designed by E+L). The address consists of two parts: - the group number from 0 to 7 - the device number from 1 to F (hex) Example: Address 0.5 Address 2.5 0 = Grp no. 5 = device number 2 = group number 5 = device number
Binary value 1 2 4 8 1 2 4 DIP switches
Each address may only be used once!
V page 3
CAN bus, serial bus There can be a maximum of 8 groups and 15 devices per group in each CAN bus system (see illustration). All CAN bus cards belonging to one control loop get the same group number but different device numbers (see block diagram). Each device has its own parameter record for defining functions, for settings and optimisation etc.
Group 0
0.X Addresses in hex. 0.1 1.X 2.X
CAN-Bus
3.X 4.X 5.X 6.X
Group 7
7.X
serial bus Address 0.F hex. (device 15 group 0) Parameter list for device e.g. interface DI .. Busorganisation
Address 7.7 hex. Device 7 of group 7 (device 7, group 7)
Parameter list for the device 7 e.g. remote control DO ..
Each device (CAN bus card, serial bus card, sensors etc.)may be selected via command stations. The following device numbers are assigned as standard to the web guider and web tension controller families:
Device number 1 2 5 6 7 Web guider Web tension controller
Right sensor Left sensor Web guider (master device) Right support beam Left support beam
web guider (master device) I/O card Operator panel RT..
3.3 Serial bus
Serial bus cards(see type overview) are connected to a CAN bus card via a serial bus. As a rule, up to 8 serial bus cards can be connected to each CAN bus card. The CAN bus card automatically assigns addresses to the attached, serial bus cardcards. These addresses are also known as a "subsystem addresses". The automatically assigned address may already be assigned to a hardware-addressed CAN bus card. In this case the serial bus card must be assigned a free address in the appropriate parameter (see parameter list).
V page 4
CAN bus, serial bus The serial bus must not be longer than 50 cm. A terminating resistor connector must be attached to the end of the serial bus. The serial bus operates on the master-slave principle.
Serial bus CAN bus card e.g. address 0.5 RK.. or ZC.. serial bus Master Slave 1 .... Slave 8 serial bus card 0 subsystem address 0.6 CAN bus card address + 1 LK.. .... serial bus card 7 subsystem address 0.D CAN bus card address + 7 RT.. Serial bus terminating resistor connector
3.4 Application examples
CAN-Bus
1st example: connection of two web tension controllers DC 6... with a remote display DO...
Main drive
Web tension controller DC 6...
Remote display DO..
Group 0 Web tension controller DC 6...

serial bus terminating element Operator panel RT .. Address 0.7 serial bus terminating element Operator panel RT .. Address 1.7
Group 1 CAN bus CAN bus terminating resistor connector
CAN bus terminating resistor connector Remote display DO..

Serial bus
I/Ocard LK.. Address 0.6 serial bus Control card RK .. Address 0.5
I/O card LK.. Address 1.6 serial bus Control card RK .. Address 1.5
Command unit RT .. address 0.B serial bus Central processor ZC .. Address 0.A
Address list: Group 0 Web controller 0.5 (Control card RK = master device) I/O card LK 0.6 Command station RT 0.7 Remote display DO.. (for group 0 and 1) Central processor ZC Operator panel RT
0.A 0.B
CAN bus terminating resistor connector
CAN bus
CAN bus terminating resistor connector
Group 1 Web controller 1.5 (Control card RK = master device) I/O card LK 1.6 Command station RT 1.7
V page 5
CAN bus, serial bus 2nd example: networking of two web guiders DR.. with digital sensors and support beam VS... operated via an external PLC.
Group 0 Left support beam
Group 1 CAN bus
CAN bus terminating connector

RK..
Left sensor
RK..
RK.. RK..
CAN bus
RK.. RK..
CAN-Bus
Right sensor Web guider DR.. CAN bus Address list: Group 0 right digital sensor left digital sensor web guider (control card RK = master device) right support beam (control card RK) left support beam (control card RK) digital interface DI.. (for group 0 and 1) central unit ZC operator panel RT logic card LK logic card LK Group 1 right digital sensor left digital sensor web guider (control card RK = master device) right support beam (control card RK) left support beam (control card RK) Right support beam
0.1 0.2 0.5 0.6
CAN bus terminating connector Central unit ZC.. Address 0.8 serial bus Operator panel RT 4.. Address 0.9
Machine control cabinet 0.7
0.8 0.9 0.A 1.A
external control (PLC)
Logic card LK 4... Address 0.A
1.1 1.2 1.5 1.6 1.7
Logic card LK 4... Address 1.A serial bus terminating connector
digital interface DI..
V page 6
CAN bus, serial bus 3.5 CAN bus adapter EK 4...

LED EK 4...
A CAN bus card is generally connected to the CAN bus via CAN bus adapter EK 4... . The CAN bus connection consists of two 3-pole diode sockets bridged on the back of CAN bus adapter EK 4... . The LED indicates whether the CAN bus card is operating error-free. If it lights up green there is no malfunction, if it lights up red, there is a malfunction on the CAN bus card. A CAN bus terminating connector must be attached to each end of the CAN-Bus.
CAN bus connector CAN bus connector (exterior view) 2 GND (optional) 1 CAN + 3 CAN -
3.6 CAN bus gateway
The E+L CAN bus system can be connected to other bus systems via E+L DI .... digital interfaces. Descriptions are available for each DI interface.
4. Technical data
CAN bus CAN bus level 5 V (potential-free) CAN baud rate 250 Kbaud Serial bus Serial bus level 5V Synchronous baud rate 1.3 Mbaud Technical data subject to modification without notice
V page 7
Erhardt + Leimer GmbH Postfach 10 15 40 D-86136 Augsburg Telefon (0821) 24 35-0 Telefax (0821) 24 35-666
Ersatzteile X Spare Parts X Pices de Rechange X Stellantrieb Drive Unit Entranement AG 2671
309645 310834 060458 002466 3074612) 309152 307462 309117 309634 309635 3074562) 3074572) 3074582) 3074592) 3074602) 309650 082769 102821 102822 311257 311258 3118803) 3118813) 3118823) 3118833) 3118843) 3074511) 3074521) 3074531) 3074541) 3074551)
307444 307445 307446 307447 307448 307437 309119 307438
050347
4)
2126034) 2130124)
0,2 mm 038123 2143204)
5)
309287 310923 ERS--250372-DE/EN/FR-02
038149
Postfach 10 15 40 D-86136 Augsburg Telefon (0821) 24 35-0 Telefax (0821) 24 35-6 66 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com
307400
307463
Stellantrieb
002466 038123 038149 050347 060458 082769 102821 102822 212603 213012 214320 307400 307437 307438 307444 307445 307446 307447 307448 307451 307452 307453 307454 307455 307456 307457 307458 307459 307460 307461 307462 307463 309117 309119 309152 309287 309634 309635 309645 309650 310834 310923 311257 311258 311880 311881 311882 311883 311884 Rillenkugellager 6007 2RS Dichtring Verschlustopfen Schrgkugellager 30/62x16 DIN 628 Gelenkkopf Bolzen (Stellweg 50 mm) Bolzen (Stellweg 25 mm) Bolzen (Stellweg 75 mm) Gleichstrom-Getriebemotor i = 28:1 Gleichstrom-Getriebemotor i = 16:1 Magnetring Hlse Flansch Flansch Kugelgewindetrieb, komplett (25 mm) Kugelgewindetrieb, komplett (50 mm) Kugelgewindetrieb, komplett (75 mm) Kugelgewindetrieb, komplett (100 mm) Kugelgewindetrieb, komplett (150 mm) Abdeckung (Stellweg 25 mm) Abdeckung (Stellweg 50 mm) Abdeckung (Stellweg 75 mm) Abdeckung (Stellweg 100 mm) Abdeckung (Stellweg 150 mm) Hlse (Stellweg 25 mm) Hlse (Stellweg 50 mm) Hlse (Stellweg 75 mm) Hlse (Stellweg 100 mm) Hlse (Stellweg 150 mm) Gewindebuchse Ring Lagerbock Gleitlager Przisions-Nutmutter Abstreifer Inkrementalgeber Ring Platte Lagerbock Fhrung Bolzen Haube Bolzen (Stellweg 100 mm) Bolzen (Stellweg 150 mm) Nherungsinitiator (Stellweg 25 mm) Nherungsinitiator (Stellweg 50 mm) Nherungsinitiator (Stellweg 75 mm) Nherungsinitiator (Stellweg 100 mm) Nherungsinitiator (Stellweg 150 mm)
Drive Unit
Grooved ball bearing 6007 2RS Gasket Plug Angular ball bearing 30/62x16 DIN 628 Rod end bearing Pin (traverse 50 mm) Pin (traverse 25 mm) Pin (traverse 75 mm) D.C. geared motor i = 28:1 D.C. geared motor i = 16:1 Magnetic ring Sleeve Flange Flange Ball screw complete (25 mm) Ball screw complete (50 mm) Ball screw complete (75 mm) Ball screw complete (100 mm) Ball screw complete (150 mm) Casing (traverse 25 mm) Casing (traverse 50 mm) Casing (traverse 75 mm) Casing (traverse 100 mm) Casing (traverse 150 mm) Sleeve (traverse 25 mm) Sleeve (traverse 50 mm) Sleeve (traverse 75 mm) Sleeve (traverse 100 mm) Sleeve (traverse 150 mm) Insert Ring Bearing block Sliding bearing Precision-type groove nut Wiper Encoder Ring Plate Bearing block Guide block Bolt Cap Bolt (traverse 100 mm) Bolt (traverse 150 mm) Proximity switch (traverse 25 mm) Proximity switch (traverse 50 mm) Proximity switch (traverse 75 mm) Proximity switch (traverse 100 mm) Proximity switch (traverse 150 mm) 1) secure with Loctite 638 2) secure with Loctite 270 3) secure with Loctite 221 5) distance to highest component Subject to technical modications without notice
Entranement
Roulement rainur billes 6007 2RS Anneau dtanchit Bouchon Roulement oblique 30/62x16 DIN 628 Rotule Boulon (course 50 mm) Boulon (course 25 mm) Boulon (course 75 mm) Moteur-rducteur c.c. i = 28:1 Moteur-rducteur c.c. i = 16:1 Bague magntique Gaine Bride Bride Vis billes complet (25 mm) Vis billes complet (50 mm) Vis billes complet (75 mm) Vis billes complet (100 mm) Vis billes complet (150 mm) Recouvrement (course 25 mm) Recouvrement (course 50 mm) Recouvrement (course 75 mm) Recouvrement (course 100 mm) Recouvrement (course 150 mm) Gaine (course 25 mm) Gaine (course 50 mm) Gaine (course 75 mm) Gaine (course 100 mm) Gaine (course 150 mm) Douille lete Bague Semelle Palier glisseur Ecrou gorge Racleur Incrmenteur Bague Plaque Semelle Unit guideur Boulon Capot Boulon (course 100 mm) Boulon (course 150 mm) Commutateur de proximit (course 25 mm) Commutateur de proximit (course 50 mm) Commutateur de proximit (course 75 mm) Commutateur de proximit (course 100 mm) Commutateur de proximit (course 150 mm) 1) xer par du Loctite 638 2) xer par du Loctite 270 3) xer par du Loctite 221 4) bute du cot collecteur de l'axe rotor 5) distance jusqu llment le plus haut Sous rserve de modications techniques
1) mit Loctite 638 sichern 2) mit Loctite 270 sichern 3) mit Loctite 221 sichern 5) Abstand zum hchsten Bauteil Technische nderungen vorbehalten
4) kollektorseitiger Anschlag der Rotorachse 4) stop on collector side or rotor axle
SOUTH UNWINDER +5010P2
NORTH UNWINDER +5020P2
+5010T2
+5020T2
os
TO 5010P2
TO NORTH UNWINDER DC 0340
TO 5020P2
TO SOUTH UNWIND DC 9142
5010T2 MOUNTED ON 5030
FLEXIBLE CABLE
5010T1 SCRIM UNWIND CART

Manual: Order Number Order Part Doc-ID Language 229983 WS ADS - 229983#1 - 00

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Worldwide Service Centers

Documentation Intended use User groups Explanation of symbols Safety instructions

Specialist personnel, unskilled personnel, Instruction by the operating organization trainees

Erhardt + Leimer GmbH

Erhardt + Leimer GmbH

EMC info sheet

Cross section > 4 mm2

Command device DO .... in desktop housing

protected signal line

Protection with cable clamps

Cable clamp with a good grounding contact

Protection with cable screw ttings

metallic cable screw tting with a good grounding contact

Cable with window in the cable sheath

Erhardt + Leimer GmbH

RMA (Return Merchandise Authorization)

Werkanschrift: Leitershofen, Albert-Leimer-Platz 1, 86391 Stadtbergen

Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com

RMA (Return Merchandise Authorization)

equipment on loan basis warranty replacement spare parts for service

over delivery delivery was cancelled transport damage

Example: web guider WSS with reel station and sensor

2.3 Support beam (optional)

2.4 Digital controller

2.5 Command stations (optional)

3.2 Support beam (optional)

Press "Decrease value" to select the "Show Cannet" menu option.

Select the required option via the "Increase/Decrease value" keys.

4.3 Allocate password

Commissioning with command station DO 200.

5. Commissioning with command station DO 200.

5.1 Setting direction of web travel on the command station

Commissioning with command station DO 200.

Position the selection bar on "Service Functions". Press "Acknowledge" key.

Commissioning with command station DO 200.

24 0.0 0.0 1.0

Invert parameter value. Change "0" to "1", or Change "1" to "0"

Effec. dir. for automatic mode on a winder

Commissioning with command station DO 200.

Note parameter value displayed. e.g. 10.0 mm

The effective direction for the winder has been changed.

5.6 Special settings

Operation with command device DO 200.

6. Operation with command device DO 200.

6.1 Multi-operation (if featured)

6.2 Actuating element operation

Operation with command device DO 200.

Operation with command device DO 200. 7.3 Oscillation

Operation with command device DO 200.

Amplication right Amplication too low

Proportional range .1.3. prop range 2,0 3,5

control deviation Positioning velocity .1.6. velocity auto 20 mm/s

Set position (sensor measuring range center )

Control deviation of 1.5 mm

Maintenance / Technical data

Erhardt + Leimer GmbH

Infra-red edge sensor FR 5001 / FR 5021

Infra-red edge sensor FR 5001/FR 5021

2.1 Intended usage

LED strip display Socket

CAN 0.1(FR5001) 0.2(FR5001) 0.5(RK4004) (CenterSwitch) 0.6(RK4003) 0.7(RK4003) 0.A(ZC4071)