Operating manual en

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.
1. Function 3
2. Assembly 5
3. Installation 5
4. Setup mode 7
5. Commissioning with command station DO 200. 9
6. Operation with command device DO 200. 17
7. Optimization 21
8. Maintenance 23
9. Technical data 23

Component descriptions:
Sensor B
Sensor support beam C
Actuating element D
Command stations H
Digital interfaces (optional) I
Control card J
Electrical components (optional) U
CAN bus, serial bus V
Service manual (optional) W
Spare parts X
Parameter lists Y
Diagrams Z

ANL--251003-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 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.

Type overview The operating manual applies for web guiders with the following ac-
tuating elements:
- reel station WS

A page 2
 Function

1. Function
1.1 Purpose 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.

1.2 Design
Unwind station

Sensor

Support beam

Actuating element

Actuator

Wind station

Sensor

Support beam

Actuating element

Example: web guider WSS with Actuator

reel station, sensor and support beam
The web guider consists of the following components:
- two sensors for actual position value recording
- an actuating element (steering roller reel station) with actuator and
a return-to-center switch
- a motor-driven support beam VS ....
- a digital controller DC .... or SE .....

optional
- command station DO ....
- command 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 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.

1.3.1 Oscillation 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.

1.3.2 Width measuring The web width is displayed in mm in conjunction with command sta-
tion DO 01.. / DO 20.. or remote display DO 002. .

A page 4
 Assembly / Installation

2. Assembly Please observe the locally applicable and professional safety

and accident prevention regulations!

2.1 Actuating element  Mount actuating element according to attached description. See
also dimensioned or set-up drawing.

2.2 Sensors 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.

2.3 Support beam (optional) 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.

2.4 Digital controller 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.

2.5 Command stations  The command stations should be mounted in such a way that the
(optional) 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 sen-
sor description for exceptions.

3.2 Support beam (optional)  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.

Press "Decrease value" to se-

lect the "Show Cannet" menu
option.

To quit setup mode you must

select the "Keyboard" menu
option. Then press the "Ack-
nowledge" 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 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 () only
ledge" key . value" keys. 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 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.
Device address Device designation 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).

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 pass-
word entry. To assure that no unauthorised persons may enter setup
mode, we recommend that a password is defined as follows:
 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).
 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.

A page 8
 Commissioning with command station DO 200.

5. Commissioning There must not be anybody present in the web guider's dan-
ger area during commissioning or operation. Please observe
with command the locally applicable and customary safety and accident pre-
vention regulations.
station DO 200.
 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 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.

5.1 Setting direction of web

travel on the command
station
The direction of web travel arrow in the display on the command sta-
Direction of web tion must match the direction of web travel in the overall machine.
travel on the
This setting defines the allocation of the keys.
overall machine
If the arrow points in the opposite direction, the value in the param-
eter "arrow direction" in the command station must be inverted as
HELP follows:
F1

F 2

F 3

F 4

 Start Setup mode. Press "Acknowledge" key and also "Increase

+ value".
System-Menu
 Position selection bar on "Rescan Cannet".
Keyboard
Canmon
Show Cannet  Press "Acknowledge" key.
Rescan Cannet
Save Cannet EEProm
CAN Status
Check Power Supply

KAP--250974-EN-01 A Page 9
Commissioning with command station DO 200.

CAN
 Position the selection bar on the command station "*ZC 4071*".
0.1(FR5001)
0.2(FR5001)  Press "Acknowledge" key.
0.5(RK4...)
(Center Switch)
0.8(AK 4022)
0.A(*ZC4071*)
0.B(LK4203)

0.A (*ZC4071*)
 Position the selection bar on the parameter heading "keyboard
ZC 4071 settings".
keyboard settings  Press "Acknowledge" key.
width
user parameter
special keys

0.A (*ZC4071*)
 Position the selection bar on the parameter "arrow direction".
ZC 4071
keyboard settings
keyboard usage  Press "Acknowledge" key.
arrow direction
used sensor values
used add. values
width

0.A(*ZC4071*)
Invert parameter value. The actual state of the parameter is marked
arrow direction by a " * " in the parameter.
( * ) Normal  Position the selection bar on the value that is not in use.
( ) Inverted

 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 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".
System-Menu
 Position the selection bar on "Rescan Cannet".
Keyboard
Canmon
Show Cannet  Press "Acknowledge" key.
Rescan Cannet
Save Cannet EEProm
CAN Status
Check Power Supply

CAN
 Position the selection bar on the master device, address X.5.
0.1(FR5001) If two or more guiders are connected together on a network, at
0.2(FR5001) this point the required guider must be selected.
0.5(RK4...)
(Center Switch)
0.8(AK 4022)
0.A(*ZC4071*)
 Press "HELP" key.
0.B(LK4203)

0.5 (RK 4...)

 Position the selection bar on "Service Functions".
Set Address
Set Default
Error List  Press "Acknowledge" key.
Possible Errors
Properties
Service Functions
Reset

0.5 (RK 4...)

 Position the selection bar on "actuator calibr. 1".
camera cal. standard
camera cal. pattern
actuator calibr. 1  Press "Acknowledge" key.
support calibration
save back parameter
save parameter
device reset
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 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
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:
HELP

F1

F2

F3

F4

ESC

 Start Setup mode. Press "Acknowledge" key and also "Increase

+ value".
System-Menu
 Position the selection bar on "Rescan Cannet".
Keyboard
Canmon
Show Cannet  Press "Acknowledge" key.
Rescan Cannet
Save Cannet EEProm
CAN Status
Check Power Supply

CAN
 Position the selection bar on the master device, address X.5.
0.1(FR5001) If two or more guiders are connected together on a network, at
0.2(FR5001) this point the required guider must be selected.
0.5(RK4...)
(Center Switch)  Press "Acknowledge" key.
0.8(AK 4022)
0.A(*ZC4071*)
0.B(LK4203)

0.5 (RK 4...)

 Position the selection bar on the parameter heading "servo con-
RK 4004 figurate".
webedge offsets  Press "Acknowledge" key.
webedge controller
servo configurate
Pos. controller

0.5 (RK 4...)

 Position the selection bar on parameter "motion direction".
reserved 21
defect range ±  Press "Acknowledge" key.
servo configuration
motion direction
motion range total
positionrange +
positionrange -

A Page 12
 Commissioning with command station DO 200.

0.5 (RK 4...)

 Invert parameter value.
motion direction Change "0" to "1",
nb : 24 or
min : 0.0 Change "1" to "0"
def. : 0.0
max : 1.0

0
The effective direction has been changed.

 Leave Setup mode. Press "Center mode" key.

If the effective direction for the manual mode has been 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 For an unwinder it is not necessary to make any settings for the auto-
mode on an unwinder matic mode.
In the automatic mode the reel moves 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).

5.5 Effec. dir. for automatic On a winder the sensor is mechanically linked to the reel. The sensor
mode on a winder 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:

 Start Setup mode. Press "Acknowledge" key and also "Increase

+ value".
System-Menu
 Position the selection bar on "Rescan Cannet".
Keyboard
Canmon
Show Cannet  Press "Acknowledge" key.
Rescan Cannet
Save Cannet EEProm
CAN Status
Check Power Supply

A Page 14
 Commissioning with command station DO 200.

CAN
 Position the selection bar on the master device, address X.5.
0.1(FR5001) If two or more guiders are connected together on a network, at
0.2(FR5001) this point the required guider must be selected.
0.5(RK4...)
(Center Switch)  Press "Acknowledge" key.
0.8(AK 4022)
0.A(*ZC4071*)
0.B(LK4203)

0.5 (RK 4...)

 Position the selection bar on the parameter heading "webedge
RK 4004 controller".
webedge offsets  Press "Acknowledge" key.
webedge controller
servo configurate
Pos. controller

0.5 (RK 4...)

 Position the selection bar on the parameter "prop range ±".
webedge controller
prop range ±  Press "Acknowledge" key.
dual-rate width
dual-rate level
velocity auto The parameter value is displayed.
velocity pos
velocity jog

0.5 (RK 4...)

 Note parameter value displayed.
prop range ± e.g. 10.0 mm
nb : 13
min : -2000.0
def. : 10.0
max : 2000.0

10.0 mm

0.5 (RK 4...)

 Press "Decrease value" key until the original value with a nega-
prop range ± tive sign is displayed.
nb : 13
min : -2000.0
def. : 10.0 The effective direction for the winder has been changed.
max : 2000.0

-10.0 mm

If two or more digital guiders are connected together on a net-

work, 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 opti-
mized, see chapter "Optimization".

Commissioning is then complete for standard applications.

5.6 Special settings 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
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 Only insert web when the web guider and processing ma-
chine are switched off.
command de- Risk of injury!

vice DO 200.
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.
 Enable web guider operating voltage

6.1 Multi-operation
(if featured)

HELP
 Select multi-operation menu
F1
Press "F 4" to start the multi-operation menu. All groups featured
F2

F3
will be displayed.
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 indi-
vidual 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.

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-
User group bers indicate the groups selected.

6.2 Actuating element and

support beam operation
 Select actuating element menu
HELP

Press "F 2" until the following symbol (actuating element) is

displayed beside the key.
F1

F2

F3

F4

KAP--251002-EN-01 A page 17
Operation with command device DO 200.

HELP
 Select center mode
F1
The web control is switched off, the web guider positions itself at
F2

F3
the set center position. The sensors move to park position.
Before inserting a new web always set the actuating element to
F4

"center" mode first.

 Set web offset to "0"
HELP Press the "Increase/Decrease value" keys at the same time.
F1

F2

F3

F4

 Insert web

 Select required actuating element operating mode

Automatic, center position or manual mode.

- Manual mode: the actuating element may be positioned at the re-

HELP

quired location via the "Increase/Decrease value" keys.

F1

F2

F3

F4

- Automatic mode: the sensors position themselves at the web

HELP

edge. The web guider is enabled when the sensors have reached
F1

F2
their web edge position. If the guider block is not connected, the
F3

F4
web guider will go into automatic mode immediately.

 Set web offset

HELP

Use the "Increase/Decrease value" keys in automatic mode to set

a web offset.
F1

F2

F3

F4

7.3 Oscillation
 Select oscillation menu
Press "F 3" to start the oscillation menu for entering the oscillation
HELP

F1

F2

F3
stroke and time.
F4

 Switch oscillation ON/OFF

Press "Increase/Decrease value" to switch oscillation ON/OFF, the
switch status is indicated on the display.

A page 18
Operation with command device DO 200.

 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.
HELP  Quit the oscillation menu
F1
Press "Acknowledge" again to quit the oscillation menu.
F2

F3

F4

A page 19
Operation with command device DO 200.

A page 20
 Optimization

7. 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
7.1 Optimization premises sensitivity, the guider will overshoot as well. In the case of too little
amplification the control loop will be too slow. Optimum amplifica-
Amplification too high
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
Amplification right to shortly cover up the sensor measuring range (with a piece of
Amplification too low 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 .1.3. prop range ±
positioning velocity 2,0 3,5
depending on propor-
tional range
15 mm/s
8 mm/s

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

Set position
(sensor measuring range Control deviation of
center ) 1.5 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

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 1/s G = 20/3,5 = 5,71 1/s
VK = 1,5 mm * 10 1/s VK = 1,5 mm * 5,71 1/s
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.

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 de-
viated 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 Maintenance may only be performed when the web guider

and processing machine are switched off .

8.1 Sensor  See sensor description.

8.2 Support beam (optional)  See support beam description.

8.3 Actuating element  See actuating element description.

9. Technical data The technical data depend on the devices implemented and are spe-
cified 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