ekrProCom60 en PDF

BST Web Guiding System
60
ekrPro Com
with analog sensors
BST International GmbH

Heidsieker Heide 53
33739 Bielefeld, Germany
Tel: +49 5206/999-0

Fax: +49 5206/999-999
e-mail: info@bst-international.com
ekrPro Com60 web guide controller EDV-No.: MD.191.01.05/1.6.x

with analog sensors Date: 23.11.2007
Symbols used in this operating manual
Warning signs
Symbols are used in this operating manual in order to clearly
indicate particularly important places.
Attention!
! You must obey this type of warning, in order to protect

yourself, as the operator, from bodily injuries arising
from mechanical movements.
Beware!
You must obey by this type of warning without fail, in
order to protect yourself, as the operator, from life
threatening injuries caused by electrical voltages.
Note
This symbol is used to point out additional useful tips,
which will help you to make optimum use of all of the
functions.
Using the keys

Using the keys is represented by the following symbols in this
manual:
Press key.
+ Key combinations, keys have to be

pressed simultaneously.
Press keys in the specified order.

1) 2)
LED operating status
indications
Some keys on the front panel of the ekrPro Com60 controller have
LED´s (light-emitting diodes) integrated in them. The different LED
operating states are represented as follows:
LED off
LED constantly lit = activated phase
LED flashing
ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x

Contents
Symbols used in this operating manual
Table of contents
Section A General information
Section B Commissioning
Section C Operation
Section D Appendix

ekrPro Com60
with analog sensors
Section A
General information
A1 Description
A2 Specifications
A3 Transport / Storage
A4 Decommissioning

Contents
Section A
General information
Symbols used in this manual
Table of contents
A1 Description A1-1
A 1.1 General information A1-1
A 1.2 Utilisation A1-1
A 1.3 Housing versions A1-1
A 1.4 General definitions A1-2
A 1.4.1 Assignment of sensors to the guiding mode A1-2
selection keys
A 1.4.2 Inverting of the sensor signal A1-3
A 1.4.2 Size of oscillation amplitude related to sensor
scanning area A1-3
A 1.4.2 Oscillation types and curves A1-4
A 1.4.2 Allocation of FVGs for a FVGPro 2MK A1-4
A 1.5 Connectable components A1-4
A 1.6 Safety information A1-5
A 1.7 Emissions A1-5
A2 Specifications A2-1
A 2.1 ekrPro Com60 controller (version XT) A2-1
A 2.2 Optical edge sensor IR2001, IR2005 A2-3
A 2.3 Optical edge sensor IR2002 A2-3
A 2.4 IRS-U-2 A opto-electronic analog sensor A2-3
A 2.5 Ultrasonic edge sensor US2003, US2007, US2008 A2-4
A 2.6 Reflecting sensor TW 54 C 5 A2-4
A 2.7 Line sensor T 62 D 1 A2-5
A 2.8 Reflected light measuring light barrier R 42 D ... A2-5
A 2.9 Photoelectric fork sensor G 53 C2/5 A2-6
A 2.10 Switched power pack A2-7
A3 Transport / Storage A3-1
A4 Decommissioning A4-1

with analog sensors Date: 23.11.2007 Page: 1/1
Description A1
The start-up, maintenance and installation

! instructions described in this operating manual
must be strictly adhered to!
A 1 Description
The aim of the operating manual is to enable you to use the
guiding system rapidly by explaining the basic settings for initial
start-up (start-up menu) and the conventional functions for
operation. In addition, the complex functions will be described
using selected examples for setting certain parameters.
A 1.1 General information
This family of control systems includes:
• ekrPro Com60: Controller with keyboard
• ekrPro Key60: External control keyboard.
Devices in the controller family can be interconnected at different
levels into a system network via a CAN-Bus.
A 1.2 Utilisation
The ekrPro Com60 is a microprocessor controlled web guiding
controller. Together with other BST components it may be used for:
• Web edge guiding (right or left)

• Web center guiding
• Guiding on continuous or interrupted printed lines
• Guiding on continuous or interrupted printed edges (still
being prepared)
• Web width measuring
The controller includes a separate control unit that can directly

control the sensor adjustment unit and it can be interconnected into
the system.
Any other utilisation must first be authorised by the manufacturer.
There are also standard PLC compatible inputs and outputs as well
as an OK-reporting system present.
A 1.3 Housing Versions

The control unit ekrPro Com60 is available in two different housing
versions:
• ekrPro Com60 XT: Mounting unit

(e.g. for wall mounting)
• ekrPro Key60 Desk XT: Built-in unit
(e.g. for insertion in a
control console)
ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A1

Description A1
A 1.4 General
Settings
A 1.4.1 Assignment of sensors to the

to the scanning mode selection keys
In this operating manual, the edge sensors that are connected to

the controller are designated with “sensor 1” and “sensor 2”. On
the operating keyboard of the controller, the guiding mode
selection keys have the lettering „SENSOR LEFT“ and „SENSOR
RIGHT“ respectively.
According to the BST definition, the following link applies:
SENSOR LEFT = Sensor 1
SENSOR RIGHT = Sensor 2
The following is valid in respect of the sensor mounting positions:
The sensor, which is located to the left of the material in the

web movement direction (when looking from the material top
side), is sensor 1.
The material top side is the side of the material web which is not in
direct contact with the deflection pulleys of the pivoting frame.
Example 1: Example 2: Example 3:

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

(Sensor 1) (Sensor 1)
Sensor right
(Sensor 2)
As standard, sensor 1 (Sensor left) must be connected to

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

Description A1
A 1.4.2 Inverting of the

sensor signal
If a BST edge sensor, of typical C-design, is mounted according to
the BST definition (see section A 1.4.1) as "Sensor left" (sensor 1),
then no inversion of the sensor signal is necessary.
If a BST edge sensor is mounted according to the BST definition
as "Sensor right" (sensor 2), then inversion should be activated via
the setup menu (see section B 3.4.4.3.1).
When the control units is delivered, inversion of the

sensor signal for sensor 2 is activated (factory setting).
Sensor left
Not permitted:
► Sensor:
Invert!
(Sensor looks to the left in the

direction of travel.)
A 1.4.3 Size of oscillation amplitude

related to sensor scanning area
0% 100 % Sensor coverage

30 % 70 %
Centre of sensor scanning area (visual range).
Oscillating web position
100 % of the sensor visual range

80 % of the sensor visual range =
maximum oscillation amplitude
40 % of the sensor visual range
The maximum possible oscillation amplitude is 80% of the sensor

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

Description A1
A 1.4.4 Oscillation types and curves
An oscillation can be implemented either as a sensor oscillation or

an FVG oscillation.
In the case of the sensor oscillation, the curve described is a delta
function.
The FVG oscillation describes a curve in accordance with a sine
function.
Selections and settings are described under Point B 3.7.5.8.2.
A 1.4.5 Allocation of FVGs for a FVGPro 2MK
Traverse the FVG using the

appropriate key in the menu window
<<< >>>
>>> <<<
FVG 1
>>> <<<
Web travel direction <<< >>>
FVG 2
internal
limit switch
external
limit switch
A 1.5 Connectable
components
The general plan (annex C2) shows the components that can be
connected to the ekrPro Com60 controller.

Description A1
A 1.6 Safety information

The safety relevant information in accordance with DIN EN 294,
DIN EN 349 and the industry specific safety regulations must be
taken into consideration when installing the BST equipment in the
production machine, these include:
• There must be a safe distance between the BST equipment and
the machinery already installed on-site, such as machine
panels, building structure, etc.
• The interconnecting lines between the control equipment and the
control components or edge sensors must be laid so that nobody
can trip over them, they are not taught and they are well
anchored.
• Ensure that there is sufficient free headroom.
If the free passage is restricted, the relevant building
components causing the restrictions must be padded and a
danger warning signs must be attached to them (yellow/black).
Only trained specialist personnel are permitted to
! undertake the assembly, installation and

commissioning!
Before starting work, ensure the equipment is
electrically isolated. To this end always carry out the
following measures:
1. Switch off
2. Prevent switching back on.
3. Check the equipment is isolated.
4. Earth.
5. Cover or shield any adjacent parts that are still live.
The mains power must always be switched off before
the equipment is opened.
If it becomes necessary to work on the open equipment
with voltage applied, then only Protection class IP 20 is
provided.
There is always increased danger because of the mains
voltage!
Do not use the chassis or machine frame as a climbing

! aid or a stepladder.
Do not remove any of the safety devices.
Positioning movements will be undertaken by the
! actuator during functional testing away from the

production machine and/or during the commissioning!
The relevant safety arrangements must implemented
during performance checks!
Monitor the overall safety concept of the production
machine during commissioning!
• Any transport safety devices that were used must be removed

prior to commissioning.
A 1.7 Emissions
The A-rated equivalent continuous sound level of the equipment is
less than 70 dB(A).
Specifications A2
A 2 Specifications
A 2.1 ekrPro Com60 controller (version XT)
Power supply 24V DC ± 5%

Power consumption 4W (without motor)
Input capacitance approx. 950µF
Controller inputs 2 x sensors, -9,75 V ...+9,75 V oder 0 V ...+9,75 V

12 bit selectable via software.
1 x sensor, -10,3 V to +10,3 V, 12 bit
1x EFE pot, -10,3 V to +10,3 V, 12 bit
1x pot return, -10,3 V to +10,3 V, 12 bit
1 x tacho, -9,0 V to + 9,0 V
1x blocking, input resistor 4.7 KΩ, operating points (<4 V (low)
and >8 V (high)), but can only be used against “+“ switched
sensors (pnp)
FVG inputs 1x blocking, no metallic separation
2x reference switch, no metallic separation
input resistor 4.7 KΩ,
operating points (<4 V (low) and >8 V (high)),
but can only be used against “+“ switched sensors (pnp),
supply 24V DC
Digital inputs 12x digital inputs, no metallic separation,
input resistor 4.7 KΩ,
operating points (<4 V (low) and >8 V (high)),
but can only be used against “+“ switched sensors (pnp),
supply 24V DC
Power supply outputs 2 x 24V (for CCD Pro camera)

Controller outputs Controller outputs -10.3V to -10 V, 12 bit 1x analog output
-10 V to +10 V, 2 mA
2x IR pulses
1x lamp supply 5 V, 1 A
Digital outputs 4 x digital outputs +24V, 1.0A per output, 1.5A in total
No metallic separation.
Protected against feedback (positive voltage)
Controller output stage 1x DC motor 24V DC, max. 3 A, short circuit protected.
Select voltage, current or tachometer control (in preparation)
PWM 20 kHz
FVG output stage 1 x stepping motor, max. 1.5A; not short circuit protected
CAN-bus 1x plug, 1x socket; no metallic separation
Screw connections / Variable through exchangeable connection plate;

plugs see Appendix D6
Protection class IP 54

Specifications A2
Display: LCD graphics module with 128 x 64 pixel and LED

background illumination
Ambient conditions: Temperature: 0° to 45°C max.
Humidity: 5% - 90%,
no condensation
Weight: ekrPro Com60: approx. 2.1 kg
ekrPro Com60 Desk: approx. 2.3 kg
Case dimensions ekrPro Com60 (Mounting unit):
160
140
240 70
Installation ekrPro Com60 Desk (Built-in unit)

240
225
125
140
105
max. 10
115 15
205

Specifications A2
A 2.2 A2.2 Optical edge sensor

IR 2001, IR 2005
Power supplies: from the controller
Measuring range, typical: 12 mm
Visual range, typical: 15 mm
Output: analog
Protection class: IP 54
Ambient conditions: Temperature: 0 to a max. 45 °C
Humidity: 5% - 90%, no condensation
Case dimensions: W = 40 mm
(standard version) H = 95 mm
D = 107 mm
A 2.3 Optical edge sensor

IR 2002
Measuring range, typical: 8 mm
Visual range, typical: 13 mm
Output: analog
Ambient conditions: Temperature: 0° to 45°C max.
D = 85.5 mm
A 2.4 IRS-U-2 A opto-electronic analog sensor

See the manufacturer’s data-sheet

Specifications A2
A 2.5 Ultra-sonic sensor

US2003, US2007,
US2008

Measuring range, typical: 15 mm (US 2008 = 4 mm)
Visual range, typical: 15 mm (US 2008 = 6 mm)
Output: analog
Case dimensions: B= 25 mm
D = 113 mm
A 2.6 Reflection button

TW 54 C5
Power supplies: 8V – 15V; from the controller
Lamp voltage: 5V; 0.8A; from the controller for:
maximum of one sensor
Measuring range: 5.0 mm at 6 mm sensing distance
2.5 mm at 13 mm sensing distance
Output signal: Negative with black areas
Positive with white areas
Weight: 240 g
H = 54.5 mm
D = 85.5 mm

Specifications A2
A 2.7 Line sensor T 62 D 1

Lamp voltage: 5 V; 0.8 A
Sensing distance: 15 -30 mm
Measuring range: 3 -8 mm
Line widths: 0.5 -5 mm
Output voltage: 0 to ±10V
Weight: 1,100 g
H = 105 mm
D = 128 mm
A 2.8 Reflected light

measuring light barrier R 42 D, etc.
R 42 D 12 R 42 D 16
Power supplies: +12V, 12 mA or
±12V, 15 mA or
±15V, 20 mA
Lamp voltage: 5V, 4W; from the controller for a maximum of
one sensor
Max. distance: 1m 2m
Measuring range 15 mm 40 mm
in front of front lens:
Diameter of light beam 25 mm 55 mm
in front of front lens:
Diameter of light beam 40 mm 55 mm
at half distance
Output voltage: Corresponding to change in illumination:
light dark
at: UB = +12 V 8.5V 2V
UB = ±12 V 8.5V 0V
UB = ±15 V 10.5V 0V
Ambient conditions: Temperature: 0° – 70°C
(temperature compensation
only up to 50°C
Weight: 1,000 g 1,200 g

Specifications A2
A 2.9 Fork light barrier

G 53 C2/5
Lamp voltage: 5V
Fork width: 29 mm
Measuring range: ± 3.5 mm
Diameter of light beam: 11 mm
Ambient conditions: Temperature: -20 to a max. 60 °C
Weight: 400 g
H = 85 mm
D = 87 mm

Specifications A2
A 2.10 Switched power pack

Supply of the ekrPro Com60 including the BST components takes
place over the switched power pack.
There are two supply possibilities:
1. over a central power pack in the machine
2. over a power pack allocated to the BST part
The following details are based on a control system comprising a

control unit ekrPro Com60, analogue sensors, sensor adjustment
unit and actuator (EMS1, EMS5, EMS10, EMS16, EMS17 or
EMS20)
1. Central supply
If supply takes place centrally from the machine the following
parameters are to be fulfilled:
• Output voltage: 24 V DC ± 5%
• Output current: 4.2 A DC
• Output power: 100 W
The power pack must be able to quickly charge (~ 5 sec) the input
capacitance (approx. 950µF) of the control amplifier after switching
on without recognizing this as a short circuit and so switching off
again.
The output should be permanently resistant to short-circuiting,
overloading and idle running.
2. Separate power pack

If a separate power pack is used for the BST components, we
recommend the use of units manufactured by PULS GmbH:
Input voltage: 85 - 264 V AC or 220 – 375 V DC

Output voltage: 24 V DC ± 5%
Output current: 4.2 A DC
Output power: 100 W
BST order number: 103 837
If a number of control systems are to be supplied from a single

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

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

Transport A3
A 3 Transport
The equipment will be shipped in accordance with the details

stipulated in the order:
• completely assembled and interconnected to the web guide

control system
• as component parts in standard cardboard boxes with cellular
lining material
If the unit will not be incorporated immediately, it should be stored

in a dry room until installation.

Decommissioning A4
A 4 Decommissioning
Decommissioning (scraping) the systems must be carried out in

together with the entire machine.
The necessary procedures must be prepared by the manufacturer
of the machine. You must take into consideration that the control
system is generally considered to be an electrical / electronic
device, which must be disposed of in accordance with the current
legal requirements.
You might also be able to return the system to BST International
GmbH, but the corresponding agreement must be made first.

ekrPro Com60
with analog sensors
Section B
Commissioning
B1 Installation
B2 Controls
B3 Commissioning
B4 Terminal assignments and service displays

Contents
Section B
Commissioning
Symbols used in this manual
Table of contents
B1 Installation B1-1
B 1.1 Installation site requirements B1-1
B 1.2 Installation ekrPro Com60 (Mounting unit) B1-1
B 1.2.1 Securing hole diagram B1-1
B 1.2.2 Installation B1-1
B 1.3 Installation ekrPro Com60 Desk (Built-in unit) B1-2
B 1.3.1 Installation dimensions B1-2
B 1.3.2 Cabling B1-2
B 1.3.3 Installation B1-3
B 1.4 Installation instructions for EMC-wiring B1-4
B 1.5 Installation contrast/line sensor B1-5
B 1.5.1 Sensor arrangement B1-5
B 1.5.2 Installation line sensor T 62 D 1 B1-6
B 1.5.3 Installation reflection sensor TW 54 C 5 B1-7
B2 Display and operating controls B2-1

B 2.1 Control panel B2-1
B 2.2 Navigating within the system B2-2
B 2.2.1 Function keys (F-keys) B2-2
B 2.2.2 Arrow keys B2-5
B 2.2.3 Buttons B2-6
B3 Commissioning B3-1
B 3.1 General information B3-1
B 3.2 Electrical connections B3-2
B 3.3 Commissioning with a CAN bus B3-3
B 3.3.1 Check unit address or set up if necessary B3-3
B 3.3.2 Terminator activation B3-5
B 3.4 Adjust password B3-7
B 3.5 Commissioning standard system B3-9
B 3.5.1 Select standard system B3-9
B 3.5.2 Carry out master setup B3-10
B 3.5.3 Setting the actuator guiding direction B3-11
B 3.5.4 Setting the actuator path limits B3-11
B 3.5.5 Servo centre position and amplification for the B3-12
“SC” operating mode
B 3.5.6 Carry out material setup B3-13
B 3.5.6.1 Automatic material set-up B3-14
B 3.5.6.2 Manual material set-up B3-14
B 3.5.7 FVG - Sensor positioning device B3-15
B 3.5.8 Additional Functions B3-19
B 3.5.8.1 Tear Off Detection B3-19
B 3.5.8.1 Oscillation B3-23
B 3.6 Save settings B3-25

B 3.7 Set-up menu B3-26
B 3.7.1 Change User - User level selection B3-26
B 3.7.2 Material Setup - Sensor compensation B3-26
B 3.7.3 Sel. Std. System - Selection of a standard system B3-26
B 3.7.4 Save/Load settings- Load or save settings B3-26
B 3.7.5 General Set-up - System parameters B3-27
B 3.6.4.1 Setting the default values B3-27
B 3.6.4.2 Actuator –Actuator settings B3-28
B 3.6.4.3 Sensors/EFE - Commissioning sensors and EFE B3-35
B 3.6.4.4 Control Loop - Control loop settings B3-37
B 3.6.4.5 FVG - Sensor positioning device B3-38
B 3.6.4.6 Width Measure - Web width measurement B3-50
B 3.6.4.7 Edge Sources - Assignment of the sensors B3-54
to the guiding modes
B 3.6.4.8 Add. Functions - Special functions B3-56
B 3.6.4.9 Dig. IO Config. - Configuration of the digital B3-60
inputs and outputs
B 3.6.4.10 Special - Special device settings B3-69
B 3.6.5 Opt. Logic - Optional logic B3-72
B 3.6.6 Fieldbus - Field bus B3-72
B 3.6.7 Remote Device - Commissioning with a CAN bus B3-73
B 3.6.8 Test - Test program for service purposes B3-74
B4 Terminal assignments and service displays B4-1

B 4.1 Board overview B4-1
B 4.2 Terminal diagrams B4-2
B 4.3 Service indicator displays B4-9

Installation B1
B 1 Installation
B 1.1 Installation site requirements

The ekrPro Com60 controller must be installed in a dry, vibration-
free area.
Ambient conditions: Temperature: 0 to a max. 45°C
Humidity: 5 - 90%, no condensation
B 1.2 Installation ekrPro Com60

(mounting unit)
B 1.2.1 Securing hole diagram

225
Ø6
ekrPro Com60 housing
125
B 1.2.2 Installation
1. Drill the securing holes as

shown in the mounting plan.
2. Use the four securing

screws to attach the
housing.
3. Wire in the electric cables (if

required) or plug in the
necessary cable
connections.
Attention! A free area of at least 300 mm in front of the housing

must be guaranteed so that it can be opened.
ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: B1

Installation B1
B 1.3 Installation
ekrPro Com60 Desk
(built-in unit)
B 1.3.1 Installation dimensions
Section
B 1.3.2 Cabling
Attention!
A space of at least 140 mm must be guaranteed for the
cabling in order to ensure that the cables are laid
correctly (see illustration).
min. 140

Installation B1
max. 10
1. Cut out the insertion hole and drill four

mounting holes
(installation dimensions see chapter B 1.3.1).
2. Slide the ekrPro Com60 Desk into the recess.
3. Use the four securing screws to secure the

controller ekrPro Com60 Desk in place.
4. Wire in the electric cables or plug in the

necessary cable connections.
Attention!
A free area of at least 300 mm in front of the
housing must be guaranteed so that it can be
opened.

Installation B1
B 1.4 Installation instructions for EMC-wiring
housing wall
Union nut
1. Unscrew in the union nut for the cable

screw-in cable glands.
Intermediate supports
2. Pull out the clamping insert from the

intermediate supports.
Attention! Do not press down on the
cable insert.
Cable insert
3. Strip cable back by 8 mm so that the

screen braiding is uncovered
4. Pull the union nut onto the cable
5. Feed the cable into the cable clamp

and bend the screening back over the
cable clamp.
6. Push the clamping insert to the

intermediate support.
7. Fit the screws.

Installation B1
B 1.5 Installation
contrast / line sensor
B 1.5.1 Sensor arrangement

The sensors must be arranged as follows in order to ensure clear
allocation of the two keys on the front foil of the controller to the
corresponding contrast transitions:
• The sensor connection cable points in the direction of
sensor 1.
Connection
cable
TW 54 C 5
T 62 D 1
Sensor 1 web running direction Sensor 2
Material web
This sensor arrangement results in the following key allocation:
→ Contrast transition
BRIGHT/DARK
→ Contrast transition
DARK/BRIGHT

Installation B1
line sensor T 62 D 1
T 62 D 1
17
ø8
Deflection roller
Scanning arrangement T 62 D 1
The following points must be adhered to during installation of the

T 62 D 1 in order to realise optimum guiding results:
• The line sensor should be mounted on a torsionally rigid base.
• The line / contrast must be placed at right angles to the
longitudinal axis of the sensor (see drawing).
• The scanning should be carried out on a deflection roller.
This will ensure that any material web height fluctuations are
eliminated at the scanning point.
• The distance between the sensor scanning optics and the
material web must be set so that there is a light spot with a
diameter of approximately 8 mm (corresponding to a scanning
distance of approximately 17 mm) on the web.
• We recommend that the sensor angle is
5°…15° 5°…15°
reduced by 5° - 15° in the web running
direction when using very reflective materials.
Web running direction
The light spot diameter can be reduced in size by

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

Installation B1
reflection sensor TW 54 C 5 5°…15° 5°…15°
TW 54 C 5
6…12
web running direction
You must abide by the following points when installing the

TW 54 C 5 reflection scanner in order to realise optimum guiding
results:
• The line sensor should be mounted on a torsionally rigid base.
• The line / contrast must be placed at right angles to the
longitudinal axis of the sensor (see drawing).
• The scanning should be carried out on a deflection roller.
This will ensure that any material web height fluctuations are
eliminated at the scanning point.
• The distance between the sensor scanning optics and the
material web has to be 6 - 12 mm, depending on the required
measuring range (diameter of the light spot).
The measuring range (light spot diameter)

depends on the distance between the contrast
transitions.
Only one contrast transition may be located within the light spot.
correct wrong wrong
Distance scanning optics D material web: 6 - 12 mm

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

Controls B2
B 2 Display and operating controls

B 2.1 Control panel
Graphics display
A contrast-rich LCD display with LED background illumination.
Display has 6 lines, each of 28 characters.
The graphics display is used for displaying the operating hours,
parameters and the set-up menus.
Keypad
The controller can be configured for operation using this keypad.
Key Function
Automatic guiding
Manual positioning
Centring the guiding device (servo-center)
Left web edge guide
Right web edge guide
+ Web center guiding
Edge / contrast control:

Contrast transition: light / dark

Contrast transition: dark / light
’Automatic’ operating mode:

• Moves the setting to the left/right
’Manual’ operating mode:
• Manual left/right positioning of the
guiding device
• Change between the operating status
displays

Controls B2
Key Function
Menu navigation: Jump back by one level

In editing box: Cancels the last entry
Select controller settings or controller gain

for change the settings
Saves the settings at the end of the set-up

functions
Activates special functions

(e.g. oscillation)
(not used at the present moment)
Menu selection
B 2.2 Navigating within the system

Use the arrow keys and the F1 – F4 function keys to navigate
within the system.
The different functions are explained in the following.
If incorrect entries are made, or if functions are active which, for

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

Controls B2
B 2.2.1 Function keys (F-keys)

The F-keys functions are assigned in different dialog windows. The
associated abbreviated names are displayed at the bottom edge of
the screen.
Press the relevant F-key several times to select the required
numerical value. The time interval in between pressing the button
twice must never exceed 0.5 seconds.
Shortcut functions
The function keys are assigned numbers in the equipment menu.

Therefore a menu option can be selected by using the arrow keys
to navigate to the required menu sub-option or it can be selected
directly by using the shortcut number instead.
For example: Selecting the actuator
The associated menu sub-option is 611

(see navigation overview as well).
1. Press key . This will display the set-up menu.
1 Current position
in device menu
Assignment of allocated
function keys
To enter the shortcut number:

2. Press F2 key 3x = 6.
51
The "General setup" menu including the first "Actuator"

submenu is called up.
3. Press the F1-key once = 1

Material Setup 511
Actuator
Sel. Std. Type
System
(EMS&Hydr.)
Sensors/EFE
Save/Load Settings Add-on
Hydraulics
Control Loop
General Setup
Direction
opt.FVG
LogicSC-Transducer
12 3 45 6 789 0
The required dialog will be displayed and you can now use the
arrow keys to select the parameter that has to be modified.

Controls B2
Entries in the editing box
The parameter values are entered directly in the editing box. This
can also be realised using the F-keys.
1. Open the required sub-menu and then press the ENTER key
to activate the editing box.
2. Use the horizontal arrow keys to mark the initial

position for the settting.
Width Measure Offset

current width:
mm
Opened
enter ref.width 078.5 editing box
123 456 789 0
3. Enter the number. For example: press F4 x 1 = 0.

The actual position will jump automatically by 1 place to the
right after 0.5 seconds without an entry being made.
4. Now enter the next number in the same way as described

above in Section 3.
5. Press the ENTER button to import the modified value.
6. Press the ESC button to cancel the value.
Editing box
The arrow keys can also be used to enter a value in the editing box
in addition to using the F-keys.

current width: Selected
mm digit
enter ref.width 078.5 Opened

editing box
123 456 789 0
Use the horizontal arrow keys to position the cursor on

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

Controls B2
Entering negative numbers

Use the horizontal arrow keys to mark the initial
position for the setting.
Now use the vertical arrow keys so that the minus sign
is entered or removed.
After this, enter the digit sequence as described above.
B 2.2.2 Arrow keys

Various entries can be made and options can be selected from the
menu mode dialog windows.
The procedure for the various controls and lists is as follows:
Control elements
Use the arrow keys to mark the required control if there are several
control elements displayed in the same dialog window.
For example:
sens.mode W XP
0 5.00
0 5.00
0 5.00
0 5.00
Use the ’right’ arrow key to scroll forward and
use the ’left’ arrow key to scroll backwards.
The vertical arrow keys do not have a function here.
Option lists
An entry from a default list can be selected from an option list. This
is realised by pressing the ENTER button to open the selected
option list.
Example:
Select an actuator type Select an actuator type
EMS 17 EMS 10
EMS 16
EMS 17
123 456 789 0
The “▼“ or “▲“ symbols displayed on the right of the option list
indicate that there are more entries in list than are displayed on the
screen.
Use the vertical arrow keys to mark the position in the

list.
Confirm the selection by pressing ENTER.

Controls B2
Checkbox
Use the vertical arrow keys

Arrow keys option using the checkbox control element.
Example:
(de)activate speed control
X = Option active
active X
= Option inactive
Read-only Checkbox
Read-only checkboxes only have a display function.

These give the operator reports about the current status of the
components (e.g. stop switch statuses).
Example:
= activated
= not activated
B 2.2.3 Buttons
Button control elements are present in certain dialog windows
Select a sensor type Inv.

sensor1 IR 2005
<<<
dark 7% bright
-2048 abs. 1775 2047
auto dark bri.
If a button is marked and the ENTER button is pressed afterwards,

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

Commissioning B3
B 3 Commissioning
B 3.1 General information
The controller ekrPro Com60 is matched to the actual configuration of
the control system (connected sensors, actuator, sensor adjustment
unit, ...) using the system parameters in the individual setup menus.
The required parameters have already been entered if the control
system is an integral part of a projected BST system. You do not
have to reset anything with regard to this.
A new system configuration is required if components or the
controller have been exchanged on-site.
The range of the settings and therefore the set-up menus that have
to be taken into consideration depend on the system being used.
To simplify commissioning, the commissioning staff can select his

system from a list of the most common standard systems (see
chapter B.3.5).
Following the selection, all of the basic settings are automatically
entered in the setup menu.
Finally the commissioning staff has only to check a few application-
related settings and if necessary adjust them accordingly.
The procedures to be used with the separate menus are described

in section B 3.7.5 General set-up.
Danger from mains voltage!

Never open the controller before switching off the
mains!

Commissioning B3
B 3.2 Electrical connections

The system must be wired according to the accompanying
connection diagram or plugged into the appropriate cable sockets.
Standard wiring sleeves with collars (DIN 46228/Part 4) must be

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

The spring-loaded terminals have been optimised for square
crimping. This can be realised using, for example, ‘WAGO’ vario-
crimp pliers.
This type of crimping also enables the connection to be connected
and disconnected without any problems.
The crimping is also gas-tight, i.e. there is no space inbetween the
conductor and the wiring sleeve.
Using cable without wiring sleeves:

For fine and multi-core cable and for fine-wired cable, whose kink
resistance is not sufficient due to its small diameter, in order to
overcome the contact force of the clamping springs, the clamp must
be correctly opened using a screwdriver.
Check that all the cables are fitted tightly after the connections have
been made (in both cases).
The ekrPro Com60 controller is protected against incorrect

connection.
If the supply voltage was inversely connected to terminals 42
and 43 of the controller, this inverse polarity would also be
connected to the 24 V output socket.
This could lead to damage to components connected to this
socket.
Attention! Applications with a sensor adjustment unit!

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

Commissioning B3
B 3.3 Commissioning
with a CAN Bus
B 3.3.1 Checking the unit address
and setting up if necessary
If the ekrPro Com60 controller is operated via a CAN bus, then the
setting of the CAN device address must be checked.
The CAN device address setting up is carried out via the S1 BCD
switch on the processor board:
BCD switch S1
The ekrPro Com60 address is preset to "1" in the factory (delivery

state).
• Set the S1 BCD switch to "1" if the ekrPro Com60 is the only
device connected to the CAN bus.
• If you want to run several ekrPro... family devices on one CAN bus
system, then different device addresses (1 – 8) must be set for
the devices.
One of the devices must be set to device address "1" without
fail! Device addresses 0 and 9 are reserved.
Each device address can only be used once per guiding

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

Commissioning B3
ekrPro Key60 (if fitted) :ekrPro Key60:
There are several plugs on the rear side of the

ekrPro Key60.
The BCD switch S1 for setting the address (node
number) is behind these plugs.
Procedure:
S1 BCD switch
2. Remove the plug.
3. Check setting of BCD switch S1. If necessary, set
device address to S1 = 1.
4. Refit the plug.
FVGPro Module (if fitted) :FVGPro Module”

The device address setting up is also crried out via the
S1 BCD switch mounted on the board:
Procedure:
1. Switch off the power to the FVG Pro module.
2. Open housing’s front cover.
3. Check the setting of the BCD switch S1. If
necessary, set device address to S1 = 1.
S1 BCD switch
The device address modification will be effective after the

power has been restored.

Commissioning B3
B 3.3.2 Terminator activation
The terminator must be activated on each of the physical first and
last CAN bus participants. The possible settings are described
below.
B 3.3.2.1 ekrPro Com60

In the ekrPro Com60, the activation is carried out using switch S3 on
the processor circuit board. Set the switch to "ON“.
Terminator S3
Procedure:
2. Open controller’s front cover.
3. Activate terminator S3 (switch position ON)
B 3.3.2.2 ekrPro Key60 (if fitted)
In the ekrPro Key60 activation

is carried out via switch S3.
Remove plug on the

back side.
Set the switch to "ON“.
Switch S3

Commissioning B3
B 3.3.2.3 BST ProLogic (if fitted)
In the BST ProLogic activation takes place using the DIP switch
segment 1 (S1 = ON) for the CAN 1.
CAN 2
B 3.3.2.4 FVGPro Module (if fitted)
In the FVGPro Module activation is carried out via switch S3 on the

processor circuit board. Set the switch to "ON“.
Switch S3
Procedure:
1. Switch-off the power to the module.
2. Open module’s front cover.
3. Activate terminator S3 (switch position ON)
4. Close the module’s front cover.

Commissioning B3
B 3.4 Adjust password

User administration in the ekrPro Com60 differentiates between four
different user levels with different user rights.
The individual user levels are each protected by a password.
Dependent on the selected user level, more or fewer paths are
activated in the setup menu. Non-activated entries are greyed out in
the menus and cannot be selected.
The user levels with the corresponding user rights are shown in the
following table.
User level Rights Default Password

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

The indicated default password should only be used for the first
access to the setup menu and then an application-appropriate
password entered. This is also true for the Mainten. user level. This
protects the system against unauthorized access.
Make sure these new passwords are only known to the authorized
personnel!
BST International GmbH is not liable for damage arising from the
incorrect use of the password(s).
An automatic logout time can be set for all user levels (timeout time).
If no key is pressed for the set time, the user is automatically logged
out and the controller changes to the user level Operator.
Changes to passwords and the timeout time is undertaken from the

menu General Setup > Special > Change Pwd
All passwords can be reset to the default passwords up to 20

seconds after switching on of the controller by pressing the key
combination F4” + “ESC.
When the controller is switched-off, the last active user level is

stored and automatically activated after a reboot.
The procedure for selecting the user level is described in the

following pages.

Commissioning B3
Selection of user level is undertaken from the Change User menu.
1. Select Change User menu and press ENTER.
Enter user level & password

User level Operator
Password 0 2. The user level selection window appears.
Current
user level: Admin.
In the lower part of the window the active user level is
displayed (Admin. in the example).
logout login
Enter user level & password Press the ENTER button and the user level option list will then
User level
Password
Operator
Mainten. be opened.
Current Admin. Select the desired user level with the up and down arrow
user level BST Support
keys.
123 456 789 0 Confirm the selection by pressing ENTER.

User level
Password
Mainten.
00000
3. Use the right and left arrow keys to select the Password
Current editing box and press ENTER.
user level: Admin
123 456 789 0

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

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

Commissioning B3
B 3.5 Commissioning standard system

own system from a list of the most common standard systems listed
under the menu Sel. Std. System.
entered in the setup menu and the system is switched to the
operating mode MAN.
B 3.5.1 Select standard system
1. Press the MENU button.

The setup menu of the controller appears in the display.
2. Select menu "Sel. Std. System“ and press ENTER.
3. The selection window for the standard system will appear.

F1 for fa ct. defaults
Choose standard system …
select a standard config.
… & press F2 to activate
4. Press the ENTER button.
De f. Set. The option list opens with the most common standard
systems. Individual entries each contain the following
information:
Type of connected Type of connected Type of the
sensor(s) actuator sensor positioning device
(if fitted)
5. Use the vertical arrow keys to select the system that matches
the present system.
Confirm the selection with the ENTER key.
The selected system is displayed.
6. To import the standard system configuration, press

function key F2 (set.).
The selection is confirmed by the message window Standard
System Set.
The base settings in the setup menu are automatically
entered by the system.
After this, the selection window is displayed again.
7. Press the ESC button to exit the window.

Choose standard system … Attention!
… & press F2 to activate After selecting the standard system, adjustment for a
particular application (e.g. material properties) must
De f. Set. take place.
Accordingly, the following steps should be carried out:

Commissioning B3
B 3.5.2 Carry out master setup

The sensor type will already have been set when the standard
system was set.
The procedure is described for Sensor 1.

The master set-up for Sensors 2 and 3 is the same.
1. Select Sensors/EFE in General set-up and then select the

Sensor 1 sub-directory afterwards. Confirm the respective
selection by pressing ENTER.
2. Select the type of sensor that is connected to the system from

the option list displayed in the new window that has opened
up and then enter it.
Attention!
If the mounting position of the selected sensor differs from the
BST setting (see chapter A 1.4) or if the sensor outputs an
inverted signal (e.g. another manufacturer’s sensor is being
used), then the checkbox Inv. must be checked.
A master set-up will be carried out afterwards.
Master set-up can be run automatically or manually.
sensor1 IR 2005
3. Automatic master set-up:
<<<
dark 7% bright ► Press the F1 button and then cover the sensor’s scanning
-2048 abs. 1775 2047
window with an opaque material for two seconds
auto dark bri.
afterwards.
► Remove the material from the scanning window and press
the F2 button two seconds later.
► This completes the master set-up for this sensor.
4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque
material and then press the F3 button.
► Remove the material so that the window is completely
uncovered and press the F4 button.
5. Run the master set-ups for Sensors 2 and 3.

Commissioning B3
B 3.5.3 Setting the actuator

guiding direction
For standard systems, the EMS17 is registered as the actuator.
The direction has to be set for it.
1. Select the sub-directory Direction from the menu Actuator.

If necessary, the actuator guiding direction for manual mode

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

“manual” operating mode.
The sensor allocation can be checked on the spot. Press the
MENU button. The operating display is shown.
Cover one sensor. The change to the coverage range shows

the allocation.
After this, press the MENU key to ENTER to the settings
menu.
B 3.5.4 Setting the actuator

path limits
From here it is possible to limit the adjustment travel of the
actuator.
Change User
1. Select Actuator in General Setup, then the sub-directory
Actuator
Material Setup
TypeType
(EMS&Hydr.) SC-Component and finally Pos. Limit.
System & Dir.
Sel.Sensors/EFE
Std. Hydraulics
Control
General SetupLoop
Directions
Add-on
Pos. Limit Confirm the respective selection by pressing ENTER.
FVG SC W & XP
opt. LogicSC-Transducer
123 456 789 0

2. Use the vertical arrow keys to deactivate the checkbox active.
This deactivates the function of both limit switches.
The settings can only be entered in the deactivated state.
3. Use the F2 key to drive the actuator until it reaches the

required left limit switch position.
The actual position of the actuator supplied by the position
feedback is shown in the middle above the F2 and F3 keys.
4. Confirm this position by pressing the F1 key.

The limit switch position is stored.
The corresponding position value is shown below the
checkbox.

Commissioning B3
5. Use the F3 key to traverse the actuator until it reaches the

required right limit switch position.
7. Reactivate both limit switches.

Select (x) checkbox active to do this.
The description is given in section 2.
Import of the limit switch position is indicated by a black circle
in the read-only checkbox above the F1 and/or F4 key.
8. Press the ESC button to exit the inputting menu.
B 3.5.5 Setting centre position

and gain for “SC” operating mode
From here the centre position and the amplification for operating
mode SC are set.

SC-Component and finally SC W & XP.
2. Press ENTER to open the inputting menu and enter the

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

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

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

the setpoint value for the centring position.
The setting from mot.pos. will be imported into set-point W.
6. The setpoint value setpoint W and the gain gain XP can also
be entered directly in the relevant window.
7. The settings can be checked on the spot by switching over to

the SC operating mode.

Commissioning B3
B 3.5.6 Carry out material setup

Automatic adjustment of the controller to match the characteristics of
the material to be scanned is carried out during material set-up
(e.g. different material transparency at the optical sensors or
different sound absorption in the case of ultrasonic sensors).
The material set-up is the same for all three sensors.
The procedure for sensor 1 is used as the example here:
1. Press the MENU button to open the set-up menu.
2. Select Material set-up and confirm by pressing ENTER.
3. Select Sensor 1 and confirm by pressing ENTER.

This will open the Sensor 1 material set-up window.
Material Setup - Sensor 1
<<<
7%
dark bright Material set-up can now be carried out either automatically or
-2048 abs. 1775 2047
auto dark bri.
manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.

Commissioning B3
B 3.5.6.1 Automatic material set-up
1. Press the F1-key.
2. Completely cover the sensor’s scanning window with the

material to be scanned for approx. 2 seconds.
3. Completely remove the material from the sensor scanning

window (no material over the sensor).
This completes the material set-up for this sensor. Material set-up is
finished when the same procedure has been carried out for any
other sensors connected to the controller.
B 3.5.6.2 Manual material set-up

material to be scanned.

4. Press the F4-key
The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or the
bright setting (steps 3 and 4) can be made first.
For sensors TW54 and T62, you must use the special
Material-Setup – Sensor 3 (see Point C 2.3.4).

Commissioning B3
B 3.5.7 FVG - Sensor positioning device

short circuits.
commissioning.
The connection cable from the ekrPro Com60 control unit to the
sensor adjustment unit must not exceed the maximum cable
length of 20 m.
Power is continuously applied to the stepping motor output

stage, even when stopped. Therefore any work undertaken on
the interconnections must only be carried out with the power
switched off.
B 3.5.7.1 Default values set
Depending on the configuration selected under Select Standard

System, various default settings are carried out in the FVG
submenu.
B 3.5.7.1.1 Configuration-dependent default values
1. Selection IR2005:EMS 17 or US2007:EMS 17

For this selection, the sensor positioning device connection
entitled "not connected" is selected and entered. No additional
entries have to be carried out.
2. Selection IR2005:EMS17:1MK60 or IR2005 EMS17:1MK75

resp. US2007:EMS17:1MK60 or US2007:EMS17:1MK75
If one of these configurations is selected, the FVG 1MK Op. sensor

positioning device connection is selected and entered.
The following settings-dependent parameters are selected and
entered:
- Homing Direction – retraction direction and limit switch assignment
• at the first setting after switching on: not reversed
- Offset 1:
• at the first setting after switching on:
Offset = 0
Inverted = no
- Offset 2:
Offset = 2000
Inverted = yes

Commissioning B3
- Range – Traversing range limits

min = 0.0
max = 5000.0
- Feed – Feed for stepping motor / gearing combination

This setting is treated as the feed per motor revolution for the
stepping motor / gearing combination.
The respective value is automatically entered when the FVG type
is selected:
for FVG 1MK60 = 20088
for FVG 1MK75 = 61666.
The manufacturer has entered this default setting and you are
only permitted to modify it (if necessary) after having obtained the
manufacturer’s agreement.
The relevant procedure then has to be agreed.
All warranty claims will be invalidated in any other case.
3. Selection IR2005:EMS17:2MK60 or IR2005 EMS17:2MK75

resp. US2007:EMS17:2MK60 or US2007:EMS17:2MK75
If one of these configurations is selected, the "FVG 2MK Op.“
sensor positioning device connection is selected and entered.
The following settings-dependent parameters are selected and
entered for the FVG 1 (Slide 1)and the FVG 2 (Slide 2):
Slide 1
- Homing Direction – retraction direction and limit switch
assignment
• at the first setting after switching on: not
reversed
- Offset - positional offset to FVG position

• at the first setting after switching on: Offset = 2000
Inverted = no

min = 0.0
max = 5000.0

is selected:
for FVG 2MK60 = 20088
for FVG 2MK75 = 61666.

Commissioning B3
Slide 2
- Homing Direction – retraction direction and end switch
assignment
• at the first setting after switching on: not
reversed
- Offset - positional offset to FVG position

• at the first setting after switching on: Offset = 2000
Inverted = yes

min = 0.0
max = 5000.0

is selected:
for FVG 2MK60 = 20088
for FVG 2MK75 = 61666.
B 3.5.7.1.2 Configuration-independent default value
The following values are general settings, which can be selected

and entered as default values independently of the FVG selected.
- Retract Mode – free-running mode

• at the first setting after switching on: SC & Man
- Norming Mode – Standardization Mode

Setting of the standardization mode is dependent on the type of
sensor being used.
Infrared sensors: The mode is always set to "bright/dark“.
Ultrasonic sensors: The mode is always set to "no norming“.
- Width Adjust – FVG operating mode for center line guiding

• at the first setting after switching on: Level Outer

Commissioning B3
- Repositioning – repositioning of the material after certain

events
The current position of the material web is saved once an event
takes place (e.g. web tear). Once the event has been rectified, the
material is repositioned to this position. This functionality is only
effective once pre-positioning has been activated.
- Velocities – adjustment of positioning speeds

Retract velocity: 60 mm / s
Edge push velocity: 5 mm / s
Slow manual velocity: 1 mm / s
Fast manual velocity: 60 mm / s
Norming velocity: 60 mm / s
- Special – Special settings for driving the FVG slides

Mode after error: Man
Carry out setting according to point B 3.7.5.5, if the settings listed

above, for the sensor adjustment unit, do not corresponding to the
operating requirements.

Commissioning B3
B 3.5.8 Add. Functions – Special functions
Useful additional functions can be realised using the ekrPro Com60.

These functions can be accessed quickly under this menu point.
These functions deal with the Tear Off Detection and Oscillation.
B 3.5.8.1 Tear-Off Det. – Tear-off detection
Tear-off detection enables, dependent on the selected sensing

type (edge / contrast guiding) the following functions:
1. With web edge guiding:

Detection of torn off sections on the web edge using edge
sensors IR2001/2005, US2007, …
This function is activated during web edge guiding, if during
operation of the web guiding system errors arise from the web
edge that is being scanned.
The function detects both tears into the material web (inward
tear) as well as projecting material (outward tear).
2. With contrast guiding:

Guiding on interrupted printed or contrast edges with contrast
sensors T62D1 or TW54C5.
Interrupted printed
or contrast edge
Light spot of the

contrast sensor
Tear-off
inwards
Tear-off
outwards
Tear-off detection can be implemented using the same sensors that

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

Commissioning B3
Criteria for detecting a tear:

To detect a tear, at least one of the two following criteria must be
fulfilled:
1. Exceeding / undershooting of the preset threshold value

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

signal.
The system continuously checks the rate of change speed of the
sensor signal in both positive and negative directions. If the
preset maximum permissible rate of change (sig. chg. lim.) is
exceeded, then this is recognized as a tear.
After a preset delay time (delay) has elapsed, the web guiding
system is automatically blocked.
If the set rate of change is undershot, then blocking of the guiding
system is not lifted.
Lifting of the blocking is only implemented if the preset threshold
value (threshold) is again undershot (see point 1).
Conditions for guiding on interrupted printed or contrast edges
For trouble-free operation of the control unit, the following conditions

must be fulfilled:
1. Minimum mark length

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

Lmin [m] = * 3 * t [s] +
60 s/min 1000 mm/m
Lmin = minimum mark length [m]

vmax = max. web speed [m/min]
t = sampling cycle [s] = 0.004 s
d = light spot diameter [mm]

Commissioning B3
Example calculation:
At a maximum web speed vmax = 300 m/min and a light spot
diameter d = 8 mm the resultant minimum mark length Lmin,
equals:
300 m/min 8 mm
Lmin = ¹ 3 ¹ 0,004 s ¬
60 s/min 1000 mm/m
Lmin = 0,068 m = 68 mm
2. Alignment of the contrast sensor:
When scanning an interrupted line, correct alignment

of the contrast sensor must be observed:
• The contrast sensor must be aligned so that the
edge of the line is located in the sensor light spot.
• Only one edge may be located within the light
spot.
correct wrong wrong
3. Operating mode setting for the contrast sensor T 62 D 1
The operating mode selection switch on the sensor must be set

to the position Kante (edge).
Operating mode
selection switch

Commissioning B3
Parameter settings
Setting of the parameters for the function tear-off detection is made

separately for each guiding mode. If necessary, a different sensor
can be allocated as the tear-off detection sensor for each guiding
mode. It is also possible to allocate two different guiding modes with
different parameters to a single sensor.
1. Select Add. Functions in General Setup and then select the

Tear Off Det. sub-directory afterwards.
Confirm the respective selection by pressing ENTER.
2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3,

Center 1&2) from the option list.
3. This will open up the inputting window for the selected guiding
mode. The following separate parameters can be set:
► Sensor: Selection of the sensor with which tear-

off detection is to be implemented.
► threshold [%]: Percentage covering of the sensor

measuring band, above which a change
is detected as a tear.
For the example value entered here
(80/20), this means that the function
detects a tear, if more than 80% or less
than 20% of the sensor measuring band
is covered.
► sig. chg. limit. [%/4ms]: Maximum permissible rate of

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

until blocking of the guiding system.
► hold [ms]: Blocking hold time in ms after the

detected end of the tear until the blocking
is lifted, i.e. until the guiding system is
activated.
4. If necessary, set parameters for further guiding modes

(see points 2 and 3).

Commissioning B3
Calculation of the maximum allowable rate of change of the sensor

signal (parameter sign. chg. limit)
The maximum permissible rate of change sig. chg. limit of the

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

vmin = min. web speed [m/min]
d = light spot diameter [mm]
Example calculation:
At a minimum web speed vmin = 30 m/min and a light spot diameter
d = 10 mm the resultant maximum rate of change of the sensor
signal equals:
30 m/min
sig. chg. limit [%/4ms] = 2 ¹ ¹ 100
60 s/min * 10 [mm]
sig. chg. limit [%/4ms] = 10 % /4ms
B 3.5.8.2 Oscillation
This special function enables the position of the web to be displaced

within the sensor´s visual range using adjustable amplitude (size of
the lateral displacement) and frequencies (displacement speed).
The format of the web displacement when the controller is operated
without a sensor positioning device follows a delta curve ( ).
When operated with a sensor positioning device, a sine-wave ( )
web displacement takes place. See also chapter A1, Point A 1.4.4‚
Oscillation types and curves’.
Osc. Mode – determine operating mode for oscillation mode

Osc. Mode sub-directory afterwards.
2. The set value for the web width (Nominal Width) is entered in
this window. Activation then takes place in the operating
status display using the F1 key.
The following settings are possible:
• • OFF: Oscillation is deactivated

(factory setting)
• Auto: Activation in operating mode
Automatic
Repositioning of material web is
carried out within the sensor visual
area with adjustable amplitude.

Commissioning B3
• SC: Activation in operating mode SC

using the servo-center component.
• FVG Auto: Oscillation with connected FVG
An FVG oscillation with sine-shaped
web repositioning.
Osc. Params. – Set oscillation parameters
The oscillation parameters, i.e. amplitude and frequency, are

set in this submenu.
1. Select the Osc. Params submenu and confirm by pressing

ENTER.
2. The parameters have the following meanings:
► Amplit. Auto [%]: Amplitude of the oscillation in operating

mode Automatic.
The percentage value relates to the size
of the sensor scanning area.
Setting range: 1 % to 99 %
► Amplit. SC [%]: Setting up the amplitude for the SC

operating mode
The percentage wise input of the
amplitude relates to the distance
between the software limit switches.
One limit switch represents 0 % and the
other 100 %.
► Amplit. FVG [mm] Amplitude of oscillation when using a

sensor positioning device.
The sample value shown here of
10 mm results in repositioning of the
web by ± 5 mm.
Setting range: 0 to 999.9 mm
► Frequency [Hz]: Oscillation frequency.

Setting range: 0.016 … 1.000 Hz

Commissioning B3
Osc. Params Add-on – Additional functions for oscillation

(can only be used for the sensor oscillation)
Additional specifications can be set for the sequence of the

oscillation in this sub-menu.
1. Select the sub-menu Osc. Params Add-on and

confirm with ENTER.
2. The parameters displayed in the setting menu have the

following meanings:
► start/stopp at act.pos:
Oscillation Add-on:
When the function is activated, the
oscillation will continue at the position
>> NOT FOR FVG OSC.!<< where it was stopped.
► start osc. after restart:

When the function is activated, the
oscillation is immediately started when
the system is switched back on.
B 3.6 Save settings

Once the parameters have been determined for the current system,
they can be saved. This enables the facility to access them again at
any time in the case that modifications have been carried out
unintentionally or by unauthorized persons.
1. Press the MENU button.

The Setup menu appears in the display.
2. Select Save/Load Settings menu and press ENTER.
3. Saving or loading the settings can now be carried out using

keys F2 or F3.
F2 = Save the entered setting
F3 = Load saved values
Attention! This setting cannot be copied to another

controller or saved externally.

Commissioning B3
B 3.7 Setup menu

The system parameters are saved in the Setup menu and they can
also be modified from here. The menu structure is shown in
Appendix D1.
B 3.7.1 Change User

Selection of user level-
User administration in the ekrPro Com60 differentiates between four
different user levels with different user rights.
The individual user levels are each protected by a password.
The procedure for selecting the user level is described in detail in
chapter B 3.4.
B 3.7.2 Material Setup - Sensor compensation
Automatic adjustment of the controller to match the characteristics of

the material to be scanned is carried out during material set-up
The procedure for material setup is described in chapter C 2.3.
B 3.7.3 Sel. Std. System –

Selection of a standard system

own system from a list of the most common standard systems listed
under the menu "Sel. Std. System".
entered in the setup menu.
The procedure for selecting a standard system is described in detail
in chapter B 3.5.
B 3.7.4 Save/Load Settings

You can use this function to save user-defined settings in the system
and call them up again. This gives you the facility for accessing them
at any time in the case that modifications have been carried out
unintentionally or by unauthorized persons.
The procedure for selecting a standard system is described in detail
in chapter B 3.6.

Commissioning B3
B 3.7.5 General Setup -

System parameters
All of the parameters that have to be set up once when aligning the
system are contained in the General set-up.
The following procedures are provided for the different operating

modes.
However, the default values should be loaded before the special
parameters are set up. This will meet the condition for a
standardised basic output.
B 3.7.5.1 Setting the default values
1. Go to the General set-up menus and then select Sel. Std.

System

Choose standard system … 2. Press the F1-key. The default settings will be loaded.
… & press F2 to activate
De f. Set.
4. The application specific parameters can be set up now.

Commissioning B3
B 3.7.5.2 Actuator – Actuator settings
B 3.7.5.2.1 Type (EMS&Hydr.) – Actuator selection
The relevant servo center component must be entered before

starting the commissioning
(see chapter B 3.7.5.2.4 ”servo-center component settings“).
Any remote control which may possibly be running, must be
deactivated!
The preset actuator is the EMS 17.

Actuator path limits and the servo-center component have to be
adjusted.
If a different motor-driven or hydraulic actuator is being used it

should first be selected from the option list.
The actuator selection procedure is shown on the left.
1. Press the MENU button, select General Set-up from the sub-
menu and then press ENTER.
2. Select Actuator in General Setup and then select the

Type (EMS&Hydr.) sub-directory afterwards.
Material Setup
Actuator
3. The default actuator will be displayed on the screen.
Sel. Std. Type
System
Sensors/EFE
Save/Load
(EMS&Hydr.)
Settings Add-on
Press the ENTER button and the actuator option list will then
Hydraulics
Control
General SetupLoop
Direction be opened.
opt.FVG
LogicSC-Transducer
Now use the vertical arrow keys to select the actual actuator
12 3 45 6 789 0 that is connected to the system.
Motor-driven actuators: EMS …

Hydraulic actuators: hyd. … mA
Select an actuator type
EMS 17
Note: If a hydraulic actuator is used, then additional
hydraulic settings must be made in the menu
Hydraulics Add On (see the following page).
Select an actuator type Press the ESC button to exit the window.
EMS 10
EMS 16
EMS 17
123 456 789 0

Commissioning B3
B 3.7.5.2.2 Hydraulics Add-on – Hydraulic settings
If a hydraulic actuator is used, then additional hydraulic settings

must be made in the menu Hydraulics Add On.

Hydraulics Add-on sub-directory afterwards.
2. This will open an inputting window, in which the settings for

the connected hydraulic actuator have to be entered.
The relevant settings are listed in the following table:
Zero elevation [%] 0
Dither amplitude [mA] 0
Use teach table
Specific current control
Unit Actuator Dither Zero Specific
name Type amplitude elevation current
Teach [mA] [%] control
SV 1-10/4 300 mA 10 0 No
SV 1-10/8 300 mA 10 0 No
SV 1-10/16 300 mA 20 0 No
SV 1-10/32 300 mA 20 0 No
SV 1-10/48 1000 mA 40 0 No
SV 1-6 300 mA 20 0 No
HR 024 300 mA 1* No
HR 040 300 mA 20 0 No
EH-St 9/3 300 mA 25 5 No

The dither frequency is 50Hz.
1* This setting is dependent on the fitted continuously operated
valve SV 1-10/x.
3. The system must be optimized to the actual settings after the

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

teach process. The relevant safety arrangements
must be implemented.
Zero elevation [%] 0
Use teach table X The flow curve determined for the controller must be activated in the
Specific current control
window if it is to be used.
Teach

Commissioning B3
Digital blocking output (oil blocking)
If a hydraulic actuator is used, then a blocking valve can be

connected to terminal 67 (X15), in order to interrupt the oil flow.
Oil blocking is only active with a hydraulic actuator and when one of
the following conditions is fulfilled:
• Man output = 0 and position controller deactivated.
• A limit switch position is reached.
• An over-temperature and a short circuit exist.
• Missing enable for the actuator:
(see actuator enable terminal 53)
Behaviour when oil blocking is switched on:

• PWM and analogue output are blocked.
• Blocking is activated after a 150 ms delay
(OV at terminal 67 (X15)
Behaviour when oil blocking is switched off:

• Blocking is deactivated
(24 V DC at terminal 67 (X15))
• Blocking is deactivated after a 150 ms delay.
B 3.7.5.2.3 Direction – setting the

actuator guiding direction
1. Select the sub-directory Direction from the menu Actuator.

If necessary, the actuator guiding direction for manual mode

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

manual operating mode.
The sensor allocation can be checked on the spot. Press the

MENU button. The operating display is shown.
Cover a sensor. The change to the coverage range shows the

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

Commissioning B3
B 3.7.5.2.4 SC Transducer -
Servo-center component settings
Type & Dir. –

Selecting the servo-center component
1. Select the sub-directory SC-Transducer from the Actuator

menu and then select Type & Dir..
2. Use the horizontal left or right arrow keys in the newly

not connected
opened window to select the servo-center component
selection window and confirm it by pressing ENTER.
3. Select and mark the relevant servo-center component from

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

The screen will ENTER to the previous window.
5. Drive the actuator using the F2 key, while monitoring the bar
indicator in the display.
Position feedback via the servo-center component must be
configured so that when the actuator is driven, the black bar
on the left side gets smaller.
If the length of the black bar increases when the F2 key is
pressed, inverting is to be switched on by selecting the check
box Inv..
Pressing key F3 must cause the black bar to increase towards

the right side.
The absolute position value supplied by the servo-center

component is displayed beneath the bar display.
Press the ESC button to exit the window.

Commissioning B3
Pos. Limit –
Setting the actuator path limits (software limit switches)
This sub-directory is only be used if an actuator with position

feedback (for example, EMS 17) is connected to the system.
This enables you to limit the actuator paths.

SC-Transducer and finally Pos. Limit.
2. Use the vertical arrow keys to deactivate the checkbox active.

This deactivates the function of both limit switches.
The settings can only be entered in the deactivated state.
3. Use the F2 key to drive the actuator until it reaches the

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

The limit switch position is stored.
The corresponding position value is shown below the
checkbox.
5. Use the F3 key to traverse the actuator until it reaches the

required right limit switch position.
7. Reactivate both limit switches.

Select (x) checkbox active to do this.
The description is given in section 2.
Import of the limit switch position is indicated by a black circle
in the read-only checkbox above the F1 and/or F4 key.

Commissioning B3
SC W & XP –
Setting the centre position and the gain for the SC operating mode
This sub-directory is only be used if an actuator with position

feedback (for example EMS 17) is connected to the system.
In this case the centre position setting option and the gain have to
be set up for the SC operating mode.

SC-Transducer and finally SC W & XP.
2. Press ENTER to open the inputting menu and enter the

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

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

actuator into the required position.
5. Press the F4 key if you want to save the actual position as the
set point for the servo-center position.
The setting from mot.pos. will be imported into setpoint W.
6. The setpoint value setpoint W and the gain gain XP can also
be entered directly in the relevant window.
7. The settings can be checked on the spot by switching over to

the SC operating mode.

Commissioning B3
B 3.7.5.2.5 Man Pos Control – Activation of the Position Controller
The position controller for ”manual” mode can be activated for

actuators with position feedback (e.g. EMS 17).
With the position controller activated, the actuator keeps the actual
position when in manual mode, independently of any external forces
acting on the drive (self-locking).
When using an OMG 4, OMG 8 or CK 37 servo-center

component, the position controller must be deactivated!

Man Pos. Control sub-directory afterwards.
2. Press the ENTER button to enter the inputting menu.
3. To switch on the position controller activate checkbox active

using the vertical arrow keys.
To test the position controller the actuator can be moved in

manual mode to a desired position using the F2 and F3 keys.
If the position controller is activated, the function can be

interrupted by pressing the F4 key (e.g. to prevent damage to
the material web).
B 3.7.5.2.6 Man Speed – adjustment speed for

manual mode
This sub-menu is used to set the positioning speed of the actuator in

manual operating mode.

Man Speed sub-directory afterwards.
2. Press the ENTER button to enter the inputting menu.
3. Enter the desired positioning speed in the editing box

MAN speed [1/1000].
Input of the positioning speed is as a percentage of the

maximum positioning speed.
The example value of 700 entered here means a positioning
speed of 700 per thousand = 70 percent of the maximum
speed.
To test the set positioning speed move the actuator using the
F2 and F3 keys.

Commissioning B3
B 3.7.5.3 Sensors/EFE – Commissioning sensors

and remote electronic fine adjustment
B 3.7.5.3.1 Sensor 1, 2, 3 – Commissioning sensors
The types of the sensors that are actually connected can be set up
in the sub-menus Sensor 1, Sensor 2 and Sensor 3.
The following must be undertaken before running the master set-up

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

The procedure is described for Sensor 1.
The master set-up for Sensors 2 and 3 is the same.
1. Select Sensors/EFE in General set-up and then select the

Sensor 1 sub-directory afterwards. Confirm the respective
selection by pressing ENTER.
2. Select the type of sensor that is connected to the system from

the option list displayed in the new window that has opened
up and then enter it.
Attention!
If the mounting position of the selected sensor differs from the
BST setting (see chapter A 1.4) or if the sensor outputs an
inverted signal (e.g. another manufacturer’s sensor is being
used), then the checkbox Inv. must be checked.
A master set-up will be carried out afterwards.
Select a sensor type Inv. Master set-up can be run automatically or manually.
sensor1 IR 2005
<<<
7% 3. Automatic master set-up:
dark bright
-2048 abs. 1775 2047 ► Press the F1 button and then cover the sensor’s scanning
auto dark bri.
window with an opaque material for two seconds
► Afterwards remove the material from the scanning window
and press the F2 button two seconds later.
► The master set-up for this sensor is finished.
4. Manual master set-up:

► Cover the sensor’s scanning window with an opaque
material and then press the F3 button.
► Remove the material so that the window is completely
uncovered and press the F4 button.
5. Run the master set-ups for Sensors 2 and 3.

Commissioning B3
Attention! If a reflection sensor is being used as Sensor 3

then only this sensor must be selected and
entered from the option list. You do not have to
run a master set-up.
B 3.7.5.3.2 EFE Remote Adj. –

Commissioning of remote electronic fine adjustment (EFE)
A remote electronic fine adjustment unit is not identified

automatically by the controller.
It must be entered in the set-up menu.
1. Select Sensors/EFE in General Setup and then select the

EFE Remote Adj. sub-directory afterwards.
2. Not connected is the default factory setting.

Select EFE 1 if a remote adjustment device is available.

Commissioning B3
B 3.7.5.4 Control Loop - Control loop settings
The parameters for the control circuit are set up in this sub-menu.
B 3.7.5.4.1 Gain & Offset – Amplification & setpoint values
1. Select Control Loop in General Set-up and confirm by

pressing ENTER afterwards.
2. Mark Gain & Offset in the selection window and then confirm
by pressing ENTER.
3. This will open up a window for the set point value and gain
settings.
The set value (W) for the web position and the gain setting
(XP) can be set up separately here for each of the guiding
modes.
We recommend that you should use the factory default
settings for standard controllers.
Setting range: 0 – 999.99

sens.mode W XP
0
0
5.00
5.00 4. Press the ESC button to exit the window after you have
0
0
5.00
5.00
entered the settings.
B 3.7.5.4.2 Adj. done Limits – Bearing position controlled
This function is only relevant when being used together with a

Profibus DP module for exchanging data with the customers
PLC. The corresponding protocol is Protocol 1049.
Using the specifications (notification threshold), evaluations are
made in this sub-menu as to when a new position that has been
approached is termed as controlled. This can then be used as
the start position for the following working sequence. This
notification threshold must be determined empirically and
individually for each application. You can only influence the
message and not to the controlling of the system.
1. Mark Adj.done Limits in the selection window and then

confirm by pressing ENTER.
2. Determine the values.

Note that: Larger values require an earlier message.

Commissioning B3
B 3.7.5.4.3 Speed Control – Speed regulation
When speed control is activated, speed variations, which can be

caused by varying loading of the actuator, are automatically
compensated.
This activation of this function is a default setting.
It must be deactivated if a tacho-generator is being used.
1. Select Speed control in the selection window and then

confirm by pressing ENTER.
2. Activate speed control using the vertical arrow keys:
active X

Commissioning B3
B 3.7.5.5 FVG –
Sensor positioning device
The control unit integrated in the controller for running the sensor
positioning device can be parameterised in this sub-menu.
A stepping motor drives the sensor adjustment unit.
short circuits.
commissioning.
The connection cable from the ekrPro Com60 control unit to the
sensor adjustment unit must not exceed the maximum cable
length of 20 m.
Power is continuously applied to the stepping motor output
stage, even when stopped. Therefore any work undertaken on
the interconnections must only be carried out with the power
switched off.
The FVG function has been set to not activated in the factory, i.e.
no further settings are required if an FVG is not connected to the
system.
The required setting must be entered if the FVG function will be

used.
B 3.7.5.5.1: Connection – Activating of the sensor positioning

device (FVG) connected
1. Select FVG in General Setup and confirm by pressing ENTER

afterwards.
2. Select Connection in the selection window and then press

ENTER to open the inputting menu.
3. Select the desired operating mode from the option list.
• Not Connected: The sensor positioning device is

deactivated (default setting).
• FVG eco: Move the sensors/FVG slides manually

by means of the controller arrow keys.
• FVG 1MK Op.: Sensor positioning device with stepping

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

Commissioning B3
Once the selection has been made, specific settings must be carried
out for the FVG eco, FVG 1MK Op. and FVG 2MK Op. modes.
B 3.7.5.5.2 FVG eco

The FVG eco mode allows the sensors/FVG slides belonging to the
FVG connected to be moved using the controller arrow keys. It
effectively represents manual operation of the FVG.
For this reason, automatic edge search functions and web width
adjustment are inactive in this mode.
The specific settings are analogue to those in the Internal FVG. The
procedure is described under point 3.7.5.5.3.
B 3.7.5.5.3 Internal FVG

The Int. FVG submenu is used when the FVG 1MK Op. mode has
been selected (normally when using a FVG 1K or FVG 1MK).
Homing Direction –
Retraction direction and limit switch assignment
The sensor’s retraction direction and the assignment of the limit

switches are set up in the next steps.
1. Mark Int. FVG in the FVG selection window and then confirm
by pressing ENTER. Select Homing Dir. from the sub-
directory and then press ENTER to open the inputting menu.
Change User
Actuator
Material Setup
Connected
Sel.Sensors/EFE
Std. Homing
Control
System Dir.
Loop
2. Press the F1 key to check the selected retraction direction.
General Setup
FVG
Retract Mode
opt. LogicErr. Behaviour By pressing the F1 key, the FVG slide must move outwards
(into the homing position).
123 456 789 0
After the homing position is reached, the limit switch with the
outer label must be activated ( ).
Exit the window without making any changes if the homing
direction and limit switch assignment are correct.
If the FVG slide moves inwards when the F1 key is pressed,
then the checkbox Homing dir. inv. should be activated.
If the limit switch with label inner is activated in the homing
position, then the checkbox Ref. switch inv. should be
activated.
Note: If the limit switch is activated but no checkbox

(outer or inner) is activated, then the limit switch
requires testing.
3. Press the ESC button to exit the inputting menu after you
have entered the setting.

Commissioning B3
The outside FVG1 limit switch has been determined as the reference
point for the FVG slide (offset = 0.0 mm)
Offset
Offset 2 (FVG)
FVG 1
FVG 2
Web running
direction
Offset 1 – position offset to FVG1 slide position

You can use the position offset to, for example, set the home
position (= 0.0 mm) to a fixed point, e.g. machine wall or a specific
point within the machine. The offset value is added to the current
FVG position, which results in the "Abs. slide pos.“
absolute position
Fixed point in the machine
(e.g. machine wall
offset actual FVG position
Home position
[Dist. from home = 0.0 mm]
Offset 2 – position offset to FVG2 slide position

The meaning of the entry and display fields is equivalent to those of
Offset 1.
2000 mm has been set as the default value for the FVG2 offset.
When carrying out initial start-up, this value must be adapted to the
actual FVG length.
If Sensor 2 moves in the opposite direction to Sensor 1, and if the

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

Commissioning B3
Range –
Traversing range limits
The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the
operating status screen.
1. Select Range from the sub-directory and then press ENTER

to open the inputting menu.
2. Press the F1 to start the retraction of the slides to the park

position (home position). After this position has been
reached, the FVG stops.
3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch
has been reached, press key F4 (set). This completes the
adjustment procedure.
4. Press key F1 to run the sensor to the park position so that you
can draw in the web at a later point.
have entered the settings.
If material has already been placed in the FVG adjustment range,

you can also enter the inside limit position directly into the editing
box.
If you are now working with a position offset, this does not need to
be referred to in this dialog window.
The following arises from the representation in the operating display.
The value shown gives the absolute

distance from the fixed point entered in
the offset dialog. In other words, the
position offset is included in the
numerical representation.
The relative position (bar representation) relates to

the range value entered.
In other words, the position offset is not included.
Feed – Feed for stepping motor/gearing combination
The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the

Commissioning B3
B 3.7.5.5.4 FVG Pro

The FVG Pro submenu is used when the FVG 2MK Op. mode has
been selected (usually when using an FVG 2MK). In this case, each
FVG needs to be adjusted separately. The terms used here FVG 1
(Slide 1) and FVG 2 (Slide 2) relate to the arrangements in
accordance with Point A 1.4.5.
The safety features are identical for both FVGs. The procedure for
FVG 1 (Slide 1) is used as the example here:
Homing Direction –
Retraction direction and limit switch assignment
The retraction direction of the sensors and the assignment of the

limit switches are set up in the next steps.
1. Mark FVG Pro in the FVG selection window and then

confirm by pressing ENTER. Select Slide 1 and confirm by
pressing ENTER.
2. Select Homing Dir. from the sub-directory and then press
3. Press the F1 key to check the selected retraction direction.
By pressing the F1 key, the FVG slide must move outwards
(into the homing position).
After the homing position is reached, the limit switch with the
outer label must be activated ( ).
Exit the window without making any changes if homing
direction and limit switch assignment are correct.
If the FVG slide moves inwards when the F1 key is pressed,
then the checkbox Homing dir. inv. should be activated.
If the limit switch with label inner is activated in the homing
position, then the checkbox Ref. switch inv. should be
activated.
Note: If the limit switch is activated but no checkbox

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

Commissioning B3
Offset –
positional offset to position of first FVG slide
You can create a reference system with an absolute reference point
using the positional offset. This reference point can, for example, be
the machine wall or another obvious point on the machine. It is also
possible to use an outer position or the centre of the FVG. If the
centre of the FVG is used, one of the FVG slides will move in a
negative direction.
The offset value is added to the current FVG position and results in
the absolute distance to this reference point (Abs. slide pos.).
The setting up of an absolute reference system is necessary for use

of the Pre-positioning function.
Example:
FVG 1
Offset FVG 1
FVG 2
Reference point
(zero position) Offset FVG 2
Tape measure
1. Press the F1-key. The FVG slides move to the home

position.
2. Measure offset FVG1 (distance between reference point Î
centre sensor measurement window) and enter the value
under offset [mm].
3. Use the F2 and F3 buttons to traverse the FVG a short path.
FVG 1
path travelled (Dist. from home)

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

Commissioning B3
The standard operating display now shows the position of the centre
of the measurement window belonging to the appropriate sensor
based on the reference point.
Range –
Traversing range limits for first FVG slide
The traversing range limits are entered in the menu Range.

They are the basis for displaying the traversing movement in the
operating status screen.
1. Select Range from the sub-directory and then press ENTER

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

position (home position). After this position has been
reached, the FVG stops.
3. Use the F2 or F3 buttons to carefully traverse the sensor in

the direction of the inner limit switch. Once the limit switch
has been reached, press key F4 (set). This completes the
adjustment procedure.
4. Press key F1 to move the sensor to the park position so that

you can draw in the web at a later point.
have entered the settings.
If material has already been placed in the FVG adjustment range,

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

Commissioning B3
Feed –
Feed for stepping motor/gearing combination
The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the
In addition to the specific settings which depend on the FVG used,

you should also carry out general settings for the FVG application in
the menu.
B 3.7.5.5.5 - Retract Mode – free-running mode
The retract mode determines when the FVG will traverse into the
park position (home position) after a specific operating mode
change.
Change User
Actuator
1. Select Retract Mode from the sub-directory and then press
Material Setup
Connected
Sel.Sensors/EFE
Std. Homing
System Dir. ENTER to open the selection menu.
Control
General SetupLoop
Retract Mode
FVG
opt. LogicErr. Behaviour
2. The following retract modes are available in the selection
123 456 789 0 menu:
• SC: The sensor positioning device will traverse into

the park position after switching over to the
Select a full retract mode SC mode
SC
Man.
• Man.: The sensor positioning device will traverse into
SC & Man. the park position after switching over to the
123 456 789 0 MAN mode
• SC & Man.: The sensor positioning device will traverse into

the park position after switching over to the
SC or MAN mode.
have made the selection.
B 3.7.5.5.6 - Norming Mode – Standardization Mode
The method for standardizing the FVG sensor can be selected in

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

Commissioning B3
1. Select Norming Mode from the sub-directory and then press

ENTER to open the selection menu.
2. The following norming modes are available in the selection

menu:
• Bright: Only a bright setting standardisation will be

carried out.
Select a norming mode This standardisation mode is normally used
for the infrared sensor IR 2002 with
Bright
Bright/Dark reflection bar.
No Norming
123 456 789 0 • Bright/Dark: Both bright and dark setting standardisations
will be carried out.
This standardisation mode is normally used
for infrared sensors with film material.
• No norming: Sensor standardisation will not be carried out.

This standardisation mode is normally used
for ultrasonic sensors.
B 3.7.5.5.7 - Width Adjust – FVG operating mode for center line guiding
Use Width Adjust to select FVG operating mode for center line
guiding.
1. Select Width Adjust from the sub-directory and then press

2. The standard values are already entered in the settings

menu. These should be adapted in accordance with the
application.
The sensor positioning unit follows the material web if more

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

Commissioning B3
25% covering
Start of sensor tracking
50% covering
End position
75% covering
Start of sensor tracking
• Lvl. Outer: The approach of the sensor towards the

material web generally occurs from the outside.
The FVG operating mode can be carried out in the MAN

mode, in the Automatic mode as well as the SC mode.
However, the change will only become effective in the
controller after the operating mode has been changed again.
If, for example, you want to change over and you are in
Automatic mode then you must change over to MAN mode
and then back to Automatic mode again. Only then will the
change become effective.
B 3.7.5.5.8 - Repositioning – repositioning of the material

after certain events
The current position of the material web is saved once an event

takes place (e.g. web tear). Once the event has been rectified, the
material is repositioned to this position. This functionality is only
effective once pre-positioning has been activated.
1. Select “Repositioning“ from the sub-menu and then press

ENTER.
2. Activate the required behaviour in the settings menu.

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

Commissioning B3
B 3.7.5.5.9 - Velocities – adjustment of positioning speeds
This function can be used to adapt the positioning speeds for

various actions.
1. Select Velocities from the sub-menu and then press

ENTER.
2. The standard values are already entered in the settings

menu.
These can be accepted as is or adapted to the application.
The parameters have the following meanings:

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

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

Speed which should be used when shifting the material web
manually in automatic operation (for example shifting the web
using remote-control arrow keys).
Fast Man. vel. [mm/s]:

Speed which should be used when moving the FVG slides in
the Manual operating mode (for example when moving the
FVG slides using a menu dialog box keys).
This parameter is only relevant for FVG eco application.
Norm. vel. [mm/s]:

Speed which is run during norming.

Commissioning B3
B 3.7.5.5.10 - Special – Special settings for moving the FVG slides

during edge searching
1. Select Special from the sub-directory and then press ENTER

2. Standard values have already been entered.

These can be accepted as is or adapted to the application.
Mode after Error:

Operating mode which the system switches to after an error
occurs (e.g. web tear).
Sensor-cover-guarding:
This monitoring function prevents destruction of the material
web due to unwanted contact with the sensors.
If the coverage of the sensor scanning area, with the
checkbox activated, exceeds 90 % of full coverage, then the
FVG slides are automatically stopped.
This monitoring function is only active when oscillation

is activated or during sensor positioning.

Commissioning B3
B 3.7.5.6 Width Measure - Web width measurement
The parameters required when using a width-measuring unit are set

up in this sub-menu.
B 3.7.5.6.1 Ref. Width – Width of the calibration sheet
A piece of material with a known width must be used once as a

reference for adjusting the web width measurement.
1. Select Width Measure in General Set-up and confirm by

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

the ENTER button to call up the inputting window.
3. Insert calibration sheet and start width measurement. To do

this you must switch over to centerline guiding and then
select Automatic operating mode.

current width:
mm
4. Enter the width under enter ref. width after the sensors have
enter ref.width .0 reached the edges of the calibration sheet and press the F3
set ref button to take over the entered value.
5. The adjustment procedure is finished.

The actual measured value (current width) and the entered
reference value (ref. width) must both show the same size.
The reference width value last entered remains saved when the
device is switched off.
Inserting the calibration sheet:
First check the dimensions of the calibration sheet.
Important:
The calibration sheet reference dimension can change marginally
due to the effects of heat. Information relating to various
temperatures is given on the calibration sheet.
To obtain the best results, use the reference dimension for the
temperature which is nearest to the actual temperature, or
interpolate the dimension between these two temperatures.

Commissioning B3
B 3.7.5.6.2 Limits – Set width, error and warning limits
The set value for the web width (Nominal Width) is entered in this
window. The lower and upper error limits (E+, E-) and the lower and
upper warning limits (W+, W-) are also set up here. The measuring
unit is mm.
These are the entries which form the basis for the operating display
when the web width measurement is active.
Five conditions are indicated.
a) Material width is in valid range.
b) Material width is too wide when related to the upper warning

limit;
it lies in the W+ area (24V DC at output 66).
Material width
W+
c) Material width is too small when related to the lower warning
limit;
it lies in the W- area (24V DC at output 65).
Material width
W-
d) The material width lies outside the absolute tolerance.
It lies in the error limit areas E+ (24 VDC at output 66)
Material width
E+
e) The material width lies outside the absolute tolerance.
It lies in the error limit areas E- (24 VDC at output 65)
Material width
E-
Digital message outputs are available for the limits.
The meaning and allocation of messages relating to digital
outputs are described under Point B 3.7.5.9.2.

Commissioning B3
1. Select Limits in the selection window and press the ENTER

key. This will open up the input window.
2. Enter the nominal value for the material width in the edit field
Nominal Width.
3. Enter selected values for the error and warning limits in the
corresponding edit fields.
80.0
-5.0
5.0
-2.0
4. Press the ESC button to exit the window after you have
2.0 entered the settings.
B 3.7.5.6.3 Opmodes – Operating modes in which the

width measurement should be active
You can use this window to determine in which operating modes the
width measurement is able to be implemented.
This makes it also possible to carry out a web width measurement
without an FVG if the checkbox has been activated for the
corresponding operating mode.
If an FVG is connected, the condition is that retraction has been

deactivated for the selected operating mode(s).
1. Mark Opmodes in the selection window and then press the

ENTER button. This will open up the input window.
2. Select the desired mode(s).
3. Press the ESC button to exit the window after you have
entered the settings.

Commissioning B3
B 3.7.5.7 Edge Sources - Assignment of the sensors

to the scanning modes
The ekrPro Com60 controller allows the free assignment of the

connected sensors to different scanning modes.
Therefore each scanning mode can have the input signal of any
sensor allocated to it. For example, it is possible to assign the
"sensor right" sample mode selection key to the sensor connected
as "sensor left".
If the controller is operated via a CAN bus, the scanning modes can
also be assigned to the input signals of sensors which are
connected to another controller of the BUS-system.
1. Select Edge Sources in General Setup and confirm by

2. A sample type selection window opens.

The following selection types can be selected:
Guiding Control input Key

Mode
Edge 1 Edge 1
Edge 2 Edge 2
Edge 3 Edge 3 (contrast transition)
Src. SC Centre position control

encoder
Src. EFE Electronic remote fine —

adjustment unit
3. Select sample mode using the vertical arrow keys and press
ENTER.
4. The input window appears for the selected sample mode.
5. If the selected sample mode is to be assigned to the input

signal of a sensor that is connected to another CAN bus unit,
then select the option list device and press the ENTER key to
open it.
All the units connected to the CAN bus are displayed in the
opened option list.
6. Select the desired CAN bus unit and press ENTER.
7. Select the option list edge using the horizontal arrow keys and
press ENTER.
8. Select the sensor from the option list to whose input signal the
selected sample mode is to be assigned and press ENTER.

Commissioning B3
9. The input value supplied by the selected sensor can be shown

in this window as either an absolute or normalized
(percentage) value.
To activate normalized display, select checkbox norm..
10. If necessary, the checkbox inv. is used to invert the input

signal delivered by the sensor.
Inverting is necessary, if the input value delivered by the
sensor changes in the wrong direction when material is
brought into the sensor measurement area.
11. Use the function keys F2 and F3 to drive the actuator in

Manual operating mode.
This enables checking of the change in the sensor signal with
an inserted material web.

Commissioning B3
B 3.7.5.8 Add. Functions – Special function
Explanations for the requirements and function of both special

functions can be obtained under point 3.5.8. The parameter settings
are carried out as follows:
B 3.7.5.8.1 Tear Off Det. – Tear Off Detection
Setting of the parameters for the function Tear-off detection is

made separately for each guiding mode. If necessary, a different
sensor can be allocated as the tear-off detection sensor for each
guiding mode. It is also possible to allocate two different guiding
modes with different parameters to a single sensor.

Tear Off Det. sub-directory afterwards.
2. Select the desired guiding mode (Edge 1, Edge 2, Edge 3,

Center 1&2) from the option list.
3. This will open up the inputting window for the selected guiding
mode. The following separate parameters can be set:
► Sensor: Selection of the sensor with which tear-

off detection is to be implemented.
► threshold [%]: Percentage covering of the sensor

measuring band, above which a change
is detected as a tear.
For the example value entered here
(80/20), this means that the function
detects a tear, if more than 80% or less
than 20% of the sensor measuring band
is covered.
► sig. chg. limit. [%/4ms]: Maximum permissible rate of

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

until blocking of the guiding system.
► hold [ms]: Blocking hold time in ms after the

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

Commissioning B3
4. If necessary, set parameters for further guiding modes

(see points 2 and 3).
B 3.7.5.8.2 Oscillation
This special function enables the position of the web of material to
be displaced within the sensor´s visual range using adjustable
amplitude (size of the lateral displacement) and frequencies
(displacement speed).
The format of the web displacement when the controller is operated
without a sensor positioning device follows a delta curve ( ).
When operated with a sensor positioning device, a sine-wave ( )
web displacement takes place. See also chapter A1, Point A 1.4.4‚
Oscillation types and curves’.
Osc. Mode – determine operating mode for oscillation mode

„Osc. Mode“ sub-directory afterwards.
2. The set value for the web width (Nominal Width) is entered in
this window. Activation then takes place in the operating
status display using the F1 key.
The following settings are possible:
• • OFF: Oscillation is deactivated

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

Commissioning B3
Osc. Params. – Set oscillation parameters
The oscillation parameters, i.e. amplitude and frequency, are

set in this submenu.
1. The Osc. Params submenu Select Sensor 1 and confirm by

pressing ENTER.
2. The parameters have the following meanings:
► Amplit. Auto [%]: Amplitude of the oscillation in operating

mode Automatic.
The percentage value relates to the size
of the sensor scanning area.
► Amplit. SC [%]: Setting up the amplitude for the SC

operating mode
The percentage wise input of the
amplitude relates to the distance
between the software limit switches.
One limit switch represents 0 % and the
other 100 %.
► Amplit. FVG [mm] Amplitude of oscillation when using a

sensor positioning device.
The sample value shown here of
10 mm results in repositioning of the
web by ± 5 mm.
Setting range: 0 to 999.9 mm
► Frequency [Hz]: Oscillation frequency.

Setting range: 0.016 … 1.000 Hz

Commissioning B3
B 3.7.5.9 Dig. IO Config. - Configuration of the

digital inputs and outputs
B 3.7.5.9.1 Configure –
selection of digital input table and activation of inputs/outputs
You can select from two tables in this dialog window. Both
contain various assignments for the digital inputs (see Point
B 3.7.5.9.3).
The tables are created so that they cover most of the
applications controllable using digital inputs, which helps
avoid time-consuming configurations.
Specific adjustments can, however, still be carried out if
required.
The procedure is described under Point B 3.7.5.9.2.
1. Select Dig. IO in General Setup and then select the

Configure sub-directory afterwards.
2. Select the required input table. The Dig.In Table 1

(Default Table) and Dig.In Table 2 (Special Shifted
Center) tables are available for selection.
The input assignment for each table is represented in
Point B 3.7.5.9.3. Confirm the selection with the F2 (Set.)
key.
Both digital inputs and outputs can be switched off for initial
startup. Please deactivate the appropriate checkboxes to do
this.
Attention! Any activated Ext.Lock functionality will be

cancelled by deactivating the IN ena. checkbox.
Thus, the actuator can carry out positioning
movements.
The controller release is, however, not
influenced.
B 3.7.5.9.2 Inputs –
Digital inputs
When necessary this sub-menu permits changing of the assignment

of various functions to the digital inputs of the controller. Moreover
the respective signal pattern (bit mask), which must be applied to the
digital inputs (terminals 74 – 85) in order to activate a particular
function, can be changed.
The procedure for changing the factory-set standard configurations

of the digital inputs is explained in the following two examples,
based on the Dig.In Table 1 (Default Table).

Commissioning B3
Example 1: The function Tear-off detection is to be assigned to

the digital inputs (lines 29 and 30).
In so doing, the standard bit-pattern for lines 29 and
30 must not be changed.
1. Select Dig. IO in General Setup and then select the

Inputs sub-directory afterwards.
2. The digital inputs setting window opens.
Truth Table Pattern

3. Use the function keys F1 (next row) or F2 (previous line) to
no. assigned function select the stored truth table.
29 Keyb.Lock ON
Bitmask
The option list displays the factory assigned function (Keyb.
85 1 74 Lock ON) for row 29.
Ln Ln deac t.
Truth Table Pattern

no. assigned function 4. Select the option list using the horizontal arrow keys and open
29 Tear Out ON by pressing ENTER.
Bitmask
85 1 74 The option list contains all the available functions.
Ln Ln deac t.
5. Select the function Tear Out ON (tear-off detection ON) using
the vertical arrow keys and press ENTER.
Truth Table Pattern
no. assigned function 6. Select line 30 using function key F2.
30 Keyb.Lock OFF The option list displays the factory assigned function ("Keyb.
Bitmask
85 0 74 Lock OFF) for line 30.
Ln Ln deac t.
7. Select the option list using the horizontal arrow keys and open
Truth Table Pattern by pressing ENTER.
no. assigned function
30 Tear Out OFF
Bitmask
85 0 74
8. Select the function Tear Out OFF (tear-off detection OFF)
using the vertical arrow keys and press ENTER.
Ln Ln deac t.
Assignment of the function Tear-off detection to the digital
inputs is now completed.
By pressing function key F3 (deact.) within the menu, all

bits of the selected bit pattern are set to “1”.

Commissioning B3
Example 2: The function Tear-off detection is to be assigned to

the digital inputs (lines 21 and 22).
The following section of the truth table shows that lines 21 and 22
belong to a bit-block with a total of 8 lines (lines 21 to 28).
Factory allocation of functions

with the corresponding standard bit-patterns
Terminal
Line Significance 85 84 83 82 81 80 79 78 77 76 75 74
20 FVG stop X X X 1 1 1 X X X X X X
21 Set Lim.Sw. 1 X 1 0 X X X X X X X X X
22 Reset Lim.Sw. 1 X 0 0 X X X X X X X X X
27 Set Overtemp. X 1 1 X X X X X X X X X
28 Reset Overtemp. X 0 0 X X X X X X X X X
29 Keyb.Lock ON 1 X X X X X X X X X X X
User defined allocations -

function Tear-off detection on lines 21 and 22
Terminal
20 dig. Left/Right Stop X X X 1 1 1 X X X X X X
21 Tear Out ON X 1 X X X X X X X X X X
22 Tear Out OFF X 0 X X X X X X X X X X
23 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
24 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
25 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
26 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
27 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
28 Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
The procedure for changing the allocations can be divided into three
steps, which are described on the following page.

Commissioning B3
Step 1: Cancel the factory allocations of functions.

As the function tear-off detection requires only lines 21
and 22 of the bit block, the factory-side allocation of
functions to the remaining lines of the block (lines 23 to
28) must be cancelled.
Accordingly the function Do Nothing is allocated to lines
23 to 28 from the option list.
The procedure for doing this is described in example 1.
Moreover the values of all bits in the non-required lines

19 to 24 must be set to “1”.
Procedure:
1. Use the function keys F1 and F2 to sequentially

select the individual block lines.
2. Use the horizontal arrow keys to the change the bit
pattern (Bitmask) display.
3. Sequentially select the individual bits using the
horizontal arrow keys and use the vertical arrow
keys to set the value of the selected bit to “1”. The
values of all 12 bits must be set to "1”.
Step 2: Assign new function

The function Tear Out ON (tear-off detection ON) is
assigned to the line 21 and the function Tear Out OFF
(tear-off detection OFF) is assigned to the line 22.
The procedure for doing this is described in example 1.
Step 3: Adjust bit pattern

In line 21 the bit for terminal 84 is assigned the value ”1“
(24 V signal applied to terminal 84).
In line 22 the bit for terminal 84 is assigned the value ”0“
(0 V signal applied to terminal 84).
The value for all the non-relevant bits (terminal 83) of the
two lines 21 and 22 must be set to the value "X"
(not relevant).
The procedure for changing the bit values is described in

step 1.

Commissioning B3
B 3.7.5.9.3 Truth table
Default values for digital input allocation: Dig. InTable 1
Terminal
1 set Auto X X X X X X X X X 1 0 0
(automatic mode)
2 set MAN X X X X X X X X X 0 0 1
(manual mode)
3 set SC X X X X X X X X X 0 1 0
(servo center position)
4 opmode clear X X X X X X X X X 0 0 0
(defined zero state operating mode)
5 set Edge1 X X X X X X 0 0 1 X X X
(edge 1)
(edge 2)
7 set Center1&2 X X X X X X 0 1 1 X X X
(center 1/2)
(edge 3)
9 set Edge3 Inv. (inverse edge 3) X X X X X X 1 0 1 X X X
10 guid.mode clear X X X X X X 0 0 0 X X X
(defined zero state guiding mode)
11 Motor stop X X X 0 0 0 X X X X X X
15 Motor left X X X 0 1 0 X X X X X X
16 FVG left X X X 0 1 1 X X X X X X
17 Motor right X X X 1 0 0 X X X X X X
18 FVG right X X X 1 0 1 X X X X X X
(stop switch 1)
(reset stop switch 1)
(stop switch 2)

Commissioning B3
Terminal
(over-temperature)
(reset over-temperature)
(keyboard interlock on)
30 Keyb.Lock OFF 0 X X X X X X X X X X X
(keyboard interlock off)
31 - Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
60 (reserved)
Alternative digital input allocation: see Dig. In Table 2:
Terminal
1 set Auto X X X X X X X X X 1 0 0
(automatic mode)
2 set MAN X X X X X X X X X 0 0 1
(manual mode)
3 set SC X X X X X X X X X 0 1 0
(servo center position)
4 opmode clear X X X X X X X X X 0 0 0
(defined zero state operating mode)
5 set Edge1 X X X X X 0 0 0 1 X X X
(edge 1)
6 set Edge2 X X X X X 0 0 1 0 X X X
(edge 2)
7 set Center1&2 X X X X X X 0 1 1 X X X
(center 1/2)
(edge 3)
9 set Edge3 Inv. (inverse edge 3) X X X X X X 1 0 1 X X X
10 guid.mode clear X X X X X X 0 0 0 X X X
(defined zero state guiding mode)
11 Shifted Center OFF X X X X X 0 X X X X X X
12 Reset Prepos. Center X X X X X 1 X X X X X X
(reset pre-positioning to centre)
13 Shifted Center ON X X X X X 1 X X X X X X
14 Set Prepos. Center X X X X X 0 X X X X X X
(pre-positioning to centre)
15 set Center1&2 X X X X X 1 X X X X X X
(center 1/2)
16 FVG left X X X 0 1 X X X X X X X
17 FVG right X X X 1 0 X X X X X X X
18 FVG stop X X X 1 1 X X X X X X X
19 FVG stop X X X 0 0 X X X X X X X

Commissioning B3
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
20 Set limit switch 1 X 1 0 X X X X X X X X X
28 Ext. Unlock 1 X X X X X X X X X X X
29 Ext. lock 0 X X X X X X X X X X X
30 - Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
60 (reserved)
0 = 0 V signal 1 = 24 V signal X = not relevant
Controller interlock
The controller interlock is generally activated. The function can only
be deactivated by application of a "1” signal (24 V=) to terminal 53.
If the controller block is activated, the output of the output stage is
switched off.
The actuator will not carry out any guiding movements.
This is valid for all operating or guiding modes (AUTO, MAN, SC).
Keyboard interlock
All of the controller’s keys are locked by a “1“ (24 VDC) on
terminal 85. The controller can be controlled via the keyboard when
this signal is no longer set.
The individual lines in the truth table can each be allocated the
following meaning:
Significance Significance Significance Significance

• Do Nothing • Motor Left • Reset Overtemp. • Reset Prepos. E1
• set AUTO • Motor Right • Keyb. Lock ON • Set Prepos. E2
• set MAN • Motor Stop • Keyb. Lock OFF • Reset Prepos. E2
• set SC • FVG Left • Osc. ON • Set Prepos. C1&2
• opmode clear • FVG Right • Osc. OFF • Reset Prepos. C1&2
• set Edge 1 • FVG Stop • Tear Out ON • Set Prepos. Center
• set Edge 2 • Set Lim.sw. 1 • Tear Out OFF • Reset Prepos.
• set Center 1&2 • Reset Lim.sw. 1 • ext. Lock Center
• set Edge 3 • Set Lim.sw. 2 • ext. Unlock • Copy cur.pos. to
Prepos.
• set Edge 3 inv. • Reset lim.sw. 2 • Set W.
• guid. mode clear • Set Overtemp. • Set Prepos. E1

Commissioning B3
B 3.7.5.9.4 Outputs –
Digital outputs
This sub-menu allows various messages to be assigned to the

digital outputs of the control unit (terminal 64 – 67).
The meaning of the individual messages can be taken from the table
on the following page.
1. Select Dig. IO Config. in General Setup and then select the

Outputs” sub-directory afterwards.
2. The digital outputs setting window opens.
3. Select the option list for the desired terminal (64 – 67) using
the horizontal arrow keys and press ENTER.
Dig. Outp. Cond. Low act.
64 no Errors
65 W. warn nor err. min.
66 W. warn nor err. max.
4. In the opened option list mark the message that is to be
67 Hyd. Lock allocated to the selected terminal and press ENTER.
def.
5. Set interface conditions for the signal via the checkbox
Low act..
Signal = high active Î deactivate checkbox
Signal = low-active Î activate checkbox
By pressing F4 (def.) the allocated messages and interface

conditions are reset for all terminals (64 – 67) to the factory
settings.
6. Press the "ESC" button to exit the window after allocating the
messages.

Commissioning B3
Signification of the messages
Report Significance
no Errors OK message output

Width err. min. Web width measurement: Web width has fallen below the lower error limit.
Width warn min. Web width measurement: Web width has fallen below the lower warning limit.
Width warn max. Web width measurement: Web width has exceeded upper warning limit.
Width err. max. Web width measurement: Web width has exceeded upper error limit.
W. warn nor err. min. Web width measurement: Web width has neither fallen below lower warning
limit nor lower error limit.
W. warn nor err. max. Web width measurement: Web width has neither exceeded upper warning
limit nor upper error limit.
Width valid Web width measurement: Valid value
Hyd. Lock Output oil blocking
Tear Off Output tear-off detection
Motor Locked Actuator is locked (the motor symbol appears in the display with a lock in it).
Current Err. The current for the selected drive has exceeded the permissible current.
Short Circ. Err. Short circuit
Mot. Temp. Err. Overtemperature
Amp. Dis. Err. Controller not released. 24 V signal on terminal 53 missing.
Limit Sw. Err. Actuator has reached a software limit switch.
Edge Search t/o Err. Sensor positioning device: Timeout for edge detection process
Norming t/o Err. Sensor positioning device: Timeout for sensor normalisation
Norming Err. Sensor positioning device: Error during sensor normalisation
Edge Search Err. Sensor positioning device: Error during edge detection
Retr. t/o Err. Sensor positioning device: Timeout during free-running process
Lock Err. Sensor positioning device: Motor output stage blocked
Width Meas. Err. Sensor positioning device: During guidance (automatic operation), a slide of
the sensor positioning device has driven into the
inner limit switch.
Width Adj. Err. Sensor positioning device: During guidance (automatic operation), a slide of
the sensor positioning device has driven into the
inner limit switch.
Low Volt Err. Collective error message
(Condition changes with a change of the error LED in the controller front plate)
opt. Logic Err. Error in the optional logic
opt. Logic Bool 1 Optional logic output 1 (Params 1)

Commissioning B3
B 3.7.5.10 Special - Special device settings
Passwords can be changed, the firmware can be restarted and the

default delivery state can be reset from the Special sub-menu.
B 3.6.4.10.1 Change Password
This window is used to set the password for current active user level
and the timeout time for an automatic logout.
The password consists of a maximum of 5 figures (0 ...9).
If no key is pressed for the duration of the set timeout time, the user
is automatically logged out and the user Operator is activated.
All passwords can be reset to the factory set delivery

condition up to 20 seconds after switching on of the
controller by simultaneously pressing the keys F4 + ESC.
1. Select Special in General Set-up and confirm by pressing

ENTER afterwards.
2. Change Pwd. is marked in the following window.

Press the ENTER button to call up the inputting window.
3. In the now open window, the current active user level is

shown in the field User level (in the example Admin).
4. Use the right and left arrow keys to select the Password
editing box and press ENTER.
5. Enter a new password in the editing box and confirm input by

pressing ENTER.
Set Password using F2 6. Finally to store the new password, press the F2 key.
Set Timeout using F3
User level: Admin
Password 0 7. Use the right and left arrow keys to select the Timeout [min]
Timeout [min] 0
editing box and press ENTER.
st.pwd set t/o
8. Enter the new timeout value and confirm the entry with
ENTER.
If the timeout time is set to “0”, then no automatic logout
occurs.
Input of a timeout time greater than 0 prevents a user with
extensive user rights from forgetting to log him(her)self out.

Commissioning B3
B 3.6.4.10.2 Dev. Config. – General unit settings
The general ekrPro Com60 unit settings are entered in the

Dev. Config. sub-menu.

ENTER afterwards.
2. Select Dev. Config. in the following window.
3. This will open up the unit settings window for the general
device settings. This contains the following separate
parameters:
► Bklght Tm.: Duration that the screen background

lighting will remain switched on after the
last button
The setting is entered in 1/10 second.
Entering ’0’ will switch the background
illumination on permanently.
► Show err.: The display is activated by default 7.

Every error occurring will be displayed and
a message will be generated. However,
the error will only be displayed for as long
as the error lasts (i.e. the error LED
illuminates).
► Conf. err.: Confirms the displayed error.

If the function has been activated, the error
will remain displayed until the operator
confirms it by pressing the ENTER button.
The report will continue to be displayed if
the error has not been eliminated.
► SW Ver.: Displays the version number of the firm-

ware which is installed in the controller.
► WC: only for service purposes!
► Low V cnt.: Counter for undershooting of the

admissible operating voltage range

Commissioning B3
B 3.7.5.10.3 Reset – Reset of the firmware
Resetting the firmware might be necessary, for example, if the

controller:
• The display settings are wrong
• The LEDs in the buttons do not illuminate
• The error LED cannot be extinguished.
A defined state is set up when the unit is reset.

ENTER afterwards.
2. Select Reset in the following window.
3. Press the ENTER button to execute a restart.
The restart will not change any of the saved data.
B 3.7.5.10.4 Watchdog Test – Test program for service purposes

Test
These functions are only used for service purposes.

They cannot be selected by the customer.

Commissioning B3
B 3.7.6 Opt. Logic - Optional logic

It is possible to integrate an optional logic module in the
ekrPro Com60 for customer specific applications.
In this case there will be a separate branch available in the set-up
menu.
The separate windows can still be called up even if an optional logic

module has not been integrated, but you cannot make any entries.
The window for Params 1 and Params 2 have an identical layout.
The entries must first be loaded using the customer specific

software.
This customer specific software is described in a separate
document.
B 3.7.7 Fieldbus
It is possible to integrate a relevant field bus module to link into the
customer’s control system / network.
A separate menu branch is also provided for this.
This part of the set-up menu enables the operator to modify or read
out the configuration settings for the field bus version that is being
used.
No settings can be entered unless the field bus connection has been
set up.
In this case the field bus status window only displays the information
unknown (field bus has not been detected).
The configuration and operation descriptions are a separate

document.

Commissioning B3
B 3.7.8 Remote Device – Unit remote control

via CAN bus
Devices in the controller family (ekrPro Com60, ekrPro Key60) can be
interconnected via a CAN-Bus to form a networked system.
The function Unit remote control allows to operate the controllers
available in the system from different sources (e.g. from another
controller ekrPro Com60 or from an external control keyboard
ekrPro Key60).
Selection of the unit to be controlled is made via the menu Remote
Device.
1. Select menu Remote Device and press ENTER.
2. The selection window for unit remote control appears.

After opening the option list device, all field bus devices found
on the CAN bus are displayed.
3. Select the device that is to be remotely controlled from the

option list and press ENTER.
The displays of the remotely controlled unit now appear in the
display. All key operations now act directly on the remotely
controlled unit.
No remote control chaining is possible. If an

Select remote device attempt is made to remotely control a further unit
device this device via an already remotely controlled unit, this is
To terminate remote prevented.
session press ENTER-ESC
4. To end unit remote control, simultaneously press the ENTER

+ and ESC keys.
Control function for unit remote control
The control function allows a user, to check the selection of a unit to

be remotely controlled without causing any change to the unit
settings.
Mistakes in selecting the unit to be remotely controlled, through
which an incorrect unit is remotely controlled via the CAN bus, are
avoided in this way.
1. Call up the adjoining CAN bus operating condition display

(see chapter C 2.1.1).
2. Press and hold the ENTER button.

All LEDs on the operating keyboard on the remotely controlled
control unit flash, as long as the ENTER key is pressed down.
The remotely controlled control unit can thus be
unambiguously identified.
If no other unit has been previously selected, then the LEDs
flash on the operating keyboard of the unit on which the
ENTER key is being pressed.

Commissioning B3
INDEX
Adjust password .............................................. 7 Material set-up
CAN-Bus Automatic .......................................................... 14
Checking and setting up the unit address .......... 3 Manual .............................................................. 14
ekrPro Com60 ............................................. 3 Sensor compensation ....................................... 26
ekrPro Key60............................................... 4 Save settings ................................................... 25
FVGPro Module........................................... 4 Setup-Menu ..................................................... 26
Commissioning ................................................... 3 Change User - Selection of user level .............. 26
Terminator activation .......................................... 5 Fieldbus............................................................. 71
BST ProLogic .............................................. 6 Optional logic .................................................... 71
ekrPro Com60 ............................................. 5 Remote control via CAN bus ............................ 72
ekrPro Key60............................................... 5 Save/Load Settings........................................... 26
FVGPro Modul............................................. 6 Selection of a standard system......................... 26
Elecrical connections....................................... 2 Sensor compensation ....................................... 26
General information ......................................... 1 System parameters........................................... 27
General Setup Special functions
Actuator settings............................................... 28 Oscillation.......................................................... 23
Assignment of the sensors to the scanning Tear off detection .............................................. 19
modes ........................................................... 54 Standard system
Commissioning sensors and EFE .................... 35 Carry out master setup ..................................... 10
Configuration of the digital inputs and outputs . 59 Carry out material setup.................................... 13
Inputs......................................................... 59 Commissioning ................................................... 9
Outputs...................................................... 66 Select .................................................................. 9
Signification of the error messages........... 67 Sensor positioning device ................................. 15
Truth table ................................................. 63 Setting the actuator guiding direction ............... 11
Control loop settings......................................... 37 Setting the actuator path limits ......................... 11
Sensor positioning device ................................ 39 Settings centre position and gain for ................ 12
Setting the default values ................................. 27 Special functions............................................... 19
Special device settings ..................................... 68
Special functions .............................................. 56
System parameters .......................................... 27
Web width measurement.................................. 51

Terminal diagrams / Service displays B4
4 Terminal assignments and service displays
B 4.1 Board overview
ekrPro Com60 web guide controller EDV-No.:MD.191.01.05/1.6.x Appendix B 4

B 4.2 Terminal diagrams

B 4.2.1 Overview
Terminal Function Remarks

strip
X1 Analog sensor 1
X2 Analog sensor 2
X3 Analog sensor 3 SC encoder / Namur
X4 Analog sensor 4 EFE
X6 Power supply 24V DC Input

X7 DC motor (controller)
X8 CAN
X10 Enable and reference switch (FVG)
X12 Stepping motor (FVG)
X14 Digital inputs

X15 Digital outputs
X16 Analog outputs ±10V and tacho
X17 Power supply (output 24V DC) for camera, etc.
X18 Power supply (output 24V DC) for camera, etc.
X19 Power supply (output 24V DC) for internal auxiliary module
X20 PLC I/O (option) PLC connection option
X40 JTAG / OCDS

X41 RS232 Bootstrap
X42 RS232_TTL Field-bus
X44 RS232_PLC PLC development
X45 Display / keyboard
X46 Micro-processor – parallel 8 bit bus for auxiliary module

B 4.2.2 Terminal strip X1; Sensor 1:
Plug Terminal Function Remarks

X1
1 Internal connection
to terminal 8
2 IR pulse + 5 V/
Synchronisation for US sensor
X50 3 IR pulse GND
4 + 12 V Output + 12 V
5 GND
6 - 12 V Output – 12 V
7 Analog input 4
B 4.2.3 Terminal strip X2; sensor 2:

X2
8 Internal connection
to terminal 1
9 IR pulse +5V/
Synchronisation for US sensor
X51 10 IR pulse GND
11 +12V Output ±12V
12 GND
13 -12V Output -12V
14 Analog input 6
B 4.2.4 Terminal strip X3; Position controller (SC) / servo-center component OMG 4 / Namur:

X3

45 GND
46 -12V Output -12V
47 Analog input 3
48 Namur Out A link must be fitted across
49 Namur A terminals 47 and 48 if you are
using a Namur encoder connected
50 Namur B to terminals 49 and 50.

B 4.2.5 Terminal strip X4; Sensor 3 / EFE / OZ3:

X4
15 +5V / 1A
16 GND (+5V)
18 GND
19 -12V Output -12V
20 Analog input 7 Sensor 3
21 Analog input 1 EFE1 / OZ3
B 4.2.6 Terminal strip X6; Power supplies:

X6
40 GND
41 +24V
B 4.2.7 Terminal strip X7; Actuator:

X7
42 Actuator A
X60
43 Actuator B
B 4.2.8 Terminal strip X8; CAN connections:
Plug Terminal Signal Remarks

X8
88 CAN_GND
89 CAN_L
X100
X101 90 CAN_SHLD
91 CAN_H

B 4.2.9 Terminal strip X10; Enable and reference switch (FVG):

X10
51 GND GND for enable actuator
52 +24V +24V output for enable actuator
53 Enable actuator Enable actuator input. Link to terminal 52
if not used
54 GND GND for enable FVG
55 +24V +24V output for enable FVG
56 Enable FVG Enable FVG input. Link to terminal 55 if
not used
57 GND GND for reference switch 1
58 +24V +24V output for reference switch 1
59 Reference switch 1 (FVG) Reference switch 1 input (FVG)
outer stop switch
60 GND GND for reference switch 2
61 +24V +24V output for reference switch 1
62 Reference switch 2 (FVG) Reference switch 2 input (FVG)
inner stop switch
B 04.02.10 Terminal strip X12; FVG stepping motor:
Plug Terminal Motor plug pin Function Remarks

X12 assignments
36 3 Winding 2A
37 4 Winding 2B Outputs are not short
38 1 Winding 1A circuit protected
39 6 Winding 1B
X65 Shield Shield The shield is not
attached. The end of
the line must be
correctly stripped back
and insulated by using
sleeves against short
circuits caused by the
screen.
Attention! The stepping motor output stages are not

protected against short circuits. Short circuits or
wrong wiring (reversed polarity) can destroy the
FVG!

B 4.2.11 Terminal strip X14; Digital inputs:

X14
72 GND
GND for inputs 0 - 11
73 GND
74 Input 0
75 Input 1
76 Input 2
77 Input 3
78 Input 4
79 Input 5 See truth table
(chapter B 3.7.5.9.3)
80 Input 6
81 Input 7
82 Input 8
83 Input 9
84 Input 10
85 Input 11
86 + 24V +24V output
87 + 24V max. 200mA
B 4.2.12 Terminal strip X15; Digital outputs:
Terminal Function Note Remarks

X15
63 GND
64 OK Displayed via the H64 LED OK relay
65 Web width Displayed via the H65 LED The lower warning
too small and/or error limit
was undershot.
66 Web width Displayed via the H66 LED The upper warning
too big and/or error limit
was exceeded.
67 Oil blocking Displayed via the H67 LED Hydraulic blocking
(hydraulic) at low level

B 4.2.13 Terminal strip X16; Analog output and tacho input:
Terminal Signal Remarks

X16
68 GND GND for analog output
69 Output ±10V Analog output for external
motor output stage.
Not for direct connection of hydraulic
components SV1 …, HR 024,
HR 040, EH-St 9/3.
(see terminals 42-43)
70 Currently not used.
71 Currently not used.
B 4.2.14 Terminal strips X17, X18, X19; Power supply (24V output for camera)
Plug Plug Terminal Function Remarks

X17,
X18,
X19
Pin 1 + 24V
X70
Pin 2 Not used
X71
Pin 3 GND
The ekrPro Com60 control unit is itself protected

against incorrect wiring (connection with reverse
polarity).
If the supply voltage was inversely connected to
the control unit, this reverse polarity would also
be connected to the 24 V output socket.
This could lead to damage to components
connected to this socket.

B 4.2.15 CAN connection assignments:
The controller is connected to the CAN bus via a 5-pin M12 micro
style connector.
The maximum individual contact nominal current

is 4A.
Contact assignments in the plug connector:
View on the screw side
4 3 3 4
5 5
1 2 2 1
Socket Plug
(female) (male)
Pin Colour Signal Significance

1 CAN_SHLD Shield
2 Directly connected to pin 2
of the second CAN-plug
connector
3 CAN_GND
4 CAN_H Bus line (dominant high)
5 CAN_L Bus line (dominant low)

B 4.3 Service indicator displays

B 4.3.1 LEDs “Power supply“
LED Name Status Significance
H20 +12V OFF Internal +12V not present
ON Internal +12V present
H21 -12V OFF Internal -12V not present
ON Internal -12V present
H22 +5V OFF Internal +5V not present
ON Internal +5V present
H24 +5PV OFF Internal +5V not present (lamp

voltage)
ON Internal +5V present (lamp

voltage)
B 4.3.2 LEDs “Digital outputs“
H64 OFF Digital output 0 OFF
ON Digital output 0 ON
B 4.3.3 LEDs “FVG stop switches“
H59 OFF Reference switch 1 (FVG)

Outer limit switch not activated
ON Reference switch 1 (FVG)

Outer limit switch activated
H62 OFF Reference switch 2 (FVG)

Inner limit switch not activated
ON Reference switch 2 (FVG)

Inner limit switch activated

ekrPro Com60
with analog sensors
Section C
Operation
C1 Controls
C2 Operation
C3 Error messages
C4 Maintenance

Contents
Section C
Operation
Table of contents
C1 Display and operating controls C1-1

C 1.1 Control panel C1-1
C 1.2 Navigating within the system C1-2
C 1.2.1 Function keys (F-keys) C1-2
C 1.2.2 Arrow keys C1-4
C 1.2.3 Buttons C1-6
C2 Operation C2-1
C 2.1 General information C2-1
C 2.1.1 Graphics display C2-1
C 2.2 Changing the settings during operation C2-5
C 2.2.1 Operating functions C2-5
C 2.2.2 Scan start C2-6
C 2.2.3 Gain adjustment C2-7
C 2.2.4 Changing the settings C2-7
C 2.3 Sensor positioning device C2-8
C 2.3.1 Use of FVG functionality, general C2-8
C 2.3.2 Use of FVGPro 2MK functionality C2-8
C 2.3.3 Arrow key functions and the functions of the C2-8
digital inputs
C 2.4 Material set-up C2-10
C 2.4.1 Automatic material set-up C2-11
C 2.4.2 Manual material set-up C2-11
C 2.4.3 Special procedure if an analog reflecting sensor C2-12
is connected as Sensor 3
C 2.4.4 Manual material set-up for sensors C2-12
T 62 D 1 and TW 54 C5
C 2.4.4.1 Settings for the T 62 D 1 C2-13
C 2.4.4.2 Material set-up C2-14
C 2.5 Tear-off detection C2-15
C 2.6 Oscillation C2-16
C 2.7 Pre-positioning C2-17
C 2.8 Pre-positioning to machine centre C2-18
C 2.9 Unit remote control via CAN bus C2-19
C3 Error reports C3-1
C4 Maintenance C4-1
C 4.1 ekrPro Com60 controller C4-1
C 4.2 Sensors C4-1
C 4.3 Electric motor powered actuator C4-1
C 4.4 Hydraulically powered actuator C4-1
C 4.5 FVG-stepping motor C4-1
ekrPro Com60 web guide controller EDV-No.:MD.191.01.05/1.6.x

Controls C1
C 1 Display and operating controls

C 1.1 Control panel
Graphics display
A contrast-rich LCD display with LED background illumination.
Display has 6 lines, each of 28 characters.
The graphics display is used for displaying the operating hours,
parameters and the set-up menus.
Keypad
The controller can be configured for operation using this keypad.
Key Function
Automatic guiding
Manual positioning
Centring the guiding device
Left web edge guide
Right web edge guide
+ Web center guiding

Contrast transition: light / dark

Contrast transition: dark / light
’Automatic’ operating mode:

• Moves the setting to the left/right
’Manual’ operating mode:
• Manual left/right positioning of the
guiding device
• Change between the operating status
displays
ekrPro Com60 web guide controller EDV-No.: MD.191.00.05/1.6.x Chapter: C1

Controls C1
Key Function
Menu navigation: Jump back by one level

In editing box: Cancels the last entry
Select controller settings or controller gain

for change the settings
Saves the settings at the end of the set-up

functions
Activates special functions

(e.g. oscillation)
(not used at the present moment)
Menu selection
C 1.2 Navigating within the system

Use the arrow keys and the F1 – F4 function keys to navigate
within the system. The different functions are explained in the
following.
C 1.2.1 Function keys (F-keys)

The F-keys functions are assigned in different dialog windows. The
associated abbreviated names are displayed at the bottom edge of
the screen.
Press the relevant F-key several times to select the required
numerical value. The time interval inbetween pressing the button
twice must never exceed 0.5 seconds.
If incorrect entries are made, or if functions are active which, for

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

Controls C1
Shortcut functions
The function keys are assigned numbers in the equipment menu.

Therefore a menu option can be selected by using the arrow keys
to navigate to the required menu sub-option or it can be selected
directly by using the shortcut number instead.
For example: Selecting the actuator
The associated menu sub-option is 611

(see navigation overview as well).
1. Press key. This will display the set-up menu.
Current position
1
in device menu
Assignment of allocated
function keys
To enter the shortcut number:

2. Press F2 key 3x = 6.
61
The "General setup" menu including the first "Actuator"

submenu is called up.
3. Press the F1-key once = 1

Material Setup 611
Actuator
Sel. Std. Type
System
(EMS&Hydr.)
Sensors/EFE
Save/Load Settings Add-on
Hydraulics
Control Loop
General Setup
Direction
opt.FVG
LogicSC-Transducer
12 3 45 6 789 0
The required dialog will be displayed and you can now use the
arrow keys to select the parameter that has to be modified.

Controls C1
Entries in the editing box
The parameter values are entered directly in the editing box. This
can also be realised using the F-keys.
1. Open the required sub-menu and then press the ENTER key
to activate the editing box.
2. Use the horizontal arrow keys to mark the initial


current width:
mm
Opened
enter ref.width 078.5
editing box
123 456 789 0
3. Enter the number. For example: press F4 x 1 = 0.

The actual position will jump automatically by 1 place to the
right after 0.5 seconds without an entry being made.
4. Now enter the next number in the same way as described

above in section 3.
5. Press the ENTER button to import the modified value.
6. Press the ESC button to cancel the value.
C 1.2.2 Arrow keys

Various entries can be made and options can be selected from the
menu mode dialog windows.
The procedure for the various controls and lists is as follows:
Control elements
Use the arrow keys to mark the required control if there are several
control elements displayed in the same dialog window.
For example:
sens.mode W XP
0 5.00
0 5.00
0 5.00
0 5.00
Use the ’right’ arrow key to scroll forward and
use the ’left’ arrow key to scroll backwards.
The vertical arrow keys do not have a function here.

Controls C1
Option lists
An entry from a default list can be selected from an option list. This
is realised by pressing the ENTER button to open the selected
option list.
Example:
Select an actuator type Select an actuator type
EMS 17 EMS 10
EMS 16
EMS 17
123 456 789 0
The “▼“ or “▲“ symbols displayed on the right of the option list
indicate that there are more entries in list than are displayed on the
screen.
Use the vertical arrow keys to mark the position in the

list.
Checkbox
Use the vertical arrow keys

Arrow keys option using the checkbox control element.
Example:
X = Option active
active X
= Option inactive
Read-only Checkbox
Read-only checkboxes only have a display function.

These give the operator reports about the current status of the
components (e.g. stop switch statuses).
Example:
= actuated
= not actuated

Controls C1
Editing box
The arrow keys can also be used to enter a value in the editing box
in addition to using the F-keys.

current width: Selected
mm digit
enter ref.width 078.5 Opened

editing box
123 456 789 0
Use the horizontal arrow keys to position the cursor on

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

Use the horizontal arrow keys to mark the initial
Now use the vertical arrow keys so that the minus

sign is entered or removed.
After this, enter the digit sequence as described above.
C 1.2.3 Buttons
Button control elements are present in certain dialog windows

sensor1 IR 2005
<<<
dark 7% bright
-2048 abs. 1775 2047
auto dark bri.
If a button is marked and the ENTER button is pressed afterwards,

an action will be executed (e.g. traversing the actuator).
The button will be displayed as being pressed down and the action
will continue to be executed all the time that the ENTER button is
kept pressed down.
=
Operation C2
C 2 Operation
C 2.1 General information
C 2.1.1 Graphics display
The various operating statuses are displayed by the graphics
display.
Use the vertical arrow keys to change between the different
displays in normal control mode.
The number of displays varies between one and four, depending
on whether a sensor adjustment unit and/or sensor 3 is
interconnected or not.
Information for the assigned operating mode is shown in the
separate displays and their significances are explained in the
following.
Display with sensor adjustment unit connected
Relative actuator position related to limit positions
Display of relative sensor scanning area coverage
Distance from sensor to external sensor positioning device

reference limit switch in mm
Controller setpoint (W) or controller gain (XP)

If you press the "SETUP“ key you will change between both
displays (W or XP).
The value displayed can be adapted in the "AUTO" operating mode
using the horizontal arrow keys.
Switching between
operating displays
Screen without a sensor positioning device (FVG)
Controller setpoint (W) or controller gain (XP)

If you press the "SETUP“ key you will change between both
displays (W or XP).
The value displayed can be adapted in the "AUTO" operating mode
using the horizontal arrow keys.
Switching between
operating displays

Operation C2
Screen with active web width measurement
(only with connected sensor positioning device)

Graphic display of current web width
Graphic representation of:

warning limit
error limit
Entry field for intended web width
Accept current web width as intended web width

Actual system condition display
Numeric display of current web width
Switching between
operating displays
Screen when sensor 3 is connected

Tear-off detection inactive
Display with tear recognition active:
Tear-off has been recognised
Tear-off detection active
Actuator is blocked
Switching between
operating displays

Operation C2
Display of pre-positioning
Display when using FVGPro

(normally FVG 2MK)
Guiding mode; E1 = Edge 1, C1&2 = centre between edge 1 and 2,

E2 = Edge 2
Position setpoint for appropriate guiding mode.
The selected entry will be displayed "inversely".
Current position value for sensor(s)
Accept current position value as

new setpoint for active guiding mode.
Pre-positioning is activated for this guiding mode.
Display when using internal sensor positioning device (normally FVG 1MK)
Due to the system, the "C1&2" columns and the F2 key

allocation is missing here.
All other parameters have the same meaning as described
under display for external sensor positioning device.
Switching between
operating displays
Pre-positioning display on machine centre (FVG 2MK)
Current position value for sensor(s)

Offset by which the material web has been displaced from
the machine centre.
Switching between
operating displays

Operation C2
Display of the CAN bus state
Display of CAN node number

Display of CANopen control unit operating status
CANopen network synchronisation operating status screen
No Sync = Control unit not receiving synchronisation impulse
No Sync = Control unit receiving synchronisation impulse
Checking functions for device remote control

If you press the ENTER key on the control unit, all LEDs
on the keypad belonging to the remote-controlled device
will start blinking.
Operating status screen for CAN controller integrated in control unit

Bus Off = Error in CAN controller
Bus Off = CAN controller working correctly

Operation C2
C 2.2 Changing the settings during operation
Use the membrane-keys to set up the operating functions and the
scanning modes as well as the settings and to optimise the
controller gain.
C 2.2.1 Operating functions

Proceed as follows to set up the required operating functions:
Automatic mode
Press the “AUTO“ key.
Manual positioning
Press the “MAN“ key.
Manual positioning of the actuator
1)
Press the “MAN“ key.
Use the horizontal arrow keys to carry out

positioning
Centre positioning
Press ”S-C” key

Operation C2
C 2.2.2 Scan start
The required scanning mode is set up as follows:
Web edge guiding: left web edge*
Press ”SENSOR LEFT” key.
Web edge guiding: right web edge*
Press ”SENSOR RIGHT” key.
* in the material running direction!
Web center guiding
Press the “SENSOR LEFT“ and “SENSOR RIGHT“ buttons

simultaneously
Contrast guiding (line or edge)
Contrast transition: LIGHT/DARK
Contrast transition: DARK/LIGHT

Operation C2
C 2.2.3 Gain adjustment
The controller gain can be set up directly in the operating status
display or in the set-up menu.
The operating status display settings are described in the
following.
The system must be in “AUTO” mode.
Press the SET-UP button and the parameters displayed in the line
at the bottom of the screen will change from the displayed setpoint
(W) to the gain setting (XP).
The controller gain can now be modified using the horizontal arrow
keys. The new setting will have an immediate effect on the
controller.
Modifying the setting via the set-up menu is described in section

B 3.6.4.4.1.
C 2.2.4 Changing the settings

This setting can also be set up direct in the operating status screen
or in the set-up menu.
The operating status display settings are described in the
following.
The system must be in “AUTO” mode.
The setting is displayed in the line at the bottom of the screen.
The setting can now be modified using the horizontal arrow keys.
The new setting will have an immediate effect on the controller.

Operation C2
C 2.3 Sensor positioning device

C 2.3.1 Using the FVG function, general
If an FVG is being used in combination with Sensor 3, the FVG

automatically retracts if the controller is switched to Sensor 3.
The requirement for this is, however, that the element which is
being used to regulate (normally a line) lies within the visual range
of Sensor 3.
C 2.3.2 Using the FVGPro 2MK function
When using an FVGPro 2MK, the following behaviour results:

1. Only the sensor activated for the controller carries out the
edge search. The other sensor retracts and is parked at
the home position.
2. If the guiding mode is changed during automatic operating
mode, e.g. from guiding to the right-hand edge to guiding
to the left-hand edge, the system continues the current
guiding mode until the other sensor has completed the
edge search and the norming (if necessary).
C 2.3.3 Arrow key functions and

the function of the digital inputs
The function of the arrow keys are generally changed using the
SETUP button.
The arrow keys act upon the web position or the controller gain in
the AUTO mode of operation. The type of web adjustment
depends on the set FVG mode.
The buttons act upon the actuator in the MAN mode of operation.
They act upon the FVG after pressing the button SETUP, in the
settings Man.Sensor Positioning.
Operating Arrow key on the keyboard Digital inputs

mode (Use the SETUP button to switch
over)
AUTO Web position / controller gain Web position
MAN Manual actuator or Manual actuator or
FVG positioning FVG positioning

Operation C2
Allocation of the change-over options to the operating modes
FVG mode available options for the available options for the digital inputs
keyboard arrow keys
terminal 80 = Low terminal 80 = High
Operating mode AUTO
w w w
not
connected switch over via SETUP button
xp
FVG eco w w FVG
switch over via SETUP button
xp
FVG
FVG 1MK with centreline guiding
w
switch over via SETUP button w (with centreline guiding) w (with centreline guiding)
xp
with edge guiding
xp
switch over via SETUP button FVG (with edge guiding) FVG (with edge guiding)
FVG
FVG 2MK xp FVG FVG
FVG
Operating mode MAN

not
connected mot (actuator) actuator actuator
FVG eco mot actuator actuator

FVG
FVG 1MK
mot (actuator) actuator actuator
FVG 2MK mot (actuator) actuator actuator
FVG1
FVG2
The w-setting via EFE has priority with active

electronic remote fine adjustment device.
w = set value
xp = gain
FVG = sensor positioning device

Operation C2
C 2.4 Material set-up

Automatic adjustment of the controller to match the characteristics
of the material to be scanned is carried out during material set-up
The material set-up is the same for all three sensors.
The procedure for sensor 1 is used as the example here:
Requirement:
The user level “Mainten” must be active.
1. Press the MENU button to open the set-up menu.
2. Select Material set-up and confirm by pressing ENTER.
3. Select Sensor 1 and confirm by pressing ENTER.

This will open the Sensor 1 material set-up window.
Material Setup - Sensor 1
<<<
7%
dark bright Material set-up can now be carried out either automatically or
-2048 abs. 1775 2047
auto dark bri.
manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.

Operation C2
C 2.4.1 Automatic material set-up

material to be scanned for approx. 2 seconds.

4. Press the F2-key
This completes the material set-up for this sensor. Material set-up
has been completed when the same procedure has been carried
out for any other sensors connected to the controller.
C 2.4.2 Manual material set-up

For the reflection sensor TW 54 C5 and the line
sensor T 62 D 1 a special material setup is to be
carried out (see chapter C 2.4.4).

material to be scanned.

4. Press the F4-key
The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or

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

Operation C2
C 2.4.3 Special procedure if an
analog reflection sensor is
connected as Sensor 3
1. Select required scanning mode

(BRIGHT/DARK or or
DARK/BRIGHT).
Automatic material set-up:
• Press the F1-key
• Position the sensor’s light spot

on the bright contrast area
for approx. 2 seconds.

on the dark contrast area
for approx. 2 seconds.
• Press the F2-key
Switch over to “AUTOMATIC“ mode to check the guiding

direction. Switch over to the other relevant scanning mode if
the actuator moves in the wrong direction or if the wrong
contrast is scanned.
Manual material set-up:
Position the sensor’s light spot

on the dark contrast area.
• Press the F3-key.

The dark value will be saved.

on the bright contrast area.
• Press the F4-key.

The bright value will be saved.
Switch over to “AUTOMATIC“ mode to check the guiding

direction. Switch over to the other relevant scanning mode if
the actuator moves in the wrong direction or if the wrong
contrast is scanned.

Operation C2
C 2.4.4 Manual material set-up
for sensors T 62 D 1 and TW 54 C5
C 2.4.4.1 Settings for the T 62 D1

Prior to carrying out of the material setup, the zero point should be
reset for sensor T62 D1. This is different dependent on whether
the sensor is being used for line sampling or for contrast sampling.
a) Line scanning (lines of 0,5 … 5 mm)

Place the switch on the housing in “Linie” position and focus the
light spot on the primary colour of the material (that is outside of
the line), then set the “Nullpunktabgleich” (zero alignment)
potentiometer for both luminous diodes to be extinguished.
We recommend that the zero point compensation is carried out
with inclined sensor (the tilt position must be determined
empirically) when both LED´s illuminate as a result of intensive
surface reflections (e.g. metal foils).
Line
Light spot
b) Contrast scanning
The switch on the casing to be switched to “Kante” (edge) mode.
Set the sensor in a manner for ensuring that the contrast to be
scanned is in the centre of the light spot. Then extinguish both
luminous diodes by employing the “Nullpunktabgleich” (zero
alignment) potentiometer on the sensor. We recommend that the
zero point compensation is carried out with inclined sensor (the tilt
position must be determined empirically) when both LED´s
illuminate as a result of intensive surface reflections (e.g. metal
foils).
Contrast
Light spot
Adjustment elements on the T62 D1
LEDs
Changeover switch
contrast/line
Zero alignment
60
ekrPro Com web guide controller EDV-No.: MD.191.01.05/1.6.x Chapter: C2
Operation C2
C 2.4.4.2 Material set-up
For critical contrast transitions, this function enables
optimum adjustment of the reflection sensor TW 54 C5 or
the line sensor T 62 D 1 to the properties of the material to
be scanned.
In addition to the normal material setup, the offset value and
gain for sensor 3 can also be set here.
1. Press the “MENU“ button to open the set-up menu.
2. Select “Material set-up“ and confirm by pressing ENTER.
3. Select “Man. Sens. 3“ and confirm by pressing ENTER.

This will open the window for the manual material setup of
Sensor 3.
4. Position the sensor’s light spot

centrally over the contrast transition.
5. Use function key F1 (reduce offset value) or F2 (increase

offset value) to change the offset such that the black bar of
the upper bar indicator is located in the indicator middle.
The current absolute offset value is shown in the "Offset"
Manual Setup - Sensor 3
50% field.
Offset 3 Gain
0 1.00
6. Position the sensor’s light spot
Of.- Of.+ Ga.- Ga.+
on the dark contrast area.
7. Use function key F3 (reduce gain) or F4 (increase gain) to

change the gain such that above the upper black bar
indicator a value of 100 % is displayed.
The target value of "100 %" must be set by

carefully increasing the value using the F4
function key, as values greater than 100 %
cannot be displayed.
The current absolute gain value is shown in the "Gain" field.
8. Position the sensor light spot centrally over the contrast

transition (see point 4) and if necessary readjust the offset
value (see point 5).

Operation C2
C 2.5 Tear-off detection
“Tear-off detection” enables, dependent on the selected
sensing type (edge / contrast guiding) the following functions:
1. With web edge guiding:
Detection of torn-off sections on the web edge using edge
sensors IR2001/2005, US2007, …
This function is activated during web edge guiding, if during
operation of the web guiding system errors arise from the web
edge that is being scanned.
The function detects both tears into the material web (inward
tear) as well as projecting material (outward tear).
2. With contrast guiding:

Guiding on interrupted printed or contrast edges with contrast
sensors T62D1 or TW54C5.
The operating mode selection

switch on the contrast sensor
T62D1 must be in the position
“Kante“ (edge).
Interrupted printed
or contrast edge
light spot of the

contrast sensor
Tear-off
inwards
Tear-off
outwards
If the function detects a tear, the web guiding system is

automatically blocked. Blocking of the guiding system is lifted
again, if the sensor signal again lies above/below the set threshold
value and the set run-on time has elapsed.
Matching of the individual parameters of the function to the
application is implemented in the menu
Add. Functions > Tear Off Det. or
General Setup > Add. Functions > Tear Off Det..

Operation C2
Activate tear-off detection

The function “Tear-off detection” is activated.
If an outward or inward tear is detected, this is indicated

in the display by an exclamation mark.
As soon as the guiding system is blocked, a lock appears

in the actuator symbol.
C 2.6 Oscillation
The function ”oscillation“ enables a position displacement of the
material web within the sensor scanning area with adjustable
amplitude (size of the transverse displacement) and frequency
(speed of the displacement).
The amplitude of the oscillation can be set separately for the
operating modes "automatic" and "SC".
The function is automatically switched on when changing to the

operating modes "automatic" and / or "SC".
Matching of the individual parameters of the function to the
application is implemented in the menu
Add. Functions > Oscillation. or
General Setup > Add. Functions > Oscillation.
Activate oscillation

The "Oscillation" function is activated.
When changing from manual operation into the mode set

for oscillation in the general setup (Auto, SC or Auto &
SC), the function is automatically switched on.
Deactivate oscillation

The "Oscillation" function is deactivated.
The oscillation zero position is used as a set point for

further guiding.
There is no shifting of the web possible during oscillation.

A message appears on the display at the attempt to carry out this.

Operation C2
C 2.7 Pre-positioning
You can use this function to carry out material web pre-positioning
to a position determined by a user.
Both the guiding mode on which the pre-positioning is to be used
and the target web position itself can be set.
Activate pre-positioning (FVGPro)
Select the required guiding mode in the "set“ line (here

E2) and enter the positional value. You can also take
over the actual positional value by pressing the F4 key
("set").
The system must be in the "MAN“ or "SC“ operating
modes to do this.
Pre-positioning can be activated or deactivated using

keys
F1 for edge 1
F2 for centre between edges 1 & 2
F3 for edge 2.
The guiding mode, the pre-positioning is activated for, is
displayed inverse (here E2).
Once the system has been switched to the "AUTO"
operating mode, the FVG slide(s) moves/move to the
edge(s) of the web and then slowly shift the web to the
position saved in the "set" line.
If the "Pre-positioning" function has been activated when
the "AUTO" operating mode is activated, the web is
moved to the predetermined position immediately.
The current positional values are displayed based on the

defined reference system (see Point B 3.7.5.5.4 in the
chapter entitled "Initial startup".
Use of an internal FVG
The adjacent figure shows the display of the operating

status. Due to the system, the "C1&2" columns and the F2
key allocation is missing here.
All other parameters have the same meaning as described
under display for FVGPro .
Activating the functions is carried out in the same manner as
described above.

Operation C2
C 2.8 Pre-positioning to machine centreline
(only with FVG 2MK)
This function is used to pre-position the material to the machine
centreline.
The predefined machine centreline is calculated from the offset
value settings which were defined during the start-up procedure
(see Point B 3.7.5.5.4 and example below).
Using the offset value in the operation status display, you can
define the position of the machine centre yourself without having to
carry out readjustments in the device menu.
1. Select the "Pre-position to center“ display from the

operation status display.
2. Enter the offset by which the web should be shifted from

the predefined machine centre.
3. Activate the function by pressing the key F2.
4. Press the “AUTO“ key.

The sensors start searching for the appropriate edge.
If the last of the two sensors has reached its edge, the
material web is shifted into the centre position by the FVGs
(working position).
Example:
Both sensors start from the home position. Measure the distance
between the centre of the sensor measurement band of each FVG.
As an example, this distance is 1070 mm.
Halve the distance!
Machine centre
1070
Now enter the value -535.0 for the

"FVG Pro slide 1 " into the offset
editing box
and the value +535.0 in the

"FVG Pro slide 2" offset editing box.
In this case, the machine centre is at 0 (zero).

Operation C2
C 2.9 Unit remote control
via CAN bus
Devices in the controller family (ekrPro Com60, ekrPro Key60) can
be interconnected via a CAN-Bus to form a networked system.
The function "Unit Remote Control" enables control of the control
units present in the system to be undertaken from different origins
(e.g. from another ekrPro Com60 control unit or from an ekrPro
Key60 external keyboard).
Selection of the unit to be operated is made via the menu
“Remote Device".
The procedure for selecting a unit, that is to be remotely controlled,

is described in chapter B 3.7.7.

Error reports C3
C 3 Error reports
Errors are indicated by the error LED illuminating.
You can chose to display them or suppress them. Furthermore, the

display duration of a reported error can be varied.
These settings are made in the menu
General Setup > Special > Dev. Config..
In generally we differentiate between two types of errors:
1. To acknowledge an error
The error report must be acknowledged by pressing the
‘ENTER‘ button and then the display and the error-LED will be
extinguished.
The error report will be displayed immediately after being
acknowledged if the error has not been eliminated.
2. Self-deleting errors
The error message is deleted automatically as soon as the error
is eliminated. The error LED will be extinguished.
In general, the system error that occurred last is the

one that is displayed. Any error messages that were
displayed previously are cleared automatically.
All error reports will be displayed in full on the screen immediately

after they occur.
Example: Actuator drawing excess current.
This error report must be acknowledged.

Error reports C3
Report Possible cause Solution
- Guiding device has moved - Activate into the opposite

MOTOR OVERCURRENT into a stop position or is direction.
blocking the motorised guide. Error report will be deleted
automatically.
- Actuator short circuit - Find the cause of the short

MOTOR SHORT CIRCUIT The actuator controller was circuit
switched off. - Exchange the actuator if
necessary.
- The maximum output stage - Leave the output stage to cool.

MOTOR TEMPERATURE motor operating temperature
has been exceeded. - Determine the cause of the
The actuator controller was error.
switched off.
- Insufficient contrast has been - Clean the sensor and repeat the
CONTRAST DIRT determined after a material material set-up.
set-up using the analog
sensors.
The setting will be imported,
but correct controlling cannot
be guaranteed.
- The actuator has reached a - Activate into the opposite

LIMIT SWITCH SET software limit switch direction.
(“Pos. Limit”).
Driving the actuator in the
corresponding traversing
direction is prevented.
- No edge was found during - Check operation of the sensor

EDGE DETECT. TIMEOUT edge detection (Search positioning unit (especially the
process timeout). slide).
No guidance is possible.
Condition:
Norming mode = „No
norming“
- No contrast transition was - Check operation of the sensor

NORMING TIMEOUT found (Search process positioning unit (especially the
timeout). slide).
Requirement:
Norming mode = "Bright“ or
"Dark/Bright“

Error reports C3
Fault Possible cause Solution
- An error has occurred during - Check sensor.

NORMING ERROR sensor normalisation. If necessary clean sensor.
- Insert material and repeat
sensor normalisation.
- During edge detection the - Insert material and repeat edge

EDGE DETECT. ERROR FVG slide has reached the detection.
inner limit switch.
- Timeout during free-running - Check operation of the sensor

RETRACT TIMEOUT process of the sensor positioning unit (especially the
positioning unit. slide).
The slide of the sensor - Check the limit switch of the

positioning unit has not sensor adjustment unit.
reached the outer FVG limit
switch after elapsing of the
max. free-running time.
- During guidance (automatic - Check the position of the web of

WIDTH ADJ. ERROR operation), a slide of the material.
sensor positioning unit has
driven into an inner limit
switch.
The control unit changes to
manual operation.
The slide of the sensor
positioning unit moves
outwards (outer limit switch).
- The operating voltage has - Ensure the stability of the supply

VOLTAGE BELOW 16V fallen below 16 V. voltage.
Use according to regulations Operating voltage range:
is no longer guaranteed. 24 V ± 5%.

Error reports C3
Fault Possible cause Solution
The controller does not respond - A remote controller has been - Check terminal 85. Remove the
to any operation. connected to the control “1“ signal (24V DC) if present.
system.
It has blocked the controller
buttons.
Undefined unit response. - A program change has - Carry out a basic unit
occurred without a restart. initialisation.
A connected sensor is not - An incorrect type was - Set the correct sensor type
working entered in the set up menu (Menu General Setup >
for the corresponding sensor. Sensors/EFE).
The actuator moves to an end - The actuator direction is - Reverse the actuator direction
position and remains there in the incorrectly set. (Menu General Setup >
operating modes "manual Actuator > Direction,
operation" or "SC". Checkbox "Mot Dir. Inverted“).
- Reverse the position feedback

- The direction of the position direction
return for the central position (Menu General Setup >
encoder is incorrectly set. Actuator > SC-Transducer >
Type & Dir., Checkbox "Inv“).
Both software end switches of - The direction of the position - Reverse the position feedback
the actuator are active return for the central position direction
simultaneously. encoder is incorrectly set. (Menu General Setup >
Actuator > SC-Transducer >
Type & Dir., Checkbox "Inv“).
All the menu settings for - The gain (XP) was - Adjust the controller gain.
actuators, sensors, central inadvertently reduced to “0”.
position encoders, etc. are No guiding takes place in
correct, but the unit does not "automatic" operating mode.
control
The control unit cannot or can - Changes to the settings of the - Check the configuration of all
only be partially controlled after digital inputs have been digital inputs and if necessary
switching on. carried out (e.g. an input for adjust a possibly present
an operating mode has been external protective circuit
configured as Low-active, so (Menu General Setup >
that the operating mode can Dig. > Inputs).
no longer be changed over
the keyboard).

Maintenance C4
C 4 Maintenance
C 4.1 ekrPro Com60 controller

The controller is maintenance-free.
Cleaning should be carried out using a dry, clean and soft cloth.
A commercial liquid cleaner may be used if the casing is very dirty.
Adhere to protection class IP 54!
Beware!
The controller has to be switched off!
C 4.2 Sensors
The sensor lenses have to be kept clean to ensure optimum
guiding results.
C 4.3 Electric motor

powered actuator
The electric motor powered actuator is maintenance-free.
C 4.4 Hydraulically
powered actuator
The hydraulically powered actuator is maintenance-free.
C 4.5 FVG-stepping motor

Power is continuously applied to the stepping motor
output stage, even when stopped. Therefore any work
undertaken on the interconnections must only be
carried out with the power switched off.

ekrPro Com60
with analog sensors
Section D
Appendix
D1 To open the set-up menu
D2 Default settings
D3 Commissioning example
D4 Connection diagram / Plug assignments
D5 System overview
D6 Flange board connection
ekrPro Com60 web guide controller EDV-No.:MD.191.01.05/1.6.x

61 Actuator 611 Type (EMS&Hydr.)
612 Hydraulics Add-on
Key
„Menu“ MENU 613 Direction 6141 Type & Dir.
614 SC-Transducer 6142 Pos. Limit
615 Man Pos. control 6143 SC W & XP
1 Change User
616 Man Speed
62 Sensors/EFE 621 Sensor 1

2 Add. Functions 21 Tear Off Det.
622 Sensor 2
22 Osc. Mode
623 Sensor 3
23 Osc. Params
624 EFE Remote Adj.
6421 Homing Dir.
63 Control Loop 631 Gain & Offset 6422 Offset 1
3 Material Setup 31 Sensor 1
632 Adj. done Limits 6423 Offset 2
32 Sensor 2
633 Speed control 6424 Range
33 Sensor 3
6425 Feed
34 Man. Sens. 3 64 FVG 641 Connection
642 Int. FVG
64311 Homing Direction
4 Sel. Std. System 643 FVGPro
64312 Offset
644 Retract Mode 6431
64313 Range
5 Save/Load Settings 645 Norming mode Slide 1
64314 Feed
646 Width adjust.
647 Repositioning
6 General Setup
648 Velocities
64321 Homing Direction
649 Special
64322 Offset
Opt. Logic 71 Params 1 6432
7 65 Width Measure 651 Ref. Width 64323 Range
72 Params 2 Slide 2
652 Limits 64324 Feed
553 Opmodes
66 Edge Sources 661 Edge 1
8 Fieldbus 81 Status 662 Edge 2
82 Profibus 663 Edge 3
83 DeviceNet 664 Src. SC
84 Monitor 665 Src. EFE
85 CanOPEN 67 Add. Functions 671 Tear Off Det.

672 Osc. Mode
673 Osc. Params
68 Dig. IO Config. 681 Configure
9 Remote Device 682 Inputs

683 Outputs
69 Special 691 Change Pwd.

692 Dev. Config.
693 Reset
694 Watchdog Test
Appendix D 1 System overview
For BST support only! EDV-No.: MD.191.01.05/1.6.x
695 Test Issue: 23.11.2007
Default settings D2
Appendix D 2 Default settings

The default settings have been set up in the controller in the
factory. The following settings are set up again after a reset has
been carried out:
Menu Parameter Level 1 Parameter Level 2 Parameter Level 3 Default Value

Change User User Level Active user level Admin.
Password 2
Actuator Type (EMS&Hydr.) EMS 17
Hydraulics Add-on Zero elevation [%] 0
Use teach table off
Specific current control off
Direction Dir. inverted off
SC Transducer Type & Dir. Type EMS Pot.
Inversion off
Pos. Limit active off
Limit left -2048
Limit right +2047
SC W & XP Setpoint 0
Gain 20.00
Man Pos. Control off
Man Speed [1/1000] 700
Sensors/EFE Sensor 1 IR2005
Dark -2048
Bright +2047
Inv. Off
Sensor 2 IR2005
Dark -2048
Bright +2047
Inv. avtive
Sensor 3 not connected
Dark -2048
Bright +2047
Inv. off
EFE Remote Adj. Choose EFE if present not connected
Control loop Gain & Offset Edge 1 W 0
xp 5.00
Edge 2 W 0
xp 5.00
Center 1&2 W 0
xp 5.00
Edge 3 W 0
xp 5.00
Speed control active
ekrPro Com60 web guide controller EDV-No.: MD.191.01.05/1.6.x Chapter: D2

Default settings D2

FVG Connection Op. Mode not connected
FVG sensor Int. FVG

adjustment Homing Dir. Homing dir. inv. not reversed
unit Ref. switch inv. not reversed
Offset 1 Offset [mm] 0
Only for internal
Inverted no
FVG!
Offset 2 Offset [mm] 2000ht/Dark
Inverted yes
Range Range [mm] 5000.0
Feed Feed in µm / rev. 20088
(for 4,2:1 gear box)
Ext. FVG FVG 1

Homing Dir. Homing dir. inv. not reversed
Only for internal Ref. switch inv. not reversed
FVG! Offset Offset [mm] 0
Inverted no
FVG 2
Range Homing Dir. Homing dir. inv. not reversed
Ref. switch inv. not reversed
Offset Offset [mm] 2000
Inverted yes
FVG Retract mode Select a full retract mode SC & Man.

Norming mode Select a norming mode Bright/Dark
General part Width Adjust. FVG width adjustment Level outer active
Width adj. lvl. [%] 75
Repositioning FVG remembers current Tear Off not active
position after:
SC or Man not active
Velocities Retract vel. [mm/s] 60
Edge push vel. [mm/s] 5
Slow man. vel. [mm/s] 1
Fast man. vel. [mm/s] 60
Norm. vel. [mm/s] 60
Special Mode after error Man.

Sensor Cover Guarding not active

Default settings D2

Width Measure Ref. Width [Press “set ref”!] 0
Limits Nominal width 80.0
Error E- -5.0
limits E+ +5.0
Warning W- -2.0
limits W+ +2.0
Edge Sources Edge 1 Device This device
Edge Sensor 1
Inverted off
Normed active
Edge 2 Device This device
Edge Sensor 2
Inverted active
Normed active
Edge 3 Device This device
Edge Sensor 3
Inverted off
Normed active
Src. SC Device This device
Edge SC
Inverted off
Normed off
Src. EFE Device This device
Edge EFE
Inverted off
Normed active

Default settings D2

Add. Functions Tear Off Det. Edge 1 Sensor none
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Edge 2 Sensor none
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Edge 3 Sensor Edge 3
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Center 1&2 Sensor none
Threshold [%] 80/20
Sign. chg. limit 10
[%/4ms]
Delay time [ms] 20
Hold time [ms] 1
Oscillation mode Osc. Opmode off
Osc. Params. Amplit. Auto [%] 40
Amplit. SC [%] 4
Amplit. FVG 10.0
Frequency [Hz] 0.50
Dig. IO Config. Configure Configure Digital I/O [Press ‚set’] Gig.IN Table 1
Dig. Inputs enabled yes
Dig. Outputs enabled yes
Inputs See chapter B3.7.5.9.2
Outputs See chapter B3.7.5.9.4
Special Change Password User Level Admin.
Password 0
(displayed)
Timeout [min] 0
Dev. Config Backlight Time 0
(permanent on)
Show errors active
Confirm errors off
SW Version -
Low V cnt. 0

Default settings D2

Opt. Logic Params 1 off
off
0
0
0
0
Params 2 off
off
0
0
0
0
Fieldbus Status Bus type unknown
Module status 0
Data exchange not running
Last interrupt 0
Profibus Address 3
Swap Bytes off
Swap Words off
DeviceNet Address 3
Baudrate 500 kbps
Swap Bytes off
Swap Words off
CANopen NMT Master One fieldbus active
device only!
Bus off off
No Sync off
Sync Time [µs] One fieldbus 4000
device only!
Node Id 11
Remote Device Select remote device This device
Material Setup Sensor 1 Dark -2048
Bright +2047
Sensor 2 Dark -2048
Bright +2047
Sensor 3 Dark -2048
Bright +2047
Man. Man. setup – Offset 0
sensor 3
Gain 1.00

Default settings D2

Outputs Clamp 64 No errors
Low act. off
Clamp 65 W. warn nor
err. min.
Low act. active
Clamp 66 W. warn nor
err. max.
Low act. active
Clamp 67 Hydr lock
Low act. active

Commissioning example D3
Appendix D 3 Commissioning example
Set-up menu navigation, menu sequences and general procedures

are described in the ”Commissioning“ section.
The details in this section refer to the special components with
information about the menus that have to be used or setting up
windows.
D 3.1 Initial startup of an actuator

with integrated position feedback
1. Wire the motor as shown in the circuit diagram.
2. Select the actuator under

General Setup > Actuator > Type (EMS&Hydr.).
Select and mark the servo-center component from the option list.
3. Check the sense of rotation of the actuator:

Go to General Setup > Actuator > Direction and test the actuator
movement by pressing the F2 (left) button.
4. Check the actuator positioning movement.

Does the actuator move in the direction of sensor 1?
Yes = no alterations required
no = activate “Mot. Dir. Inverted“ checkbox (x)
5. Set up the positioning limits – if required.

Go to General Setup > Actuator > SC-Transducer > Pos. Limit
and traverse to the required positions and then set them up as the
stop switch positions.
6. The function ‘servo-center position’ will no longer automatically set

to the middle between the two limit positions after the positioning
limits have been set up.
Go to General Setup > Actuator > SC-Transducer > SC W & XP
and set up the servo center position and the gain.
It only saves the last centre position setting.
ekrPro Com60 web guide controller EDV-No.:MD.191.01.05/1.6.x Appendix: D2

D 3.2 Start-up an actuator

with OMG 4 / 7 / 8
1. Wire in the motor and servo-center component as shown in the circuit
diagram.
2. Go to General Setup > Actuator > Type (EMS&Hydr.) and select

the actuator. All of the actuators present can be activated from the
options list.
3. Go to General Setup > Actuator > SC-Transducer > Type & Dir.
and select and enter the servo-center component.
4. Check the actuator positioning movement.

Does the actuator move into the centre position?
Yes = no alterations required
no = activate “Inv“ checkbox (x)
5. Go to General Setup > Actuator > SC-Transducer > SC W & XP

and set the gain for the servo-center component.
D 3.3 Start-up an actuator

without a servo-center component
1. Wire the motor as shown in the circuit diagram.
2. Go to General Setup > Actuator > Type (EMS&Hydr.) and select

the actuator.
All of the actuators present can be activated from the options list.
3. Go to General Setup > Actuator > SC-Transducer > Type & Dir.
and deactivate the servo-center component, i.e. select and enter
“not connected“ in the options list.

D 3.4 Initial startup with sensor

positioning device FVGPro 2/MK
1. Carry out electrical connections as specified in the circuit diagram.
2. Reset the parameters to the works settings.

To do this open the “Sel.Std.System” menu and select F1 („Def.“).
The ekrPro Com60 carries out a restart.
3. Select standard system

Now select a standard system which corresponds as closely as
possible to that you are using.
To do this, call up the "Sel.Std.System“ menu again and select the
appropriate system from the option list. Press key F2 ("set") to
activate this setting.
4. Check the actuator and the servo-center component connected.
4.1 Check actuator connected and readjust it if necessary.
4.2 Check sense of rotation.

Press the F2-key. The guiding frame must move in the
direction of sensor 1. If this is not the case, activate ‘Inv.’ and
repeat the adjustment.
4.3 Check the servo-center component.

If a servo-center component is fitted, the value of the
percentage display must decrease if the actuator moves to the
left (using key F2). If not, activate ‘Inv.’.

5. Check sensors connected and readjust it if necessary.
Check to ensure that the percentage display value increases the

more the sensor is covered. If not, check whether inverting is set.
After this, the Master setup for this sensor has to be carried out.
Press the F1 („auto“) button. Then cover up the sensor measuring
window completely and then hold it free. Press key F2 ("auto OK“)
to confirm.
6. Repeat the setting for Sensor 2.

If Sensor 3 is connected, no master set up should be carried out.
7. Check the FVG stepper motor and limit switch.
Check the FVG stepper motor rotation direction settings. Confirm

this position by pressing the F3 key. The checkbox “Homing dir.
inv.” must be activated if the traversing directions are reversed.
Now cover the external limit switch with a metal object (e.g. a coin).
The "outer“ radio button must be active ( ). If, instead of this, the
inner limit switch is shown as „active“, the checkbox "Ref. Switch
inv.“ must be activated.
Recheck both limit switches for safety reasons.
8. The settings carried out above for "Slide 1“ should now be

repeated for "Slide 2“.
9. Now, the FVGPro 2/MK has been made completely ready for
operation.
Once the basic settings have been made for the FVGPro 2/MK, you
can now carry out additional functionalities such as material width
measurement, pre-positioning etc.
These settings are described in the chapter entitled "Initial startup“,

Point B 3.7.5.5 "FVG – Sensor positioning device".

System overview D5
BST Bus System

60
ekrPro Com ekrPro Key60
EFE1
Actuator without Electronic remote

position feedback fine adjustment
FVG 1K.../FVG 1MK...
Remote control
Analog sensors
Sensor positioning device with and

Servo-center
without material width measurement
Actuator with component
position feedback
FVG 2K.../FVG 2MK...
230 V
Power module EMS 3/..., EMS4/...
FVGPro module
Line sensor/
Reflection sensor
Appendix D 5: System overview
EDV no.: MD.191.01.05/1.6.x Issued: 23.11.2007 Hydraulic system
Flange connection plate D6
Appendix D 6 Connecting plate
ekrPro Com60; XT version

Actuator (motorised/hydraulic)
Line / contrast sensor
Sensor positioning device Analog sensors CAN Bus connection
X50 X51
X60 X100
External 24 VDC
X65
X101
X70 X71
Outputs 24 VDC Servo-center

power supply component
ekrPro Com60 web guide controller EDV-No.: MD.191.01.05/1.6.x Appendix: D6


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BST Web Guiding System

BST International GmbH

Tel: +49 5206/999-0

ekrPro Com60 web guide controller EDV-No.: MD.191.01.05/1.6.x

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

Using the keys

+ Key combinations, keys have to be

Press keys in the specified order.

LED constantly lit = activated phase

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x

Section A General information

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x

A3 Transport / Storage A3-1

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x

The start-up, maintenance and installation

• Web edge guiding (right or left)

The controller includes a separate control unit that can directly

Any other utilisation must first be authorised by the manufacturer.

A 1.3 Housing Versions

• ekrPro Com60 XT: Mounting unit

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A1

A 1.4.1 Assignment of sensors to the

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

According to the BST definition, the following link applies:

SENSOR LEFT = Sensor 1

SENSOR RIGHT = Sensor 2

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

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

Example 1: Example 2: Example 3:

Sensor left Sensor left

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

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A1

A 1.4.2 Inverting of the

When the control units is delivered, inversion of the

(Sensor looks to the left in the

A 1.4.3 Size of oscillation amplitude

0% 100 % Sensor coverage

Oscillating web position

100 % of the sensor visual range

40 % of the sensor visual range

The maximum possible oscillation amplitude is 80% of the sensor

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A1

A 1.4.4 Oscillation types and curves

An oscillation can be implemented either as a sensor oscillation or

Selections and settings are described under Point B 3.7.5.8.2.

A 1.4.5 Allocation of FVGs for a FVGPro 2MK

Traverse the FVG using the

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A1

A 1.6 Safety information

Only trained specialist personnel are permitted to

! undertake the assembly, installation and

Do not use the chassis or machine frame as a climbing

Positioning movements will be undertaken by the

! actuator during functional testing away from the

• Any transport safety devices that were used must be removed

A 2.1 ekrPro Com60 controller (version XT)

Power supply 24V DC ± 5%

Controller inputs 2 x sensors, -9,75 V ...+9,75 V oder 0 V ...+9,75 V

Power supply outputs 2 x 24V (for CCD Pro camera)

CAN-bus 1x plug, 1x socket; no metallic separation

Screw connections / Variable through exchangeable connection plate;

ekrPro Com60 web guide controller EDV No.: MD.191.01.05/1.6.x Chapter: A2