BST CLSPro 600 User Manual

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.
01
with removable control panel Issued: 07.11.2008

CLS Pro 600
Line and contrast sensor
with removable control panel

Operating Manual

BST International GmbH
Heidsieker Heide 53
33739 Bielefeld

Tel: +49 (0) 5206/999 0
Fax: +49 (0) 5206/999 999
E-mail: info@bst-international.com

This document may not be copied or accessed by a third party without our specific consent and even then the third party or
person to whom the copy is given must not use it improperly in any way whatsoever. BST International GmbH
Contents 0
CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01
with removable control panel Date: 07.11.2008
Table of contents
1. Description 1
1.1 Symbols used in this operating manual 1
1.1.1 Warning signs 1
1.1.2 Using the keys 1
1.1.3 LED operating statuses 1
1.2 General information 2
1.3 Intended use 3
1.4 System description 4
1.4.1 System design 4
1.4.2 Operating principle 5
1.5 Terms used in this manual 7
1.5.1 General information 7
1.5.2 Set position 7
1.5.3 Measuring range 8
1.5.4 Search area 8
1.5.5 Status bar 8
1.5.6 Footnote 8
1.5.7 First edge / second edge 8
1.6 Control panel 9
1.6.1 Graphics display 9
1.6.2 Control panel 9
1.7 Safety information 11
1.8 Laser 12
1.9 Emissions 12
2. Assembly 13
2.1 Installation site requirements 13
2.2 Sensor installation 13
2.2.2 Installing the sensor using the holder supplied
in the package 13
2.2.3 Installing the sensor using a holder supplied
by the customer 14
2.2.4 Setting the gap between the sensor and the
sensing roller 15
2.2.5 Turning the control panel 15
2.3 Installing the control panel 17
2.3.2 Dismantling the holder 18
2.3.3 Wall mounting 18
2.3.4 Control console installation 21
3. Installation 23
3.1 Fitting the cable connections 23
3.2 Sensor 23
3.2.1 Enclosure socket 23
3.3 Service indicator displays 24
3.3.1 Bus status LEDs 24
3.3.2 Unit status LED 24
3.4 DIL switch settings 25
4. Commissioning 26
4.1 Menus 27
4.1.2 Input options 27
4.1.3 Main menu 30
Contents 0

4.2 Commissioning with a controller 33
4.2.1 ekrPro Com60 33
4.2.2 ekr 500 Plus 36
4.2.3 EKR 1500 / CCD line guider and CAN - Module bus
coupler 36
4.3 Commissioning as a stand-alone system 37
5. Operation 38
5.2 Operating display 38
5.2.1 Set-up mode display window 38
5.2.2 Scanning mode display window 39
5.2.3 Status bar 40
5.3 Controlling the ekrPro Com60 / ekr 500 Plus
controllers remotely 41
5.3.1 Manual mode 41
5.3.2 Automatic 41
5.3.3 Servo-center position 42
5.3.4 Moving the set point position (W-value) 42
5.3.5 Moving the guiding device 42
5.3.6 Adjusting the controller gain. 42
5.4 Operation 43
5.4.2 Activating line set-up / edge set-up 43
5.5 Standard operation 43
5.6 Extended operation 48
5.6.1 Change user 48
5.6.2 Job administration 49
5.6.3 Assigning user levels to the parameters 50
5.6.4 Setting up quick menus 51
5.7 Main menu parameter significances 52
5.7.1 Configuration 52
5.7.2 Parameter 60
5.7.3 Remote control ekr 66
5.7.4 Display 67
5.7.5 System Info 68
6. Factory default settings 69
6.1 Device addresses 69
6.1.1 Sensor device address 69
6.1.2 Control panel device address 70
6.2 Terminator resistors 71
6.2.1 Sensor terminator resistors 71
6.2.2 Control panel terminator resistors 72
6.3 Resetting factory default settings 73
7. Troubleshooting / FAQ 74
8. Technical data 75
8.1 Sensor 75
8.1.1 Environmental conditions 75
8.1.2 Power supply 75
8.1.3 Digital inputs 75
8.1.4 Digital outputs 75
8.1.5 Analog output 75
8.1.6 Measuring window cover 75
8.1.7 Control panel interface 76
8.1.8 Weight, dimensions 76
Contents 0

8.2 Control panel 76
8.2.1 Environmental conditions 76
8.2.2 Power supply 76
8.2.3 Display 76
8.2.4 Weight, dimensions 76
8.2.5 Space requirement 77
8.2.6 Plug pin assignments 79
9. Maintenance 81
9.2 Sensor 81
9.3 Control panel 81
10. Transport / Storage 82
10.1 Transportation 82
10.2 Storage 82
11. Decommissioning 83

I Index

A1 Appendix 1; Commissioning example A1

A2 Appendix 2; Saving the parameters and
loading the firmware A2

A3 Appendix 3; Factory default settings A3

A4 Appendix 4; BST signal terminal box 1 connections A4

A5 Appendix 5; Teach-in model A5

Description 1
12
CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Chapter: 1
with removable control panel Date: 07.11.2008 Page: 1/86
1. Description
1.1 Symbols used in this
operating manual

1.1.1 Warning signs
Symbols are used in this operating manual in order to clearly
indicate particularly important places.

Warning!
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.

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

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

Press key.

1.1.3 LED operating statuses
Some of the keys on the control panel have LEDs (Light Emitting
Diodes) built into them. The different LED operating states are
represented as follows:

LED off

LED constantly lit = activated phase

LED flashing
!
Description 1
12

1.2 General information

The start-up, maintenance and installation
instructions described in this operating manual
must be strictly adhered to!

You are only permitted to install and commission the CLS
Pro 600 line and contrast sensor after you have read the
accompanying operating manual.
This will help to avoid hazards and prevent the sensors
from being damage due to improper installation or
operation.

Everyone working on or with the CLS Pro 600 sensor must
abide by this operating manual and the safety instructions
in particular.

You must read, without fail, the safety instructions
given in Chapter 1.7 of this operating manual prior to
starting the installation and commissioning work!

Solely BST staff or other persons specifically
authorized by BST are permitted to modify or add to the
firmware of this sensor. Ignoring this warning might result
in the warranty rights being invalidated.

The settings and details shown in this operating manual
(e.g. in the display screens) are given as examples only,
unless the text explicitly states otherwise.

The latest version of the operating manual for the CLS Pro
600 line and contrast sensor can be obtained via the
Internet in all available languages under the following
address:

http://www.bst-international.com

!
Description 1
12
1.3 Intended use
The CLS Pro 600 is a microprocessor controlled line and contrast
sensor with a removable control panel. It must only be used for:
Guiding on continuous or interrupted printed lines
Guiding over continuous or interrupted printed edges
Web edges

The CLS Pro 600 line and contrast sensor has been designed to
be fitted in another machine or to be combined with other
machines to form a complete machine in the sense of the Directive
98/37/EC (machine directive).
Start-up of the system is forbidden until the user / operator has
determined that the machine, in which the system is installed,
conforms to the conditions of this directive.

The CLS Pro 600 line and contrast sensor is an integral part of our
BST web guiding systems. You are only allowed to use BST web
guiding systems to correct the position of web-shaped materials
(e.g. those made from paper, film, cardboard, rubber, etc.).
The sensor and the control panel must never in be installed and
used in potentially explosive areas.

BST web guiding systems have been designed and built in
accordance with state-of-the-art standards and the recognized
safety regulations.
Nevertheless, its use may constitute a risk to life and limb of the
user or of third parties or damage the BST web guiding systems
and other equipment.
Therefore BST web guiding systems are only to be used if they are
working correctly and in a technically safe condition.
Any part found to be working incorrectly must be replaced
immediately.
Only original spare parts are to be used for this. Spare parts
obtained from third parties cannot be guaranteed to comply with
the design and manufacturing conditions and safety regulations. In
this case any guarantee claims made against the BST web guiding
system will be invalidated.
Only qualified personnel who have been trained on the system are
allowed to undertake any work required on the BST web guiding
system (i.e. installation, commissioning, operation, maintenance,
etc.).
Intended use also includes adhering to the instructions given in this
operating manual.
Use for any purpose other than those mentioned above is
considered as contrary to the intended use. BST International
GmbH does not accept liability for any damage resulting from this
type of use.
Description 1
12
1.4 System description

1.4.1 System design
1.4.1.1 General information
The CLS Pro 600 consists of the sensor and the removable control
panel.
The sensor enclosure holds the entire electronics and the control
panel and controller connections.

1.4.1.2 Sensor with fitted
control panel
The sensor is operated via the control panel, which is fitted to the
sensor in the factory. The control panel is pivotable.

Sensor with fitted control panel
1.4.1.3 Sensor with removable
control panel
If necessary (i.e. if the sensor is installed in a difficult to access
position on the machine) the control panel can be removed and
installed in a central control console or a customer-supplied control
station.
In this case the connection between the sensor and control panel
is completed using a cable extension that is available as an
optional extra.

Sensor with control panel removed

The length of the connection cable between the
sensor and the control panel must never exceed
20 m (maximum).
cable extension
(2 m, 5 m, 10 m)
Sensor Control panel
Description 1
12
1.4.2 Operating principle
The sensor records the actual position of a line or a contrast
transition point on the material web in automatic mode and then
transmits the relevant information to the interconnected controller.
The controller compares the actual recorded position against the
default set point position. A relevant correction signal will be sent to
the guiding devices actuator if a deviation is found to exists
between the two values.
The actuator will drive the guiding device (rotating frame or
swivelling roller guide) until the material web returns to its set point
position.
The CLS Pro 600 sensor can be used in the following
configurations:
1.4.2.1 Stand-alone mode

1.4.2.2 In conjunction with an ekrPro Com
60
controller

Customers machine
controller
Sensor CLS Pro 600
with control panel
BST Signal Terminal Box1
CAN bus connection
(optional)

Customers machine
controller
BST Signal Terminal Box1 Sensor CLS Pro 600
with control panel
Description 1
12

1.4.2.3 In conjunction with ekr 500 Plus

1.4.2.4 In conjunction with EKR 1500 / CCD line guider
as a CCD 2004 replacement

Customers machine
controller
BST Signal Terminal Box1
(optional)
Sensor CLS Pro 600
with control panel
EKR 1500
Sensor CLS Pro 600
with control panel
CCD Line Guider
CAN Module bus coupler
CAN bus connection
(optional)
Description 1
12

1.5 Terms used in this manual

1.5.1 General information
In principle, the windows displayed on the keyboards graphics
display are laid out as follows:

1.5.2 Set position
The set position is the required line / contrast transfer point position
in the sensor scanning area. It can be set up in Automatic mode
using the control panels arrow keys (see Chapter 5.3.2).
The set point position will be indicated by a white triangle
displayed on the control panels screen.

The deviation will be faded in as plaintext during displacement of
the set position. The deviation can take positive values and
negative values as well.

The contrast quality will be graphically displayed in the bottom
section of the window.
Status bar
Display area
The content shown in this area
depends on the mode setting.
Detailed descriptions can be
found in Section 5.2.1 for the
set-up mode and in Section
Footnote
Contrast quality
(graphical)
Deviation of the
SET POINT position
SET POINT Position
without deviation
Center of
measuring range
Standard
SET-position
Center of
measuring range
Standard
SET-position
Numeric indication
of the deviation
Description 1
12

1.5.3 Measuring range
The sensors measuring range is 25 x 3 mm (W x H).

1.5.4 Search area
The search area is a section within the measuring area. The line /
edge that has to be evaluated and controlled afterwards is located
in this section.

1.5.5 Status bar
The actual sensor status and the controllers actual operating
status are both displayed in the status bar.
See Section 5.2.3 as well regarding this.
The controller details are not displayed in the stand-alone version.
1.5.6 Footnote
Operating help is integrated in the footnote. This tells you when
optimisations can be implemented in the displayed window or what
the actual setting of the selected parameter is and how it can be
configured.

1.5.7 First edge / second edge
The edge that will be controlled afterwards can be defined for the
line scanning process. First edge and second edge are both
available for use as options.
The edge position on the left of the display must be used for setting
up the first edge.

The second edge is used for setting up the second edge.

first edge second edge
Description 1
12
1.6 Control panel

The control panel contains all of the display and operating controls
needed to operate the CLS Pro 600.

1.6.1 Graphics display
Different parameters as well as main and quick menus (depending
on the mode selected) are displayed on the control panels screen
during operation.
The symbol significances are described in Chapter 5.2.

1.6.2 Control panel
Three different groups of keys are integrated in the control panel
and they have the following functions:

SET-UP keys: Used to select set-up mode

Blue keys: Used to access the menu; import the parameters
or exit the parameter entering process

Arrow keys: Used to enter settings as shown in the operating
help page

You will find the separate key significances listed in the table on
the following page.
Description 1
12

Function Button Name Description

Edge SET-UP

Calls up the edge guiding set-up mode
(only possible in MAN mode)

Line SET-UP

Calls up the line guiding set-up mode
(only possible in MAN mode)

Arrow keys

Used to carry out operations as shown
in the footnote

ENTER
Imports the mode / parameter
settings
Exit set-up mode
Set-up mode

ESC

Aborts the parameter entering
process
Menu

MENU

Calls up or exits the quick menus
The key must be held down for
at least 3 seconds to call up the
menus

Right arrow key Used to enters a sub-menu or
parameter

Left arrow key Pages back by one menu level
(does not exit the menu)

ENTER Used to open a sub-menu or select
a parameter

ESC Pages back by one menu level and
might also close the menu

Description 1
12
1.7 Safety information
The safety relevant information in accordance with
DIN EN ISO 13857, DIN EN 349 and the industry specific accident
prevention regulations must always be taken into consideration
when installing the BST equipment in the production machine,
these include:

There must always be a safe distance between the BST equipment
and the machinery already installed on-site, such as machine
panels, building structures, etc.
Connection lines between the individual system components must
be laid so that nobody can trip over them, not pulled tight and well
anchored down.

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 affixed to them (yellow / black).

In principle, if the cable connections are (e.g. between the sensor
and sensors) disengaged then the sensor is no longer connected
to the power supply. Any infringements will result in the warranty
claim being invalidated.

The sensor has not been ATEX certified, i.e. it is not approved for
use in potentially explosive areas and must never be used in them!

Any transport safety devices that were attached to the guiding
device must be removed prior to commissioning.

Only trained specialist personnel are permitted to
undertake the assembly, installation and
commissioning!

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

Danger of crushing!
Never reach into the area inbetween the fixed lower
frame and the guiding devices moving upper frame
(rotating frame or swivelling roller guide).
Never reach into the area inbetween moving rollers!

!
!
!
Description 1
12

Ensure the equipment is electrically isolated before
starting work. To this end always carry out the
following activities:

1. Switch off and disconnect.
2. Protecting against the voltage being switched back
on
3. Determine that the unit is voltage-free
4. Earth the unit.
5. Cover or shield any adjacent parts that are still live.

Only then can the relevant work be undertaken!

Do not use the chassis or machine frame as a
climbing aid or a stepladder.
Do not remove any of the safety devices.

Actuator movements will be run by the drive even
during function checks away from the production
machine and/or during commissioning.
The relevant safety arrangements must implemented
during performance checks!
Monitor the overall safety concept of the production
machine during commissioning!

1.8 Laser
A laser is used as a positioning aid when positioning
the sensor.

This laser unit has been classified by the manufacturer as a
Class 1 laser in compliance with DIN EN 60825-1:2001-11.
This laser will not cause eye damage, even after long radiation
periods and even if other optical tools (lenses, etc.) are used in the
beams path.

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

!
!
Assembly 2
10
2. Assembly
2.1 Installation site requirements

The following points must be taken into consideration when
choosing the sensor and control panels locations:

The sensor and the control panel must be installed in a dry,
non-vibrating area and be positioned ergonomically.
The operator must be able to access the control panel easily.
Ensure that sunlight or other external light sources do not cause
unwanted reflections on the screen.

Strong electro-magnetic fields in the immediate vicinity of the
sensor, the control panel or the sensors can result in
malfunctions.

Take note of the permitted ambient conditions.
Temperature: 0 - +45C (maximum)
Humidity: 5 - 90%, no condensation
See chapter 2.1.1 as well regarding this.

The sensor and the control panel have not been ATEX
certified, i.e. they are not approved for use in potentially
explosive areas and must never be used in them!

2.2 Sensor installation

This chapter describes the procedure for installing the sensors
using the holders supplied in the package or the connection
options available if using a holder supplied by the customer.

2.2.2 Installing the sensor using the holder supplied in the package

A square holder bar has to be used with the holder supplied in the
package for the CLS Pro 600 sensor. Two sizes can be used,
25x25 mm and 35x35 mm.
The holder consists of a special holding device that enables both
sizes to be used.
Fit the holding device onto the square holder bar and slide it into
the required position together with the camera.
Now tighten up the securing bolt to clamp the holding device into
place on the square bar.
See drawing on the next page.

Assembly 2
10

2.2.3 Installing the sensor using a holder
supplied by the customer
If the sensor has been supplied without a holder, then the
customer must provide a relevant securing device. Securing
threads are available at the sensor enclosure for this purpose.
The connection sizes can be found in the following drawing.

Square bar Holder unit
Securing screw
M6 / 7 deep securing threads for
securing holder provided by customer
(on both sides)
1
0
,
7

6 55
5
5
,
5

4
9
,
8

20,5 67

1

Assembly 2
10

2.2.4 Setting the gap between the
sensor and the sensing roller
The optimum gap between the sensor and the sensing roller can
be set up using the measuring window protective packaging.
The measuring window protective packaging is an integral
part of the overall packaging!
In this case you must attach the protective packaging to area
around the sensor enclosures measuring window.
Slide the sensor along in the sensing roller direction until the
protective packaging lies up against the sensing roller (see
drawing).
Pull the protective packaging out to one side afterwards.

2.2.5 Turning the control panel
The control panel can be mounted on the sensor in four different
positions (each one offset by 90 from the other) (see diagram).

The sensor is prepared for installation in Position when
delivered from the factory.
The control panel mounting position must be altered accordingly if
the sensors control panel cannot be operated correctly due to the
existing installation situation. The relevant procedure is described in
the following.
1 2 3 4
1
Sensor enclosure
Sensing roller
Protective packaging
20
Assembly 2
10

1. Unscrew the four control panel
securing screws.

2. Carefully pull the control panel
upwards and away from the
sensor.

3. Turn the control panel into the
required position
(see illustration above).

4. Take note of the cable guide for
the connecting cable.
Do not crush or clamp the
cable.
There is a cut-out in the control
panels enclosure and the cable
should be fed out through it.

5. Use the four securing screws to
attach the control panel to the
sensor.
Securing screws
Cut-out
Assembly 2
10
2.3 Installing the control panel

This Chapter describes the procedure for installing the control
panel when using the sensors with control panel removed (see
Chapter 1.4.1.3).

Strong electro-magnetic fields in the immediate
vicinity of the control panel can result in
malfunctions. You must ensure that the control
panel is not mounted close to components that use
mains power or power lines when installing in a
control console or a control station. Always
maintain a minimum clearance of 100 mm!

2.3.1.1 Installation versions
The control panel enclosure enables the following installation
versions to be used:

1. Wall mounting
The control panel is secured to a level surface.
Refer to Chapter 2.3.3 for the procedure.

2. Console mounting
The control panel is installed in an existing on-site control
console or a control station.
Refer to Chapter 2.3.4 for the procedure.

A CLS Pro 600 securing kit, which is available as
an option, is needed to install the control panel
in a control console (BST Order-No. 133 459).

2.3.1.2 Cable extension
An optional cable extension is needed to connect the control panel
to the sensor.
Cable extensions are available in the following lengths:

Cable lengths BST Order-No:
2 m 131 993
5 m 131 994
10 m 131 995

It is also possible to combine different cable
lengths. The maximum permitted full length of 20 m
between the sensor and the control panel must
never be exceeded!

Assembly 2
10

2.3.2 Dismantling the holder
The holder must be removed before the control panel and holder
can be removed.

1. Unscrew the holders securing screws in
the enclosure
2. Pull out the holder.

3. The next procedures depend on the type
of installation.
Refer to Section 2.3.3 for a wall mounting
or Section 2.3.4 for a console mounting.

2.3.3 Wall mounting

2.3.3.1 Securing hole diagram

Sensor enclosure
Securing screws
Holder
93
105
9
3
1
0
5
Control panel
enclosure
4x M3
Assembly 2
10

2.3.3.2 Preparations

1. Unplug the control panel connecting
cable from the sensor (plug X100).

2. Unscrew the holders four securing
screws from the sensor enclosure.

3. Pull the holding ring and control
panel sideways out of the groove
in the sensor enclosure.

Plug X100
Control panel
connection cable
Securing screws
Securing screws
Plug
Assembly 2
10

securing screws and place to one
side.
These screws will be needed for
the wall mounting later on.

Pull the control panel out of the
control panel enclosure
Now pull the connecting cable and
the plug carefully through the cut-
out in the controller enclosure.

2.3.3.3 Assembly

1. Fit the M3 threads in the holes as
shown in the securing screw hole
template
(see Chapter 2.3.3.1).

2. Use the four M3 screws to screw
the control panel on.
The four hexagon screws that
secured the control panel to the
sensor when the unit was
delivered can be used for this.

3. Use the optional extension cable to
connect up the control panel to the
sensor (see Chapter 2.3.1.2).

4. Plug the extension cable connector
into the sensors X100 socket.
Securing screws
Dont crush or clamp
the cable!
Assembly 2
10
2.3.4 Control console installation

2.3.4.1 Installation cut-out

2.3.4.2 Preparations
A securing kit, which is available as an option, is
needed to install the control panel in a control
console (BST Order-No. 133 459).

1. Unplug the control panel
connecting cable from the
sensor (plug X100).

101
+1
1
0
1
+
1
Installation cut-out
Plug X100
Control panel
connecting cable
Assembly 2
10

securing screws and place to
one side.
These screws will be needed
for the console installation later
on.

3. Pull the control panel out of the
sensor enclosure
Pull the connecting cable and
the plug carefully through the
hole in the sensors enclosure.

2.3.4.3 Assembly
1. Cut out the section
(see Chapter 2.3.4.1).

2. Carefully push the control panel
into the cut-out section.

2. Use two of the securing screws
to screw the two securing plates
(part of the installation kit) onto
the back of the control panel.
The four hexagon screws that
secured the control panel to the
sensor when the unit was
delivered can be used for this.

4. Screw the four threaded pins
into the securing plates until the
control panel is held firmly in
place.

5. Use the optional extension
cable to connect up the control
panel to the sensor (see
Chapter 2.3.1.2).

6. Plug the extension cable
connector into the sensors
X100 socket.

Securing screws
Securing screws
Plug
Threaded
pins
Securing plates
Top view
m
a
x
.

1
5

m
m

Control panel
Threaded pin Threaded pin Securing plates
Installation 3
3
3. Installation
3.1 Fitting the cable connections

Warning!
All connecting cables must be laid without being tight
and you must ensure that there is no danger of
anyone tripping over them.

Cable connections between the specific units
(sensor, sensors, guiding device, etc.) must
comply with the connection diagram.
Tighten up the securing screws in the plugs
Ensure that the voltage supply has the correct
potential equalisation in accordance with the local
regulations.
3.2 Sensor

3.2.1 Enclosure socket

Enclosure plug /
socket
Function Remark
X100

Control panel connection (plug)
X101

Controller connection (socket)
X80

I/O connection
(optional: Terminal Box BST STB 1)
connection box with terminal strip for
onsite connections; See Appendix 4
for layout
Analog O/P 0 - 10V
External lighting , trigger
O/P, +12V / 5 mA
External lighting,
switched against +24V
Error O/P,
switched against +24V
!
X80 X101 X100
Installation 3
3

3.3 Service indicator displays
There are 3 service LEDs fitted on the sensor enclosure and they
have the following significances:

3.3.1 Bus status LEDs

LED Name Status Bus name Meaning
OFF STOPPED
The unit is in the initialization phase. No data
transfer can take place.
FLASHES PREOPERATIONAL
The unit is in PREOPERATIONAL mode.
Initialisation is completed.
The unit can be started.
H1 RUN
ON OPERATIONAL The unit is in OPERATIONAL mode.
OFF NO ERROR
The unit is running OK.
No errors present.
FLASHES 3 x SYNC ERROR No SYNC report has been received.
H2 ERR
ON BUS OFF The interface controller is in BUS OFF mode.

3.3.2 Unit status LED
LED Name Status Meaning
OFF The unit is in an undefined state.
FLASHES The unit program is running OK. H3 PROG
ON The unit is in an undefined state.

H3 H1
H2
Installation 3
3

3.4 DIL switch settings

The S4 DIL-switch is used for making application specific settings.

DIL switch Meaning
S4.1 Not used at the moment
S4.4 = ON Sets the sensor up as a stand-alone system
In this case the sensor is used as the NMT master and
bus system sync generator.
S4.4 = OFF Set up the sensor to work with ekrPro Com
60
/
ekr 500 Plus / EKR 1500 / CCD Line Guider

Commissioning 4
12
4. Commissioning

Warning!
Only qualified and trained personnel are permitted to
undertake the commissioning!

Danger from the power supplies!
You are only allowed to open the sensor or other
components if the power supplies have been switched
off!

Requirements:
The web guiding system has been fully wired in, i.e. the
cable connections between the specific web guiding
components have been made.
The sensor is connected to the power supply.
The sensor switches (see 3.4 and 6.1.1) and the panel
(see 6.1.2) have been set up for the appropriate
application.
The following information window will be superimposed on
the screen if the panel cannot make bus contract with the
sensor:

The following are displayed:
The panels node number on the bus
(Commander Node)
The synchronization status (SYNC)
The module status (Modulstate)
Whether the sensor has been detected
on the bus (Sensor at ...)
Whether the terminator resistor has been
set up (Resistor)

There must always be one sensor and one panel with
corresponding nodes present on the bus (e.g. sensor = 41
and panel = 111) so that the system can work correctly.
If the sensor is not detected then this will be indicated, as
the bus connection has not been made. Always check the
connection cable and the plug in this case.
Furthermore, you can also read whether the terminator
resistor has been set up correctly or not.
!
Commissioning 4
12

4.1 Menus
Setting up and operating the sensor are menu-controlled
processes. The menus differ between:
Main menu
Quick menu
Set-up mode

All of the parameters that are needed to set up the sensor are
included in the main menu. The structure is a hierarchal structure
(see menu structure in Section 4.1.3.4).
The parameters are user organized, i.e. you can assign any
parameter to a user level. In this case only the parameter that the
logged-on user has access rights to will be displayed
(see Section 5.6 Expanded operation as well).
Parameters that are required for the respective application can be
assembled in the quick menu. This gives you direct access.
Assigning the quick menu is covered in Section 5.6.4.
Set-up mode enables you to set up the job specific parameters for
the material and define the guiding mode (line / edge).

4.1.2 Input options

Entries must be made in different sections of the menus; select the
entries from the options list or activate the functions.
The changes are made as follows:
Direct via the entry screen. The positions that have to be
changed will flash.

or
In the footnote. The selected parameter is displayed
showing the current setting here. The current setting will
flash, which is the indication that adaptation is needed here.

Commissioning 4
12

4.1.2.1 Alphanumerical /
numerical entries
Proceed as follows to make direct entries in the input screen:

The positions that have to be changed will flash.
Use the up or down arrow keys to select the required
number / the required letter. The numbers 0 - 9 will be
displayed first and then the alphabet from A - Z.
Press ENTER to confirm the selected number / selected
letter.
If the entry consists of several places then you must use the
right arrow key to select the next place. The entry must
now be made as described above.

Proceed as follows to make an entry in the footnote:

The positions that have to be changed will flash.
Use the up or down arrow keys to select the required
number / the required letter. The numbers 0 - 9 will be
displayed first and then the alphabet from A - Z.
Press ENTER to confirm the selected number / selected
letter.
If the entry consists of several places then you must use the
right arrow key to select the next place. The entry must
now be made as described above.
0
Commissioning 4
12

4.1.2.2 Options list
An entry from a default list can be selected from an option list.
Example:
Select the required parameter.

Confirm the selection by pressing ENTER. This will open up the
settings window.

Use the up / down arrow keys to scroll through the entries
displayed in the list.
Press ENTER to confirm the selected entry.
The entry will be imported.

4.1.2.3 Checkbox
The associated parameter can be activated or deactivated using
the checkbox.
Example:
Select the required parameter. The current status will be displayed
in the footnote at the bottom of the setting up window.
Use the up / down arrow keys to activate or deactivate the
function.

Commissioning 4
12
4.1.3 Main menu
The menu contains all of the parameters needed to run the sensor.

4.1.3.1 Navigating around the main menu
Use the arrow-keys to navigate within the main menu.
The selected entry will be displayed with a highlighted background.
The entire main menu cannot be displayed in a single window. The
window will scroll down automatically when the bottom of the
window is reached. The menu displayed in the window will be
moved upwards automatically when scrolling downwards and
downwards when scrolling upwards.

Press ENTER to confirm the parameter or sub-menu selection.

Press the ESC key to cancel the entry.

4.1.3.2 General information
The separate menu section descriptions assumes that the menu
has already been called up.
Opening the menu will only be displayed once. Follow this
procedure before you start to edit the specific parameters:

1. Hold the MENU key on the panel down for at least 3 seconds.

2. The main menu will be displayed in the footnote at the bottom
of the screen.

3. Select the enter m entry here (will have a green border
around it) and then confirm the selection by pressing ENTER.

4. This menu will be displayed.

You can now select and optimize the parameter that you need
(see Section 5.7 as well).

Commissioning 4
12
4.1.3.3 Entering the path
The relevant path going to the description of a specific main menu
section will be displayed alongside the description. Only the
relevant window will be displayed in the actual description.

Example: Proceed as follows to set up the sensor parameter:

1. Log on as Admin.
2. Open the main menu first.

3. Now select the configuration sub-menu.

4. Select sensor and then open the setting up window.

The path details will then be displayed in the description
\\configuration\sensor.

Commissioning 4
12
4.1.3.4 Menu structure

Access to the different menus and sub-menus depends on the assignment
to the password levels.
You will find the assignment according to the factory default settings in
appendix A3.
You can adapt those assignments. The procedure is described in section
5.6.3.

change user (Section 5.6.1)
configuration (Section 5.7.1)
sensor
remote control ekr
save configuration
commander
select configuration
mounting position
edit menu configuration
delete configuration
parameter (Section 5.7.2)
jobs
illumination
contrast tracking
line width tolerance
splice misalignment
position averaging
web stop detection
recapture factor
adaption settings
contrast detection
gain factor Xp
signal view type
remote control ekr (Section 5.7.3)
display (Section 5.7.4)
system info (Section 7.5)
Explanations for the specific menu sections
can be found in Section 5.7 Signification of
the main menu parameters.
Access password level: administrator
System in setup mode
Access password level: operator /
maintenance
Access password level: operator
Access password level: maintenance
Commissioning 4
12
4.2 Commissioning with a controller
4.2.1 ekrPro Com60
ekrPro Com60 firmware > 1.7.6 is needed to run the system!
Attention: You must connect the sensor up to the controller and
turn the sensors S1 rotary switch to Position 1 (default)
and then switch the sensor on before you select the
standard system with CLS Pro 600.
Proceed as follows:

1. Wire in and switch on the ekrPro Com60 controller as stipulated
in the operating manual. Start the system, without BUS
STATUS; SYNC: Failed will be displayed even if the
connection between the controller and the sensor is OK.

2. Configure the ekrPro Com
60
controller
Select the standard system for use with the CLS Pro 600 as
follows.

a) Press the MENU key on the controller. The set-up menu will
be displayed on the screen.

b) Select Sel. Std. system and then press ENTER.

c) The standard system selection window will now be displayed.
Now press ENTER.

d) The option list opens with the most common standard
systems.

e) Now select the CLS: EMS 17 entry and then confirm the
selection by pressing ENTER.
This entry can be used with all applications that use
CLS Pro 600. Optimization of the application specific
components (e.g. EMS 16) is made afterwards.

f) Press the function key F2 (Set).

g) Close the set-up menu.

h) Now switch the controllers power supply off for a few
seconds and then restart.

Commissioning 4
12

3. Now switch the CLS Pro 600 sensor over to set-up mode.
The controller must be in MAN mode to do this!
Press the set-up line or set-up edge key.
A blue background will now be displayed around the window
the sensor lighting flashes and the laser is switched on.

4. Open the main menu by pressing down the menu key for
approx. 3 seconds. Select the Change User sub-menu from the
main menu and then log on as Administrator. The procedure
is given in Section 5.6.1.

5. Now open Mounting Position in the Configuration sub-menu
and teach-in the sensors mounting position. This procedure
consists of 4 sub-steps.

Teach-in cannot be used in stand-alone mode!

Follow the example shown in the operating manual to help you
use the teach-in process. You must ensure that this example
also moves when you move the material web in step 3.

Mounting position A is shown as the example in this procedure:
Note that mounting positions B, C and D must first be activated
before you can use them.

1. Call up and open the sub-menu configuration.

2. Call up config positon A.

3. Start the teach-in process for this mounting position.
Select the teach-in parameter and then confirm your
selection by pressing ENTER. The teach-in process
has now started.

3a) The first step is to set up manual adjustment.
Use the left / right arrow keys to move the guiding
device.
The settings can be inverted from here if the arrow
key assignments are incorrect. This is realized by
using the up / down arrow keys.
Press ENTER to confirm your settings.

Commissioning 4
12
3b) The window for the second step is now open.
Position the teach-in model line in the green field
and then press ENTER to confirm the process:

The line identification process will now be run.

3c) Move the line to the left in Step 3 afterwards. This is
realized by briefly pressing the left arrow key
If the teach-in model does not move as well
(e.g. when scanning using a fixed roll) you can use
your hand to move it slightly to the left.
The system will now calculate all of the parameters
automatically.

3d) Press key ENTER. Set-up is now complete.

You can further optimize the parameters displayed
in the Step 4 window whenever necessary.

sensor inverted:
Determines whether the sensor signal for this
mounting position should be read in as inverted or
not.
The setting should be made so that the image on the
screen concurs with the actual conditions.

guiding direction inverted:
Determines the sensors guiding direction so that
the system feeds the material web along in the
correct direction.
This parameter must be checked without fail during
the commissioning.

manual control inverted:
The material web arrow key assignments for
manually adjusting the guiding device can be
inverted here, e.g. the left arrow key can also be
moved to the left.

W-Val display inverted:
The arrow key assignments for adjusting the set
point value can be inverted here.
Laser line
Material to be
scanned
Fix teach-in model, e.g. use
adhesive tape
Teach-in model.
The teach-in model must
move when the material
is adjusted.
Commissioning 4
12

6. Return to the Change User sub-menu after you have
completed these settings. Now log on as Operator here.

7. This completes the commissioning of the sensor connected to
an ekrPro Com
60
controller.

8. Press Menu key to leave the set-up menu.

4.2.2 ekr 500 Plus
See ekr 500 Plus manual (MD.299.01.xx).

4.2.3 EKR 1500 / CCD line guider
and CAN - Module bus coupler
Being prepared

Commissioning 4
12
4.3 Commissioning as a
stand-alone system
1. Aligning the sensor for stand-alone mode. Switch the sensors
S4 DIL-switch to ON for this mode.

2. Now switch the CLS Pro 600 sensor over to set-up mode.
Press the set-up line or set-up edge key.
A blue background will now be displayed around the window.
3. Open the main menu by pressing down the menu key for
approx. 3 seconds. Select the Change User sub-menu from the
main menu and then log on as Administrator. The procedure
is given in Section 5.6.1.
4. Now open the Select configuration position in the
Configuration sub-menu and then select the STAND ALONE
setting.

5. Test the controller to ensure that it is working correctly. Sensor
orientation and/or the mounting position guiding direction
might have to be configured as well.

6. Return to the Change User sub-menu after you have
completed these settings. Now log on as Operator here.

7. Commissioning the sensor as a stand-alone system is now
complete.

Operation 5
31
5. Operation
If the sensor will be used an integral part of a projected BST
system then the standard configuration has already been
completed. However, the onsite set-up (line or edge) still has to be
undertaken.
If required or if necessary, you can:
a) Create a quick-menu
b) Create and save a job specific configuration.
The procedure for this part is given in Section 5.5 Standard
operation.
If the sensor is changed onsite (with or without the panel) then a
new component optimization is required. Parameter settings might
have to be remade. Optimizing the specific parameters and their
significances are described in Section 5.6 Expanded operation.
5.2 Operating display
The CLS Pro 600 screen display depends on the mode that the
sensor will be working in. We differentiate between set-up mode
and scanning mode. The menu can be called up from either
mode. However, access to the specific sub-menus is differs.
5.2.1 Set-up mode display window
The sensor settings are made via the guiding job in set-up mode.
The parameters needed for the setting up will be displayed using
graphic symbols and numerical values on the control panel screen.
You will find the significances for the individual symbols in the
following illustration.

Possible contrast
Contrast quality of the edges / lines lying
in the searched area graphically
displayed.
Import the settings by pressing the
ENTER key
Sensor details
Runs the settings for the
selected function
Measuring area
Shows the edges / lines lying in the
measuring area and marks the
selected edge / line.
Current operating mode
(controller)
Status bar
Shows you which modes the sensor
and the controller are working in.
See Section 5.2.3 as well.
Numerical contrast
quality details.
Operating help
Operating help has been integrated
in the footnote. This shows you how
the optimization can be run in the
displayed window.
Pre-select the setting up functions by using the up / down arrow keys.
Activated in the standard settings are:
1. Move search area
2. Change size of search area
3. Other functions are being prepared
Operation 5
31

The background is always blue in set-up mode.

5.2.2 Scanning mode display window

The background will flash red if an error occurs (line or edge
not detected), regardless of the mode being used

The background is green in automatic mode (controller).

Current operating mode
(controller)
Status bar
Shows you which modes the sensor
and the controller are working in.
See Section 5.2.3 as well
Measuring area
Shows the tested edge / line and
displays the standard set point.
Numerical contrast
quality details.
Contrast
Contrast quality of the tested edge /
line is graphically displayed.
Operating help
Operating help has been integrated in
the footnote. This shows you how the
optimization can be run in the displayed
window.
Set point adjustment (W)
in AUTO mode
Move guiding device left / right (mot)
in MAN mode
Pre-selects the ekrPro Com60
mode and other remote control
functions
Operation 5
31

5.2.3 Status bar
The current statuses that the sensor is in are displayed in the
status bar as well as the controllers current operating mode
(except for stand-alone mode).

Sensor in edge mode

Sensor in line mode

Sensor in set-up mode

Sensor in stand-alone mode

Sensor transmitting an interlock

Sensor has not detected a valid edge

Controller has activated Watchdog edge 1

Controller has activated Watchdog edge 2

Controller is in manual mode

Controller is in automatic mode

System is in servo-center position (SC mode)

No controller detected on the bus.

Operation 5
31
5.3 Controlling the ekrPro Com60 /
ekr 500 Plus controllers remotely

The sensors panel enables the controller to be controlled
remotely. In this case the remote control function must be activated
beforehand. Check this setting. Log on as Admin and call up the
main menu afterwards and then select the \\configuration\remote
control ekr sub-menu. The enable remote control function must
be activated.
5.3.1 Manual mode
Set-up and system configuration is carried out in this mode.

Use the up or down arrow keys to select manual mode.
The selected mode will be displayed with a green border
around it.

Press ENTER to confirm your selection

The current mode will be displayed in the top right corner of the
screen.
The sensor will switch over to manual mode.

5.3.2 Automatic
Automatic material web controlling is carried out in this mode,
depending on the scanning mode that was selected (edge or line).

Use the up or down arrow keys to select automatic mode.
around it.


screen.
The sensor will switch over to automatic mode.

Operation 5
31

5.3.3 Servo-center position
The material web will always be kept in the servo-center position in
this mode.

Use the up or down arrow keys to select servo-center
position.
around it.


screen.
The sensor will switch over to the mode servo-center position.

5.3.4 Moving the set point position (W-value)
Use the left / right arrow keys in automatic mode to adjust the set
point.

5.3.5 Moving the guiding device
Use the left / right arrow keys in manual mode to move the guiding
device to the left or right.

5.3.6 Adjusting the controller gain.
The controller gain can be reset via the \\configuration\remote
control ekr\gain factor XP parameter.

You must be logged on as Admin.
Move set point.
Move guiding device
Operation 5
31

5.4 Operation

Danger of cuts!
Never touch the edges of moving material webs!
You are only allowed to run set up when the
production machine is stopped.

The guiding mode is determined and an automatic equalization to
the characteristics of the material that has to be scanned is run
during the set-up.

5.4.2 Activating line set-up / edge set-up
Use the set-up keys to select the type of set-up (line or edge) that
you want to use.
Attention: Set-up can only be run when the controller is in MAN
or SC mode.
An information window will be opened if you attempt
to call up set-up in AUTO mode. This will tell you that
this action is not possible in this mode.
Press ESC or ENTER to exit the window.

5.5 Standard operation
Certain settings, i.e. the so-called jobs, have been set up in the
main menu for the current applications (e.g. slitter, etc.). All of the
necessary basic settings will be implemented when the required
job is selected. You only have to enter the necessary set-up (edge
or line) for the work. The system is now ready for operation.

5.5.1.1 Selecting a job
Jobs are loaded via the \\parameter\jobs\load menu.

The following selection window will be displayed.

!
Operation 5
31
You can select between the jobs entered in the factory here.

DEFAULT: Resets the default factory settings
COLORED LINE: These settings are used when a colored line
has to be tracked and it lies in a field with
changing conditions.
SMALL LINES: This setting must be used if lines with a width
of less than 0.5 mm have to be scanned.
STRICT CHECK: Select this setting if very constant measuring
and printing conditions are present,
regardless of whether there is a lot of noise
present in the field. In this case the system
will block it relatively quickly, but the danger
of latching on to contrast caused by noise is
minimal.
Use, for example, if there are large breaks in
the line (ratio between the broken and usable
signal > 20%).
VERY TOLERANT: Select this setting if extremely poor
measuring conditions are present (uneven
web running, changing print quality, etc.) but
no noise spikes. The number of blocking
actions undertaken will be kept to a minimum
in this case.
Use, for example, when the color of the edge
being scanned changes frequently or if the
print in alignment mode is uneven.
If you are unable to enter any of these settings for your application
you can use the relevant settings to create your own jobs. The
procedure is described in Section 5.6.2.

If you have changed over to set-up mode or if the set-up line or
set-up edge keys are pressed again in set-up mode, then the
currently loaded job will be displayed on the screen for 2 seconds.

If it is not displayed, then the system will be operated using the
machine default values or manual modified parameters, which
have not been assigned to a job.

Operation 5
31

5.5.1.2 Edge set-up mode

1. Use the arrow keys to select
MAN mode .
The selected mode will be displayed
with a green border around it.
Confirm the selection by pressing
ENTER.
The current mode will be displayed in
the top right of the screen.

2. Press key SET-UP EDGE .

The LED inside the SET-UP key will
illuminate. The LED inside the ENTER
key will flash.
The camera light will be switched on
and it will flash. The laser line will be
visible simultaneously.

3. Use the laser line to position the
camera on the required edge.
Use the mechanical adjustment device
to fix it in position.
The edge with the best contrast will be
selected automatically by the system.
In this case it is edge K1.

4. a) If the pre-selected edge is to be
used for the controlling, then no
other settings have to be entered.
Press the ENTER button.
The LEDs inside the ENTER and
SET-UP keys will be extinguished.
The display will change over from
set-up mode to scanning mode.

b) If edge K2 has to be used for the
guiding then the arrow keys must
be used to define the search area.
In this case you must select
define search area and set up the
size of the search area accordingly.

5. Press the ENTER button.
The system will now switch back to
AUTO mode (operating mode).

2
1
1
2
K1
K1 K2
K2
3

m
m

25 mm
Laser line
or
Operation 5
31
5.5.1.3 Line set-up mode
Standard

1. Use the arrow keys to select
MAN mode .

The selected mode will be displayed
with a green border around it.
Confirm the selection by pressing
ENTER.
The current mode will be displayed in
the top right of the screen.

2. Press LINE SET-UP.

The LED inside the SET-UP key will
illuminate. The LED inside the ENTER
key will flash.
The camera light will be switched on
and it will flash. The laser line will be
visible simultaneously.

3. Use the laser line to position the
camera on the required line.
Use the mechanical adjustment device to
fix it in position.
The line with the best contrast will be
selected automatically by the system.
In this case it is line L1.

4. a) If the automatically pre-selected line is to
be used for the controlling, then no other
settings have to be entered.

b) If line L2 has to be used for the
guiding then the arrow keys must
be used to define the search area.

In this case you must select the
search area position and then the
search area size functions and
then define the search area.
The display will change over from set-up
mode to scanning mode.

5. Press the ENTER button.
The system will now switch back to
AUTO mode (operating mode).
1
2
2
1
Laser line
25 mm
3

m
m

L1
L2
L2 L1
or
Operation 5
31

Area-Tracking

If the conditions are present, as shown in the example, then the
displayed pre-selection will be used for the standard settings.

This can result in the controller producing unclean web guiding,
due to the unevenness of LK1.

The Area-Tracking will have to be used in this case.
Only one edge (LK2) will be tracked, but this will be compared
by checking the color of an area alongside the edge.
This will enable the noise spikes to be suppressed and prevent
the system from jumping around.

LK1 can no longer be included, as the search area has been
reduced. The search area is displayed here.
We recommend that the setting is made so that the left edge of
the search area lies approx. over half of the smallest point in
the line.
The area that has to be checked must always lie on the side of
the edge on which the crosshairs lie.

The panel display will look as follows:

If the search area is enlarged then the are that has to be
checked will be enlarged automatically.
Normal line tracking using two edges will be resumed
automatically as soon as a second edge is detected inside the
search area.
LK1 LK2
Left edge
= =
Smallest
position
in the line
Tested area
42%
This edge will
be tracked.
Search area limit
(left edge)
Operation 5
31

5.6 Extended operation
The system parameters are saved in the main menu.
The menu structure is shown in Section 4.1.3.4.
You can run the required optimization from here if the pre-
configured settings cannot be fully used for a specific type of
machine.
The settings must be entered in set-up mode.
The significances of the specific parameters are described in the
following.
5.6.1 Change user
Use this parameter to assign or change the user level in a dialog
window. Different setting up options are available, but they depend
on the user level. Which parameter a user can adapt and which
functions he can use are defined in the configuration menu (see
Configuration section). Assignments have already been set-up in
the factory (see factory default settings).
However, the system should be created so that the user only has
to log on as the administrator, in order to run a complete
commissioning process. Implement any relevant adaptations
necessary when you assign user levels to the specific parameters
(see Section 5.6.3).

The procedure for selecting the user levels is described in the
following, e.g. for commissioning or operating.

1. Mark the change user entry and press ENTER to confirm it.

2. Define the user levels in the following dialog window. The
following are available for use:

operator (no password)
maintenance (password = 00001)
administrator (password = 00002)

Use the up or down arrow keys to select the required level
and then press ENTER to confirm it.

3. You will be asked to enter a password afterwards.
Enter a valid password here and then press ENTER to confirm
it.

You are now logged into the selected user level. You can now
adapt the parameters that can be accessed from this level.
Operation 5
31

5.6.2 Job administration
It might be necessary to enter different measuring settings due to
the variety of materials and print images processed in the different
applications. A relevant measuring parameter set, consisting of
material and/or job specific parameters can be saved as a Job.
These jobs can be called up whenever necessary. This enables
you to set up repeat jobs quickly and without any errors.
Certain basic jobs have already been pre-configured in the factory
and are available under the \\parameter\jobs\load menu (see
Section 5.5.1.1 as well).

5.6.2.1 Saving a job
Proceed as follows if you want to create specific jobs for the
application:
1. Set up the necessary parameters first.
2. Select the \\parameter\jobs\save job menu afterwards. An
entry screen will be displayed, in which you can use the arrow
keys to enter the job name.
3. Press ENTER to confirm your entry. The settings will be saved
under this name in the job list.

5.6.2.2 Selecting a job
1. Call up the \\parameter\jobs\choose job menu.
The selection list of existing jobs will be displayed on the
screen.
2. Use the up / down arrow keys to select the job that you want
and then press ENTER to confirm your selection.
3. The selected job will be loaded. A relevant information window
will be displayed after the loading has been completed
successfully.

5.6.2.3 Deleting a job
A saved job that is no longer wanted can be deleted.
Call up the \\parameter\jobs\choose job menu. A selection list of
saved jobs will be displayed. Use the up / down arrow keys to
select the job that you want to delete and then press ENTER to
confirm your selection. The job will be deleted.

Operation 5
31

5.6.3 Assigning user levels
to the parameters
Access rights can be assigned to specific parameters via the
Configuration sub-menu, i.e. only those holding access rights can
access parameters that have been assigned a user level.

Attention: The Configuration sub-menu can only be called up in
set-up mode and you have to be logged on as Admin.
A relevant information window will be opened up if you
try to call it up from scanning mode.

Procedure:

1. Call up the configuration sub-menu.

The dialog window is sub-divided into the following sections:

Parameter display
Assigned user levels
Footnote with user help.

Only the parameters that the current user hold access rights to will
be displayed in the parameter screen.
Assignment:

1. Use the up / down arrow keys to select the parameter that you
want to optimize and then press ENTER to confirm your
selection.

2. The associated editing window will be opened. The time [ms]
parameter window is used as an example here.

3. Now select access at level.
You can now define the user level in the option field on the right
that will enable users to view / use this parameter. Confirm the
entry by pressing ENTER.

4. The display will return to the configuration screen.
The relevant symbol will be displayed in the user level column.

1
2
3
1
2
3
Operation 5
31
Symbol definitions are as follows:

Operator
Maintenance
Administrator
BST-Support

5.6.4 Setting up quick menus
Parameters that are required for the current application can be
assembled in the quick menu.
15 places can be assigned. The displayed sequence is determined
by the numbering (no slot). A known weighting can be used here.
The entries with the highest numbers (slot places) will be ignored if
there are more than 15 entries.
Procedure:

1. Call up the configuration sub-menu.

The dialog window is sub-divided into the following sections:

Parameter display
Entry defining if the parameter will be displayed in the
quick menu or not.
Footnote with user help.

Only the parameters that the current user holds access rights to
will be displayed on the screen.

Assignment:

2. Use the up / down arrow keys to select the parameter that you
want to optimize and then press ENTER to confirm your
selection.

3. The associated editing window will be opened. The
illumination parameter window is used as an example here.

4. Now select quickmenuslot.
You can now select from the option field on the right if, when
and in which place this parameter will be displayed in the quick
menu.
Confirm the entry by pressing ENTER.

5. The display will return to the configuration screen.
The entry will be displayed with the symbol in the quick menu
column.

You can easily call up the quick menu whilst working just by
pressing the MENU key. However, there must be at least one
parameter selected for the quick menu. Otherwise it is virtually
deactivated.

1
2
3
1
2
3
Operation 5
31
5.7 Main menu parameter significances

5.7.1 Configuration
The sensor, panel and mounting position settings are entered via
the Configuration sub-menu.

Attention: You can call up this sub-menu with password level
Admin and in set-up mode.

commander The parameters that apply to the panel are
configured in this sub-menu.

display dimtime: This parameter can be used to dim the
panels LCD display. The screens
background illumination brilliance will be
dimmed after a set period has expired. The
screen will be brightened once again when a
key is pressed and the action will also be
executed.

Setting range: 0 15 min
Default setting: 5 min
The screen will not be dimmed if 0 min is
entered as the setting.

active USB: Activates the memory function.
The panels configuration data can also be
accessed via the USB interface and this data
can also be saved externally if necessary.
Furthermore, this also gives you the option of
loading firmware updates. Press the ENTER
or ESC buttons to shut down the connection.

manual settings: Other setting up options can be activated in
set-up. These are:
enable alternative edge:
This gives you the option of selecting an
alternative contrast. The left edge limit will
flash red on the screen. You can select any
other edge that is found.

enable alternative 2
.
edge:
This gives you the option of selecting a rear
edge for line scanning. The right edge limit
will flash red. You can select any other edge
that is found.

enable alternative line:
This gives you the option of selecting an
alternative line. Both edge limits will flash red.
You can select any other line that is found.
\\configuration\commander\
Operation 5
31

hide menu: If the parameter is active you can call up the
main menu by holding down the menu key for
3 seconds.
If the parameter is inactive you can access
the main menu via the entry in the quick
menu.

Note: You must completely exit the menu
(quick menu as well) at least once before you
can deactivate hide menu. Do not press the
ESC key as otherwise the changes will not be
imported.

disable operating error dialog:
Warning and information dialogs can be
suppressed whilst working if this parameter is
activated.

Operation 5
31

sensor The parameters that apply to the sensor are
configured in this sub-menu.

guiding mode: Use this parameter to define the control
process to be used when exiting set-up.

Setting options:
to middle: It will be controlled from the
center of the sensor measuring
area.

Attention: With this setting:

to setupposition:
The edge / line will be stopped in
the position entered during set-
up. The controllers set point will
be reset.
The material will not be moved.

keep value: The setting will not be changed
automatically when you exit set-
up.
The material will not be moved.

Pre-adjustment: keep value

active USB: Activates the memory function.
The panels configuration data can also be
accessed via the USB interface and this data
can also be saved externally if necessary.
Furthermore, this also gives you the option of
loading firmware updates. Press the ENTER
or ESC buttons to shut down the connection.

white balance: Use this parameter to run a white balance for
the sensor and to equalize the center of the
sensors measuring area using the projected
laser line.
This setting requires a three step dialog for
completion.

\\configuration\sensor\
Set-up will be run
from this line
The material will be moved
into the laser position after
switching over to automatic
mode
Operation 5
31
1. In the first step you will be asked to place a
white material under the sensor.

2. White balance will be run automatically
after you press ENTER. The run will be
displayed as an advancement cursor.

3. The successful white balance will be
displayed in an information window.

4. Now press the ENTER key to exit the
white balance process.

Operation 5
31

guiding lock delay: Use this parameter to set up how long the last
measured value must be retained for until a
blocking signal is sent.
This will ensure that a minimum control time is
run when scanning a broken line and that the
guiding device can react.

Setting range: 0 9999 ms
Default setting: 20 ms.

dig. out reset delay: Use this parameter to set up the delay
time needed for resetting the digital outputs.

Default setting: 0 ms

dig. out set delay: Use this parameter to set up the delay time
needed for setting up the digital outputs.


mode digital out: You can define which signal will be
transmitted from the digital outputs from here.
Only the guiding unlock and guiding lock
settings are available for these parameters at
the moment.

guiding edge: Use this parameter to define the edge that will
be used for the controlling. This parameter is
only available for line scanning applications.
Setting options:
median of 1 and 2:
Standard setting
A median value will be created
using both edges of the line and
this will be generated as the
control position.

first edge: It will be controlled by the left
edge as displayed on the screen

second edge: It will be controlled by the
second edge.

Int. watchdog: Not used at the moment.

Pre-adjustment: median of 1 and 2

Operation 5
31

remote control ekr The parameters for the controllers remote
control are set up in this sub-menu.

internal W-Val: Use this parameter to run a W-value internal
simulation.
We recommend that the parameter is only
activated in stand-alone mode, as a controller is
not used in this mode.
Setting options: ON, OFF
Pre-adjustment: OFF

enable remote control:
Use this parameter to switch the controllers
remote control option on and off.
Pre-adjustment: ON

unit for guiding position:
Use this parameter to define the measuring unit
that will be displayed on the screen with the W-
value.
Setting options: no
mm
inch
Pre-adjustment: mm
If parameter no is set then the display will
concur with the controller.

step width of guiding position:
Use the left / right arrow keys in automatic
mode to set up the W-value. The size of the
adjustment made each time a key is pressed is
defined by this parameter.
If an arrow key is kept held down for 350 ms
then a new 150 ms adjustment step will be
introduced automatically.
If the arrow key is kept held down for longer
than the time defined in the time to increase
step width parameter it will switch over to the
adjustment step width defined in the fast step
width of guiding position parameter.
Setting options: 0.01 mm
0.02 mm
0.05 mm
0.10 mm
0.20 mm
0.50 mm
1.00 mm
Pre-adjustment: 0.05 mm
\\configuration\remote control ekr\
Operation 5
31

fast step width of guiding position:
You can define the adjustment step width here
after which it will switch over from the time to
increase step width parameter if the arrow key
is kept held down for longer than the defined
time. It will reset back to the smallest
adjustment step width automatically when the
arrow key is released.
Setting options: 0.01 mm
0.02 mm
0.05 mm
0.10 mm
0.20 mm
0.50 mm
1.00 mm

time to increase step width:
Use this parameter to define the time until it
switches over to the biggest step width.
Setting options: off
0.5 s
1.0 s
1.5 s
2.0 s
2.5 s
3.0 s
3.5 s
4.0 s
4.5 s
Pre-adjustment: off
Operation 5
31

mounting position The sensors mounting position is
defined in this sub-menu and the
different configurations are also set up
here.
select: Use the select parameter to select a pre-
configured mounting position. You can
select from 4 different mounting positions
in principle, but mounting position A is
the standard setting and mounting
positions B D are optional and these
must be activated before you can use
them.
configuration: Use the configuration parameter to
configure the selected mounting position.
The same configuration content and
procedure is used for all of the mounting
positions.
The procedure is described in detail in
Section 4.2.1 when commissioned in
conjunction with the ekrPro Com60.

edit menu configuration

The menu access rights and the quick menu position are defined in
this sub-menu.

See Sections 5.6.3 and 5.6.4 for more detailed descriptions.

\\configuration\mounting position
\\configuration\edit menu configuration\
Operation 5
31

5.7.2 Parameter
The parameters that apply to the measuring process are
assembled in this section of the main menu.
Significances and procedures for the individual settings are
described below.

jobs The job administration procedure is described in detail in
Section 5.6.2.

illumination The parameters that apply to the lighting are set
up in this sub-menu.

time [ms]: Use this parameter to set up the CCD line
illumination time. This affects the control
measuring cycle time.
If a value of > 2 ms is selected, then no more
details can be selected, e.g. slightly broken lines.


internal: Use this parameter to configure the bright field
illumination.
The settings are set up automatically in the
standard application.
If a reasonable value cannot be set up in
automatic mode, e.g. due to the expected
different illumination situations (undulating,
smooth material), then automatic will be switched
off and the required value can be set up using the
brightness parameter.
brightness
Setting range: 0 100 %
0% means that the bright field illumination is
switched off.
100% means maximum brightness.

automatic
Pre-adjustment: ON

The optional and external parameters are not used at the
moment.

\\parameter\jobs\
\\parameter\illumination\
Operation 5
31
destination Use this parameter to set up over- or
underexposure for the relevant area in automatic
mode.
These settings can also be used for weak colors
inside a light background.
Setting range: 0 300%
Pre-adjustment: 100%
(i.e. no overexposure)

contrast detection
The parameters that apply to the contrast
detection are set up in this sub-menu.

quality: Use this parameter to set up the lower contrast
search threshold.
This setting is only available when the auto
adjustment parameter is switched off.
Determining the search threshold can be helpful
when, for example, a contrast that varies
considerably is present.
Setting range: 10 100
Pre-adjustment: Automatic
A 10 setting is used to detect weak contrasts
and a 100 setting is used for detecting good
contrasts

auto adjustment:
Switches the automatic determining of the
contrast detection search threshold on and off.
Setting options: ON / OFF
Pre-adjustment ON

min. line width:
This parameter is used to define the minimum
width and it is needed to ensure that the system
detects a line as a line.
Setting a high value will prevent noise being
generated by high-contrast scratches, etc.
A smaller value can be set up if very small lines
are detected reliably.
Settings: 0.1, 0.2, 0.3, 0.4 & 0.5 mm
Default setting: 0.3 mm

contrast tracking
The tracking conditions for exceptional materials
are optimized in this sub-menu, e.g. poor contrast
or print edges with different colors.

\\parameter\destination\
\\parameter\contrast detection\
\\parameter\contrast tracking\
Operation 5
31

plausibility check:
This sub-menu includes the parameter that will be
used to check the plausibility.
This is described below.

edge color
This parameter defines the type of color checks to be
used for edge scanning.
The details of how the color will be checked always
refer to the screen display.

Setting options: all
off
right side only
left side only
Pre-adjustment: all

edge intensity
This parameter defines the type of intensity checks to
be used for edge scanning.

off
right side only
left side only
Pre-adjustment: off

line color
This parameter defines the type of color checks to be
used for line scanning.
It describes which color will be checked.

Setting options:
all = color checks the right side, the left
side and the line
off = no color checks
only left side = color checks run on the
left side only
only right side = color checks run on the
right side only
only line = only the line color will be
checked
only not line = color checks the right side
and the left side but not the
line

Default setting: only line

Operation 5
31
line intensity
This parameter defines the type of intensity checks to
be used for line scanning.
off
only right side
only left side
only line
only not line
Pre-adjustment: only line

edge polarity
Use this parameter to define whether a polarity test
will be run or not. We recommend that this parameter
is always switched on.
Switching off is only makes sense if an object with
changing colors has to be scanned.
Pre-adjustment: ON

edge sharpness
Use this parameter to define whether the contrast
transfer point sharpness (slope) has to be checked.
Pre-adjustment: OFF

environment
The system will check the gap to the next contrast on
the left and right alongside the contrast that has to be
scanned during edge scanning. If the function is
switched then blocking will be released again after an
interruption when the gap corresponds to, is larger
than or is missing when compared to beforehand. If a
contrast that lies closer to the contrast being scanned
is detected, blocking will remain in place.
Pre-adjustment: ON

contrast quality
Use this parameter to define whether the contrast
strength has to be checked or not.
This must remain stabile over the measuring process.
Pre-adjustment: OFF

See
line color
for the
significance
Operation 5
31

adaption settings
Use this sub-menu to set up how the plausibility
check will be run using the comparable values.

general balancing:
Use this parameter to define the weighting that
will be applied with the new valid measurements
for the marked respective reference.
The parameter is only effective when used with
an ekrPro Com
60
in automatic mode.
Setting options: off = no weighting
2 values
4 values
8 values
16 values
32 values
64 values
128 values
256 values
Pre-adjustment: 256 values

A new comparison value must be determined as
follows for the default setting of 256 values:

color: This parameter defines whether the color
comparison value should be guided.
Pre-adjustment: ON

contrast: This parameter defines whether the search
contrast threshold should be guided.
This parameter is only active if contrast
detection /auto adjustment is switched on.
Pre-adjustment: ON

edge sharpness: This parameter defines whether the contrast
sharpness should be guided.
Pre-adjustment: ON

line width: This parameter defines whether the line width
should be guided.
Pre-adjustment: ON

\\parameter\adaption settings\
Sum of the last 256 values last value + new value
256
Operation 5
31
environment: This parameter defines whether the gap to the
next existing contrast alongside the contrast that
has to be scanned should be updated.
Parameter ON =
the smallest gap between the contrast that has
to be scanned and the next existing contrast is
used.
Parameter OFF =
the value is used that was defined during set-up
procedure. There is no update.
Pre-adjustment: ON

splice misalignment
Use this parameter to set up the maximum
expected deviation from two subsequent
evaluation characteristics when tracking broken
edges / lines or a splice.
If it proves difficult to check the material and the
gap between one evaluation characteristic and
the next is big then the parameter must be set up
more precisely in order to prevent the system
jumping to a wrong edge / line.
Setting range: 1 8 mm
Pre-adjustment: 2 mm

line width tolerance
Use this parameter to define the tolerance with
which the line being checked will be seen as a
valid line.
The line width can only deviate from the
reference by the value set up here.
The tolerance value setting is always a value.
Setting range: 0.02 2.50 mm

position averaging
This parameter can be applied to the measured
value output. A new measured value will be
imported directly if the setting is set to off.
The numerical value describes the new
measurement weighting used in the new
measured value.
This can attenuate the control process, so that,
for example, the system will be prevented from
overreacting by the torn material present after a
splice.
\\parameter\splice misalignment\
\\parameter\line width tolerance\
\\parameter\position averaging\
Operation 5
31
Setting options: off
2 values
4 values
8 values
16 values
32 values
64 values
128 values
256 values
Pre-adjustment: off

Example: The new measured value is
determined as follows when using a weighting of
64 values:

recapture factor
Use this parameter to define the step width that
the system will use for scanning the new edge /
line position after the contrast was lost.
The following benchmark value applies:
Small value for broken lines
Big value for a splice
Setting range: 0.001 10.000
Pre-adjustment: 0.01

web stop detection
Use this parameter to switch the automatic web
movement detection on and off. If this function is
switched on then web movement will be checked
if the edge was lost. The search area will be only
be opened if web movement has been detected
or if an edge cannot be found.
We recommend that the default setting is never
changed.
Pre-adjustment: ON

5.7.3 Remote control ekr
The remote control ekr sub-menu includes the gain factor Xp
parameter.
This enables you to enter the controllers remote gain factor
adjustment.
Setting range: 0.00 999.99

Sum of the last 64 values last value + new value
64
\\parameter\recapture factor\
\\parameter\web stop detection\
Operation 5
31

5.7.4 Display
Attention: You can call up this sub-menu with password level
Admin and in set-up mode.

The sensor signal can be displayed on the panels screen in
several different ways
The display sub-menu is used to configure the signal display.
You can select the type of display from here. You can select from
the followings display settings:
1. Extended contrast view (default)
2. RGB
3. R
4. G
5. B

This display mode is essentially for service
purposes and is used by BST for evaluating the
sensor conditions.
Operation 5
31

5.7.5 System Info
General system information is displayed in the System Info sub-
menu.
You need this information to identify the equipment, e.g. when
requesting support from BST service.
The following pages will be displayed after you have called up this
sub-menu:

Factory default settings 6
5
6. Factory default settings
There are four stoppers fitted on the sensors connection side and
the relevant switches are located behind them.
The control panel switch is located on the back behind the stop.
Which switches lie behind which stoppers is described below.

6.1 Device addresses
The device addresses for the sensor and the control panel are pre-
set in the factory.
The settings usually do not have to be modified.
Check the device address settings if malfunctions or non-defined
sensor or operator panel processes occur or re-occur after the
devices have been changed.

6.1.1 Sensor device address
The sensor device address was preset to "1" in the factory (delivery
state).
You are only allowed to modify the device address
if authorized to do so by the manufacturer!
The sensors device address is set up using the S1 rotary switch.
The current setting is displayed in the System info sub-menu as
Sensor Node (see Section 5.7.5).

Danger from the power supply!
You are only allowed to open the sensor if the power
supply has been switched off!

Setting the device address:

1. Switch-off the power to the sensor.
2. Unscrew the stopper in the sensor enclosure
3. Check the S1 rotary switch setting
The S1 rotary switch must be set to position 1 .
4. Switch the S1 rotary switch to position 1 if necessary.
5. Screw the stopper back into the sensor enclosure.
6. Switch the power supply back on.
Switch settings Address
0 Reserved
1 41
2 42
3 43
4 44
5 45
6 46
7 47
8 48
9 Reserved

5
6.1.2 Control panel device address
The control panels device address is set up using the S1 rotary
switch fitted on the panel board.
The S1 rotary switch is mounted behind stopper B on the back of
the control panel.

The control panels device address was preset to "1" in the factory
(delivery state).
The current setting is displayed in the System info sub-menu as
Commander Node (see Section 5.7.5).

You are only allowed to modify the device address
if authorized to do so by the manufacturer!

The control panels connecting cable plug must be
disconnected from the controller before you open the
control panel!

Setting the device address:

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

Rotary switch S1
0
1
2
3
4
5
6
7
8
9
Switch settings Address
0 Reserved
1 111
2 112
3 113
4 114
5 115
6 116
7 117
8 118
9 Reserved

5
6.2 Terminator resistors
The internal terminator resistors for the sensor and the control
panel were switched on in the factory. The settings usually do not
have to be modified.
Check the terminator resistor settings if malfunctions or non-
defined sensor or operator panel processes occur or re-occur after
the devices have been changed.

6.2.1 Sensor terminator resistors
The sensors internal terminator resistor is switched on or off using
switch S3. The current setting is displayed in the System info sub-
menu as Can Resistor Sensor (see Section 5.7.2).

The terminating resistor should only be switched
off after first obtaining agreement from the
manufacturer!

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

You are only allowed to open the sensor if the power
supply has been switched off!

Setting up the terminating resistor:

1. Switch-off the power to the sensor.
2. Unscrew the stopper in the sensor enclosure
3. Check the S3 switch setting.
The S3 switch must be set to the ON position.
4. Switch S3 to the ON position if necessary.
5. Screw the stopper back into the sensor enclosure.
6. Switch the power supply back on.
Switch S3
5
6.2.2 Control panel terminator resistors
The control panels internal terminator resistor is switched on or off
using switch S3. The current setting is displayed in the System
info sub-menu as Can Resistor Commander (see Section 5.7.2).
The S3 switch is mounted behind stopper C on the back of the
control panel.

The terminating resistor should only be switched
off after first obtaining agreement from the
manufacturer!

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

The control panels connecting cable plug must be
disconnected from the controller before you open the
control panel!

Setting up the terminating resistor:

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

The Configuration sub-menu can only be called up in set-up
mode and you have to be logged on as Admin.

Warning!
All of the settings made during operation will be
overwritten when the factory default settings are
reset.

1. Open the main menu.
2. Select the select configuration menu option. Press
ENTER to open the menu.
The following window will now be displayed:

3. Select the DEFAULT entry and then press ENTER to
confirm your selection.

4. An information window will be displayed after the setting
has been successfully imported.

5. Press ENTER to exit the menu. .

!
\\configuration\select configuration
Troubleshooting 7
1
7. Troubleshooting / FAQ

Item Error Possible cause Solution
1

2

3

4

5

6

7

Technical data 8
6
8. Technical data
8.1 Sensor

8.1.1 Environmental conditions
Working temperature: 0 to 45C
Storage temperature: -10.3V to 50.00 , 12 bit +
158.00
Working humidity: 5 to 90%, not condensing
Protection class: IP 54
Place of installation: In closed buildings
< 2000 m above sea level
External light: The sensor and control panel
should be protected from direct
sunshine

8.1.2 Power supply
Voltage: 24V DC 10% (including ripple)
Power consumption: max. 0.5 A
(including panel, 2 x lights 100%
switched on and 80 mA external
outputs)

8.1.3 Digital inputs
2 x digital inputs with metallic separation for path cycle / reset,
Input resistance: 4.7 kOhm each
Switching threshold: < 4V (low), > 8V (high)
switching sensor can be used for
+ only (pnp)

8.1.4 Digital outputs
1x error output, switched against +24V
1x external light switched against +24V
1x external light, trigger output, +12V / 5 mA
both external light outputs have a joint load rating of 80 mA

8.1.5 Analog output
1 x analog output 0 - 10V, 5 mA
Not protected against external overvoltage / polarity reversals

8.1.6 Measuring window cover
Laminated safety glass with PVB film as per EN 1565 and EN 167

Technical data 8
6

8.1.7 Control panel interface
Voltage: 24V DC
(corresponds to the power supply)
Current: max. 0.5 A
(protected by a polyfuse)
Bus interface: 500k baud,
No metallic isolation
Connection: Plugged in from the outside using
a 4-pin micro style M8 connector

8.1.8 Weight, dimensions
Weight: Approx. 1.18 kgs
(sensor without control panel and
holder)
Dimensions: See Chapter 8.2.5

8.2 Control panel

8.2.1 Environmental conditions
Working temperature: 0 to 45C
Storage temperature: -10.3V to +70C
Working humidity: 5 - 90%, not condensing
Protection class: IP 50

8.2.2 Power supply
Voltage: 24V DC
(power supplied by the sensor)

8.2.3 Display
LCD TFT color graphics module
Resolution: 320 x 240 pixels,
LED background lighting

8.2.4 Weight, dimensions
Weight: approx. 0.26 kgs
Dimensions: See Chapter 8.2.5

Technical data 8
6
8.2.5 Space requirement
Sensor with mounted control panel
and holder:

Sensor with holder but
without control panel:

(Details in mm)
Swiveling panel
View A
Material web
74 52
(4)
17
52
(4)
10,5
43,5
6
0

Scan point
8
5

77
Sensing roller
1
1
2

A
Adapter
1
6
0

2
5
(
1
)

1,5
25
(1)

20
116
123,5
(2)
/ 128,5
(3)

175
(2)
/ 180
(3)

Scan point
Material web
1
1
2

1
9
0

2
5
(
1
)

1,5
25
(1)
20
116
175
(2)
/ 180
(3)

123,5
(2)
/ 128,5
(3)

(1)
The details refer to the use of a 25x25 mm square bar.
The adapter is not needed if a 35x35 mm square bar is used.
(2)
Gap when using a 25x25 mm square bar.
(3)
Gap when using a 35x35 mm square bar.
(4)
Sensor offset by 180
Sensing roller
Technical data 8
6

Sensor with mounted control panel
but without holder:

Holder must be provided by the customer;
See Section 2.2.3 for the connection dimensions

Sensor without control panel
and holder:

Holder must be provided by the customer;
See Section 2.2.3 for the connection dimensions

Swiveling panel
Securing points for customers
holder (on both sides)
m
i
n
.

1
7
0

m
m

s
p
a
c
e

n
e
e
d
e
d

t
o

s
w
i
v
e
l

t
h
e

p
a
n
e
l

Material web
Scan point
8
5

77
1

Sensing roller
1

Note
interference
contours
9
0

1,5
90 20
Measuring
area
145
143 min. 75
B
Laser position
Securing points for customers
holder (on both sides)
Material web
Scan point
Sensing roller
4
9
.
8

9
0

6
0

Measuring
area
143
Laser position
min. 75
Customers
holder
20
1,5
90
Technical data 8
6

Control panel:

8.2.6 Plug pin assignments
A 4-pin micro style M8 connector is used to connect the control
panel to the sensor and the sensor to the controller.

Contact assignments in the plug connector:

8.2.6.1 Plug X100; control panel
Plug (male)

8.2.6.2 Plug X101; controller connection
Socket (female)

Contact Signal Remark
1 +24 V +24 V power supply
2 CAN_H CAN Bus
3 GND Power supply ground
4 CAN_L CAN Bus

21 105
6
93
9
3

1
0
5

1
0
0

X
View X
1
2
3
4
1
2
3
4
X
View X
Technical data 8
6

8.2.6.3 Plug X80; I/O connection

Contact assignments in the plug connector:

Socket (female)

Plug (male)

Contact Function Remark
1 GND Ground for Contact 2 and Contact 3
2 DOUT +24V output
3 LAMP_PLUS External lighting
+24V output
4 LAMP_TRIG External lighting, trigger O/P, +12V / 5 mA
5 ANALOG_OUT Analog output 0 - 10V
6 EXT_GND Insulated ground for Contact 7 and Contact 8
7 EXT_GEAR External synchronization cycle
8 EXT_RESET External synchronization reset

X
View X
1 2
3
4
5
6
7
8
1
2
4
5
6
7
X
View X
3
8
Maintenance 9
1
9. Maintenance

Beware!
Maintenance and cleaning work must only be
undertaken on the sensor and the control panel after
the power supply has been switched off.

Ensure the equipment is electrically isolated before you start any
work. To this end always carry out the following measures:

1. Switch off and disconnect.
2. Protecting against the voltage being switched back on
3. Determine that the unit is voltage-free
4. Earth the unit.
5. Covering or protect yourself from any adjoining part that are still
live.

Only then can the relevant work be undertaken!

The maintenance and/or cleaning intervals depend on the
environment conditions at the installation site.
If the customer is processing very dusty materials then the
maintenance / cleaning intervals must be reduced accordingly.

In principle, cable connections can only be disconnected after the
sensor itself has been disconnected from the power supply.
Any guarantee claims will be invalidated if this instruction is
ignored.

9.2 Sensor
The sensor is classified as an optical instrument. It must be looked
after accordingly.
The cleaning of the casing should be carried out with 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!
The measuring windows protective lens cover must be cleaned
regularly in order to obtain optimum guiding results.
Spotted or homogeneous dirtying of the lenses can result in wrong
readings.

9.3 Control panel
The control panel is a maintenance-free unit.
The cleaning of the casing should be carried out with 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!

Transport/Storage 10
1
10. Transport / Storage
10.1 Transportation
The equipment will be shipped in accordance with the details
stipulated in the order:

Completely assembled and interconnected to the web guiding
control system
as component parts in standard cardboard boxes with cellular
lining material

The unit must only be transported when it is packed in the original
BST transport packing.

BST International GmbH will not be liable for damage to the
sensor or control panel caused by incorrect transport
packaging!

10.2 Storage
If the sensor and the control panel have been shipped as individual
parts and will not be installed immediately, they must be stored in a
dry room prior to installation.

Storage conditions: Temperature: -10C up to +70C (max.)
Humidity: 10 - 90%,
no condensation

Decommissioning 11
1

11. Decommissioning
Decommissioning (scraping) of the system must be carried out
together with the entire machine.
The necessary procedures must be prepared by the manufacturer
of the machine. You must take into consideration that the edge and
line contrast sensor is generally considered to be an electrical /
electronic device, which must be disposed of in accordance with
the current legal requirements.
You may also be able to return the system to BST International
GmbH. The corresponding agreement must be made first.

Index I
1
CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Index
Index
Assigning user levels to the parameters ......... 50
ATEX ......................................................... 11, 13
Automatic mode............................................... 41
Benutzerebene zuordnen................................ 48
Bus status........................................................ 24
Cable connections............................... 11, 23, 81
Cable extension........................................... 4, 17
Commissioning
Stand alone system..................................... 37
Commissioning with controller CCD Line Guider
..................................................................... 36
Commissioning with controller EKR 1500 ....... 36
Commissioning with controller ekr 500 Plus.... 36
Commissioning with controller ekrPro Com60 33
Control panel ................................................. 4, 9
Cable guide ................................................. 16
Connection cable........................................... 4
Console mounting ....................................... 21
Dimensions.................................................. 79
Display......................................................... 76
Environmental conditions............................ 76
Installation ................................................... 17
Installation cut-out ....................................... 21
Installation versions..................................... 17
Key functions............................................... 10
Maintenance................................................ 81
Power supply............................................... 76
Securing hole diagram................................ 18
Securing kit.................................................. 21
Securing set ................................................ 17
Setting the device address.......................... 70
Technical data............................................. 76
Terminator resistors .................................... 72
Turning the control panel ............................ 15
Wall mounting.................................. 17, 18, 19
Weight ......................................................... 76
Decommissioning ............................................ 83
Deleting a job................................................... 49
Device addresses............................................ 69
DIL switch
DIL switch S4 .............................................. 25
Setting for stand-alone system.................... 25
Setting for use with ekrPro Com
60
............... 25
Display............................................................. 76
Scan mode .................................................. 39
Set-up Mode................................................ 38
Emissions ........................................................ 12
Environmental conditions ................................ 13
Expanded operation ........................................ 48
Factory default settings ............................. 69, 73
Resetting factory default settings................ 73
Fehlersuche (FAQ) .......................................... 74
Firmware
Firmware adding ........................................... 2
First edge / second edge................................... 8
Free headroom................................................ 11
Graphics display................................................ 9
Input options.................................................... 27
Alphanumerical input .................................. 28
Installation ....................................................... 23
Installation site................................................. 13
Intended use...................................................... 3
Laser................................................................ 12
Laying of cables .............................................. 11
LED operating statuses..................................... 1
Main menu....................................................... 30
Navigation ................................................... 30
Maintenance.................................................... 81
Manual mode................................................... 41
Menu structure ................................................ 32
Menus.............................................................. 27
Operating display ............................................ 38
Operating manual
Use................................................................ 2
Operating Manual
Symbols ........................................................ 1
Operating mode
Center positioning....................................... 42
Operating modes
Automatic .................................................... 41
Manual mode .............................................. 41
Operating principle ............................................ 5
Operation................................................... 38, 43
Operation display ............................................ 39
Parameters of the main menu
Configuration............................................... 52
Commander ................................................ 52
edit menu configuration............................... 59
mounting position........................................ 59
remote control ekr ....................................... 57
Sensor......................................................... 54
Display ........................................................ 67
Parameter ................................................... 60
adaption settings......................................... 64
contrast detection........................................ 61
contrast tracking.......................................... 61
destination................................................... 61
illumination .................................................. 60
jobs.............................................................. 60
line width tolerance ..................................... 65
position averaging....................................... 65
recapture factor ........................................... 66
splice misalignment..................................... 65
web stop detection...................................... 66
Remote control ekr...................................... 66
System info ................................................. 68
Plug pin assignments ...................................... 79
Index I
2
CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Index
Potentially explosive areas................................ 3
Remote control ................................................ 41
Move the guiding device ............................. 42
Move the set point ....................................... 42
Safety information........................................ 2, 11
Saving a job..................................................... 49
SC mode.......................................................... 42
Selecting a job................................................. 49
Sensor
Analog output .............................................. 75
Control panel interface................................ 76
Digital inputs................................................ 75
Digital outputs.............................................. 75
Dismantling the BST holder ........................ 18
Enclosure socket ......................................... 23
Environmental conditions............................ 75
Installation ................................................... 13
Installation with BST holder......................... 13
Installation with holder supplied by the
customer ................................................. 14
LED ............................................................. 24
Maintenance................................................ 81
Measuring window cover............................. 75
Power supply............................................... 75
Service indicator displays............................ 24
Setting the device address.......................... 69
Setting the gap between the sensor and the
scanning roller ........................................ 15
Structure........................................................ 4
Technical data............................................. 75
Terminator resistor...................................... 71
Set position........................................................ 7
Setting up quick menus................................... 51
Set-up.............................................................. 43
Activating set-up ......................................... 43
Edge mode.................................................. 45
Line mode ............................................. 46, 47
Standard...................................................... 46
Tracking area.............................................. 47
Space requirement .................................... 77, 78
with holder, with panel ................................ 77
with holder, without panel ........................... 77
without holder, with panel ........................... 78
without holder, without panel ...................... 78
Status bar ........................................................ 40
Storage............................................................ 82
System
Standard working........................................ 43
Technical data........................................... 75, 76
Terminator resistors ........................................ 71
Terms used ....................................................... 7
Transportation ................................................. 82

Commissioning example A1

CLS Pro 600 line and contrast sensor EDV-No.: MD.323.01.01 Chapter: A1

A1 Commissioning example

Saving parameters A2

A2 Saving the parameters and
loading the firmware

A2.1 Save parameters
System configurations and saved jobs can be backed-up and
saved on an external medium (a PC running MS Windows).
Use the sensors USB interface to transfer the data.

Procedure:

1) Unscrew the stop from the sensor enclosure that is fitted
in front of the USB interface and then find the button
that activates the memory function .
2) Use a mini USB cable to connect the sensor up to a
PC or a laptop.

3) Activate the sensors memory function.
In this case you must press the function activation button.

The sensor will now be seen as another PC / laptop
drive.
4) Copy the required data from the settings directory into a
directory that you previously created for this purpose in
the PC / laptop.
5) Call up the Safely remove hardware function from the
task-bar after you have saved the data and then cancel
the connection.
6) Disconnect the cable afterwards and then screw the stop
back into the sensor enclosure.
7) Now run a sensor restart (mains OFF / ON).

2
1
2
1 +24 V
4
3
3
4

A2.2 Loading the firmware
If the sensor or control panel firmware has been modified then the
firmware must be loaded separately for both devices.
Use the control panel and sensor USB interfaces to load the
firmware updates.

A2.2.1 Loading the sensor firmware

Procedure:

1) Unscrew the stop from the sensor enclosure that is fitted
in front of the USB interface and then find the button
that activates the memory function .
2) Use a mini USB cable to connect the sensor up to a
PC or a laptop.

3) Activate the sensors memory function.
In this case you must press the function activation button
.

The sensor will now be seen as another PC / laptop
drive.
4) Load the new firmware.
Sensor firmware can be recognised by the S in the file
name, e.g. CLSPro600_S_1.6.1_A.bim.
The new firmware must be copied into the Update
directory. The directory must be created if it does not
exist.
5) Call up the Safely remove hardware function from the
task-bar after you have loaded the firmware and then
cancel the connection.
6) Disconnect the cable afterwards and then screw the stop
back into the sensor enclosure.
7) Now run a sensor restart (mains OFF / ON).
The restart should take approx. 40 seconds. The
firmware will be automatically loaded into the system
during this time.

3
2
1
4
2
1 +24 V
3
4

A2.2.2 Loading the panel firmware

1) Unscrew the stop from the back of the panel that is
fitted in front of the USB interface and then find the
button that activates the memory function .
2) Use a mini USB cable to connect the panel up to a
PC or a laptop.

3) Activate the panels memory function.
In this case you must press the function activation
button .

The panel will now be seen as another PC / laptop
drive.
4) Load the new firmware.
Panel firmware can be recognised by the C in the file
name.
The new firmware must be copied into the Update
directory. The directory must be created if it does not
exist.
5)
6) Call up the Safely remove hardware function from
the task-bar after you have loaded the firmware and
then cancel the connection.
7) Disconnect the cable afterwards and then screw the
stop back in.
8) Now run a panel restart.
The restart should take approx. 40 seconds. The
firmware will be automatically loaded into the system
during this time.

2
4
1
2 1
3
+24 V
3
4
Default settings A3
A3 Factory default settings
Menu Sub-menu 1 Sub-menu 2 Parameters Access
password level
Default
value
Applicatio
n
Change User User level Operator Operator
display dim time
[min]
Admin 5 commander
active USB Admin
Manual settings enable alter-
native edge
Admin Deactivated
enable alter-
native 2
nd
edge
Admin Deactivated
enable alter-
native line
Admin Deactivated
hide menu Admin activated
disable
operating error
dialog
Admin activated
guiding mode Admin keep value
active USB Admin
white balance Admin
adjust sensor Service
guiding block
delay [ms}
Admin 20
dig. Out reset
delay [ms]
Admin 0
dig. Out set delay
[ms]
Admin 0
mode digital out Admin
sensor
guiding edge Admin median of 1
and 2

internal W-Val Admin Deactivated
enable remote
control
Admin activated
unit of guiding
position
Maintenance mm
step width of
guiding position
Maintenance 0.05 mm
fast step width of
guiding position
Maintenance 0.2 mm
remote
control ekr
time to increase
step width
Maintenance Deactivated
select Admin A
(A) Teach in Admin
(A) Sensor
inverted
Admin Deactivated
(A) Guiding
direction
Admin Deactivated
(A) Remote
control inv.
Admin Deactivated
Configuration
mounting
position
config. position A
(A) W-Value
control inv.
Admin Deactivated

Default settings A3
Menu Parameter level
1
Parameter level
2
Parameter
level 3
Access
password level
Default value Applicatio
n
(B) enable Admin Deactivated
(B) Teach in Admin Deactivated
(B) Sensor
inverted
Admin Deactivated
(B) Guiding
direction
Admin Deactivated
(B) Remote
control inv.
Admin Deactivated
config. position B
(B) W-Value
control inv.
Admin Deactivated
(C) enable Admin Deactivated
(C) Teach in Admin Deactivated
(C) Sensor
inverted
Admin Deactivated
(C) Guiding
direction
Admin Deactivated
(C) Remote
control inv.
Admin Deactivated
config. position C
(C) W-Value
control inv.
Admin Deactivated
(D) enable Admin Deactivated
(D) Teach in Admin Deactivated
(D) Sensor
inverted
Admin Deactivated
(D) Guiding
direction
Admin Deactivated
(D) Remote
control inv.
Admin Deactivated

config. position D
(D) W-Value
control inv.
Admin Deactivated
edit menu
configuration
Admin
select
configuration
Admin
save
configuration
Admin

delete
configuration
Admin
choose job Operator
save job Admin
jobs
delete job Admin
time [ms] Maintenance 2
internal Operator Automatik
brightness Maintenance 7
automatic Maintenance activated
optional Operator
brightness Maintenance 0
Parameter
illumination
automatic Maintenance Deactivated
Default settings A3

Menu Parameter level
1
Parameter level
2
Parameter level
3
Access
password level
Default
value
Applicatio
n
external Operator Deactivated
brightness Maintenance
automatic Maintenance
destination [%] Maintenance 100
quality Maintenance 45
auto adjustment Maintenance activated
contrast
detection
min. line width
[mm]
Maintenance 0.3
edge color Operator All
edge intensity Maintenance Deactivated
line color Maintenance Deactivated
line intensity Maintenance Deactivated
edge polarity Maintenance activated
edge
sharpness
environment Maintenance activated
contrast tracking plausibility check
contrast quality Maintenance Deactivated
general balancing Maintenance 256 value
color Maintenance activated
contrast Maintenance activated
edge sharpness Maintenance activated
line width Maintenance activated
adaption settings
environment Maintenance activated
splice
misalignment
[mm]
Maintenance 3
line width
tolerance [mm]
Maintenance 0,1
position
averaging
recapture
factor
Maintenance 00.050

web stop
detection
Maintenance activated
remote
guiding
controller
gain factor Xp 006.00
display signal view type Maintenance extended
contrast view

System info Operator

Connection BST STB 1 A4
A4 BST Signal Terminal Box 1 (BST STB 1) connections

General information
The sensor can be connected up to the customers controller using
via a terminal strip (optional). A BST STB 1 must be used in this
case. This will link to the sensor via a cable and plug. The
separate cable wires will be fed to a terminal strip inside the BST
STB 1. The connections to the customers machine can then be
made from here.

Terminal Function Remark
1 GND Ground for Pin 2 and Pin 3
2 DOUT +24V output
3 LAMP_PLUS External lighting
+24V output
4 LAMP_TRIG External lighting, trigger O/P,
+12V / 5 mA
5 ANALOG_OUT Analog output 0 - 10V
6 EXT_GND Insulated ground for Pin 7 and
Pin 8
7 EXT_GEAR External synchronization cycle
8 EXT_RESET External synchronization reset

Installation

Warning!
Only qualified and trained personnel are permitted to
undertake the 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 mm.
Wiring sleeves must not be used with cables from
0.75 mm up to a maximum of 1.5 mm.

Using wiring sleeves:
The crimping is also gas-tight (no cross crimping) i.e. there is no
gap between the conductor and the wiring sleeve. We recommend
using VarioCrimp-4-Zange 206-204 crimping pliers made by
WAGO.
The length of the metal sleeves fitted on the wiring sleeve must be at
least 8 mm.
Connection cable
(from X80)
Terminal strip
M16 cable screws
Optional outputs
(sealed by plugs)
!
Metal 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).

Installation instructions for EMC-wiring

1. Unscrew in the union nut for the cable
screw-in cable glands.

2. Pull out the clamping insert from the
intermediate supports.

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.

Union nut
Clamp insert
Enclosure wall
Attention! Do not squash the
clamping insert when
removing it (do not press
down on it
Intermediate support

6. Push the clamping insert to the
intermediate support.

7. Fit the screws.

Teach-in model A5
A5 Teach-in model

CLS Pro 600
Teach-in model
Aligning the teach-in model in front of the CLS Pro 600
Material web

BST CLSPro 600 User Manual

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