Operating manual
Contents
1. 7 Io x m x n A EI Y Ee SHE ns DES System Menu Keyboard Canmon Show Cannet Rescan Cannet CAN Status Save Cannet EEProm Check Power Supply CAN 0 1 FR5001 0 2 FR5001 0 5 RK4 Center Switch 0 8 AK 4022 0 A ZC4071 0 B LK4203 5 RK 4 RK 4004 webedge offsets servo configurate Pos controller Fas webedge controller motion range total positionrange 5 RK 4 reserved 21 defect range servo configuration motion direction positionrange A Page 12 L DB D N N L LD 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 rota tion of the motor must be inverted gt Start Setup mode Press Acknowledge key and also Increase value Position the selection bar on Rescan Cannet Press Acknowledge key 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 con fig2. Operating manual Digital web guider WSS Hybrid guiding web center with motor driven sensor positioning device VS with position controller DC 03 DC 23 and command device DO 200 Function Assembly Installation Setup mode Commissioning with command station DO 200 Operation with command device DO 200 1 Optimization 21 Maintenance 23 Technical data 23 N OO N 01 O01 ce IPS Component descriptions Sensor Sensor support beam Actuating element Command stations Digital interfaces optional Control card Electrical components optional CAN bus serial bus Service manual optional Spare parts Parameter lists Diagrams NI lt x s lt clel T oo0w ANL 251003 EN 01 Operating instruction notes Explanation of symbols Operating manual structure Type overview A page 2 jobs to be performed IT important information and instructions sections of the manual due particular attention to assure the e Safe operation of the web guider 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 diag
3. DO 200 A page 20 7 Optimization 7 1 Optimization premises Amplification too high Amplification right Amplification too low Optimization 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 amplifica tion may be determined with a characteristic curve tracer In prac tice amplification 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 fur ther data on the amplification The smaller the set proportional range at a constant maximum po sitioning 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 Proportional range established correction N 1 3 prop range 2 0 3 5 positioning velocity depending on propor 257 tional range 20 i 15 mm s 5 7 8 mm s 107 gt Pi 4 3 2 Y 23 4 control devi
4. in the direction of the free sen sor if a sensor is free one sensor covered one sensor free On an unwinder the parameter value for P13 prop range on the control card must have a positive sign no sign On a winder the sensor is mechanically linked to the reel The sensor is therefore positioned with the reel In the automatic mode the reel moves in the direction of the web if a sensor is free one sensor covered one sensor free On a winder the parameter value for P13 prop range on the control card must have a negative sign no sign Check the setting gt 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 Ne la 0 5 RK 4 RK 4004 webedge offsets webedge controller servo configurate Pos controller S 0 5 RK 4 webedge controller prop range dual rate width dual rate level velocity auto L lt velocity pos velocity jog Ne J a N 0 5 RK 4 prop range nb 13 min 2000 0 def 10 0 max 2000 0 10 0 mm el N 0 5 RK 4 prop range nb 13 min 2000 0 def 10 0 max 2000 0 10 0 mm _ gt D N L ie Commissioning with command station DO 200 Position t
5. 20 3 5 5 71 VK 1 5 mm 10 VK 1 5 mm 5 71 VK 15 mm 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 im mediately Reduce the proportional range until the guider starts to oscillate The increase the proportional range again until no more oscillation may be observed Select operational mode Automatic gt Select parameter 1 3 prop range gt 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 de viated so that oscillation is detected immediately Leave the setup mode after setting the proportional range select the equipment address of the relevant web guider before If two or several digital controllers are networked it is necessary to selecting the parameter see chapter Setup Editor 8 Maintenance 8 1 Sensor 8 2 Support beam optional 8 3 Actuating element 9 Technical data Maintenance Technical data Maintenance may only be performed when the web guider e and processing machine are switched off gt See sensor description gt See support beam description gt See actuating element description The technical data depend on the devices implemented and are spe cifi
6. ating 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 6 Operation with command de vice DO 200 6 1 Multi operation if featured JAMAIS INI 6 2 Actuating element and support beam operation Operation with command device DO 200 Only insert web when the web guider and processing ma chine 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 se quence is to be applicable must be selected via the multi opera tion function gt Enable web guider operating voltage gt Select multi operation menu Press F 4 to start the multi operation menu All groups featured will be displayed gt 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 indi vidual groups one after another via the Decrease value key and make your selection Quit multi operation menu Press Ac
7. ation Positioning velocity 1 6 velocity auto 29 20 mm s 257 Y u REE x am See l iy RS un U SUDAAN a IT DOUSWNN_O 7 foe i di ar gt Baer i Set position sensor measuring range Control deviation of center 15 mm 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 actua tor may be determined on the basis of the characteristic curve re gardless of the control deviation KAP 250547 EN 01 A page 21 Optimization 7 2 Optimizing the proportional range A page 22 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 Amplification G parameter 1 6 Parameter 1 3 Correction velocity VK control deviation amplification G Example 1 Example 2 G 20 2 10 G
8. ctuator calibr 1 support calibration save back parameter save parameter device reset WB E N Z HELP t lt Commissioning with command station DO 200 During the initialization run the guider detects the two mechanical end points actuator stop and the actuator limit switches These po sitions 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 gt Press Acknowledge key 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 gt Press HELP key Position the selection bar on Service Functions Press Acknowledge key Position the selection bar on actuator calibr 1 gt Press Acknowledge key The actuator s initialization run is performed gt Leave Setup mode Press Center mode key If two or more digital guiders are connected together on a net work this chapter must be undertaken for each guider installed A Page 11 Commissioning with command station DO 200 5 3 Checking effective direc tion for manual mode
9. ecrease value keys ES The parameter value may be changed via the Increase Decrease value keys mn inc h key filter customer FIN u m La ie kn a an sd Fo i direction used devices width 2C4678 6662F_2_ 6 Normal Right dInverted Lett Select the required para To change a parameter Select the required A tick is set via the Ack meter via the Increase the latter must be ope option via the In nowledge key With Decrease value keys ned via the Acknow crease Decrease round brackets X only ledge key value keys one menu option may be selected with square brackets W several KAP 250211 EN 01 A page 7 Setup mode 4 2 Important additions Device address Device designation 4 3 Allocate password A page 8 The following two options are available to quit setup mode 1 Jump back in the menu to the start window as described in sec tion 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 CANMON may only be called up once either via the CANMON program or command station DO 200 A flashing device address means that two devices are featured in the CAN network with the same device address If the device designation flashes the device is not featured is not identified via CANMON All settings in setup mode may be protected by a freely
10. ed in the relevant descriptions Technical data subject to modification without notice KAP 250502 EN 01 A page 23 Erhardt Leimer GmbH 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
11. er special keys 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 A Page 10 Position the selection bar on the command station ZC 4071 4 oe gt Press Acknowledge key Position the selection bar on the parameter heading keyboard settings Press Acknowledge key Position the selection bar on the parameter arrow direction Press Acknowledge key Invert parameter value The actual state of the parameter is marked bya in the parameter Position the selection bar on the value that is not in use gt Press Acknowledge key The changes to the parameter value selected The direction of web travel has been changed on the command station gt Leave Setup mode Press Center mode key 5 2 Actuator initialization run 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 RK4 Center Switch 0 8 AK 4022 0 A ZC4071 0 B LK4203 5 RK 4 Set Address Set Default Error List Possible Errors Properties Service Functions Reset U A 5 RK 4 camera cal standard camera cal pattern a
12. he 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 Position the selection bar on the parameter prop range Press Acknowledge key The parameter value is displayed gt Note parameter value displayed e g 10 0 mm gt Press Decrease value key until the original value with a nega tive sign is displayed The effective direction for the winder has been changed If two or more digital guiders are connected together on a net work this chapter must be undertaken for each guider installed gt Leave Setup mode Press Center mode key A Page 15 Commissioning with command station DO 200 5 6 Special settings A Page 16 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 opti mized see chapter Optimization Commissioning is then complete for standard applications If necessary the settings for the following functions can be re ferred 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 Actu
13. knowledge to quit the multi operation menu The group selected by the selection bar prior to quitting the menu is now selected as user group The first number indicated in the Group display represents the user group The remaining num bers indicate the groups selected gt Select actuating element menu Press F 2 until the following symbol actuating element is displayed beside the key KAP 251002 EN 01 A page 17 Operation with command device DO 200 gt Select center mode The web control is switched off the web guider positions itself at the set center position The sensors move to park position Before inserting a new web always set the actuating element to center mode first gt Set web offset to 0 Press the Increase Decrease value keys at the same time gt Insert web gt Select required actuating element operating mode Automatic center position or manual mode Manual mode the actuating element may be positioned at the re A quired location via the Increase Decrease value keys Automatic mode the sensors position themselves at the web edge The web guider is enabled when the sensors have reached their web edge position If
14. ler 2 5 Command stations optional 3 Installation 3 1 Sensor 3 2 Support beam optional Assembly Installation Please observe the locally applicable and professional safety e and accident prevention regulations gt Mount actuating element according to attached description See also dimensioned or set up drawing The sensors are pre mounted on the actuating element Sensor sup port beam In exceptional cases see sensor and actuating element descriptions application instructions section The support beam is pre mounted on the actuating element In ex ceptional 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 appli cation 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 gt 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 Please observe the locally applicable and professional safety e and accident prevention regultions gt Run electrical leads accordi
15. ng to the attached wiring diagram gt No installation work is requried for compact systems See the sen sor description for exceptions gt No installation work is required for compact systems See the de scription Suppor beams for exceptions KAP 250504 EN 01 A page 5 Assembly Installation A page 6 Setup mode 4 Setup mode Setup settings should be performed by qualified 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 modifiable pa rameter values also changed by each device featured in the CAN 4 1 Basic operation in setup network mode 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 In crease Decrease value keys Press F2 to select each indivi dual place an Cannet Cannet EEPROM ota tus din EEE Press Decrease value to se lect the Show Cannet menu alici Sho i annet escan Kanne Rescan arnet Sat re C Baik FEPROM Save net EEPROM Can Status an Fa atus Check Power Supply Je To quit ur oda you must select the Keyboard menu option Then press the Ack nowledge key Select the required device via the Increase D
16. ntion regulations gt Check the individual connecting cables are correct gt Connect all the web guider s equipment to the operating voltage gt Check CAN bus connections The light emitting diodes for the CAN bus connections on the web guider and the command sta tions illuminate green i e ready If a light emitting diode illumi nates 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 mechani cal assembly as well as the correct CAN addressing of the indi vidual components The direction of web travel arrow in the display on the command sta tion must match the direction of web travel in the overall machine This setting defines the allocation of the keys If the arrow points in the opposite direction the value in the param eter arrow direction in the command station must be inverted as follows Start Setup mode Press Acknowledge key and also Increase value Position selection bar on Rescan Cannet Press Acknowledge key KAP 250974 EN 01 A Page 9 Commissioning with command station DO 200 CAN 0 1 FR5001 0 2 FR5001 0 5 RK4 Center Switch 0 8 AK 4022 0 A ZC4071 0 B LK4203 i _ _ _______ _ y di N 0 A ZC4071 ZC 4071 keyboard settings width user paramet
17. ram includes a schematic of your system The block diagram also includes the address settings in the case of web guid ers designed by E L See the parameter lists for explanations of the individual setup parameters See Setup editor section 4 for procedure on check ing changing parameters The operating manual applies for web guiders with the following ac tuating elements reel station WS 1 Function 1 1 Purpose 1 2 Design Example web guider WSS with reel station sensor and support beam Function The web guider positions the moving web according to the web cen ter It corrects deviations from the set position and thus prevents it wandering off to the side Web oscillation within the operating range of the actuating element and width measuring are possible Unwind station Sensor Support beam Actuating element Actuator Wind station Sensor Support beam Actuating element Actuator The web guider consists of the following components two sensors for actual position value recording anactuating element steering roller reel station with actuator and a return to center switch amotor driven support beam VS a digital controller DC or SE optional command station DO command
18. selected password Settings in setup mode are only possible following pass word entry To assure that no unauthorised persons may enter setup mode we recommend that a password is defined as follows gt Start setup mode Select the customer PIN parameter in the device ZC 4070 and enter a five 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 gt Quit setup mode Should unauthorised persons attempt to establish the password by entering numbers after the third entry of an incorrect pass word setup mode is inhibited and in addition a commentary ente red in the error memory Switch off the power briefly on command station DO 200 to re enable it 5 Commissioning with command station DO 200 5 1 Setting direction of web travel on the command station Direction of web travel on the overall machine a N System Menu Keyboard Canmon Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply Commissioning with command station DO 200 There must not be anybody present in the web guider s dan e ger area during commissioning or operation Please observe the locally applicable and customary safety and accident pre ve
19. station NT web offsetting command station RE digital interface DI e g CAN SPS CAN ARCNET CAN INTERBUS KAP 250967 EN 01 A page 3 Function 1 3 Operating principle 1 3 1 Oscillation 1 3 2 Width measuring A page 4 To insert the web move the actuating element to its center position and drive the sensors to their outer position Once the web is insert ed drive the sensors to the web edge If the web guider is in auto matic and the guider stop contact is enabled the web is guided The sensors follow up in the event of web width deviations The sensor scans the web edge If the web edge deviates from its set position the sensor sends the magnitude and direction of the de viation to the digital controller for evaluation The position controller corrects the web edge back to its set position via the actuating ele ment The oscillating function is used to offset the web to the left right of the set position Use command station DO 01 DO 20 or the setup pa rameters to set the oscillating time and stroke With path dependent oscillation the oscillating time and stroke can be specified by the cus tomer reel station controls The web continues to be guided during oscillation The web width is displayed in mm in conjunction with command sta tion DO 01 DO 20 or remote display DO 002 2 Assembly 2 1 Actuating element 2 2 Sensors 2 3 Support beam optional 2 4 Digital control
20. the guider block is not connected the web guider will go into automatic mode immediately gt Set web offset Use the Increase Decrease value keys in automatic mode to set a web offset 7 3 Oscillation Select oscillation menu Press F 3 to start the oscillation menu for entering the oscillation n stroke and time a ode gt Switch oscillation ON OFF Changierung EEE Press Increase Decrease value to switch oscillation ON OFF the Amplitude 22 mm Zeit 27 s switch status is indicated on the display A page 18 Operation with command device DO 200 gt 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 gt Enter time Press the acknowledge key again to enter the time oscillation time for a cycle via the Increase Decrease value keys n gt Quit the oscillation menu Press Acknowledge again to quit the oscillation menu E N x INIL Ri BEBE o RO 4 i Y Kine N A page 19 Operation with command device
21. urate Press Acknowledge key Position the selection bar on parameter motion direction Press Acknowledge key Commissioning with command station DO 200 di N 0 5 RK 4 gt Invert pat nisi valle motion direction Change 0 to 1 nb 24 or min 0 0 Change da to o def 0 0 Max 1 0 0 I The effective direction has been changed Ic gt Leave Setup mode Press Center mode key If the effective direction for the manual mode has been in verted chapter 5 2 must be performed again If two or more digital guiders are connected together on a net work 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 5 mode on a winder 5 Effec dir for automatic to T h e System Menu Keyboard Canmon Show Cannet Rescan Cannet Save Cannet EEProm CAN Status Check Power Supply A Page 14 For an unwinder it is not necessary to make any settings for the auto matic mode In the automatic mode the reel moves
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