Description B

Infra-red edge sensor FR 5001 / FR 5021

Software:

ZC 3202-0001 F_ZB ZC 3202-8001 F_ZD

1 . General instructions 2. Function 3. Assembly 4. Installation 5. Commissioning 6. Operation 7. Parameters 8. Maintenance 9. Technical data

Infra-red e d g e s e n s o r FR 5 0 0 1 / F R 5021 1 . G e n e r a l t i o n s 1.1 E x p l a n a t i o n of s y m b o l s - j o b s to be performed II important information a n d instructions i n s t r u c -

1.2 O p e r a t i n g m a n u a l

P l e a s e k e e p the a b o v e in a safe place and m a k e a c c e s s i b l e to personnel at all times. T h e manual is part of t h e p a c k a g e supplied and should be read c a r e fully prior to assembly, operation a n d m a i n t e n a n c e . All j o b s listed in this description should be performed by qualified or suitably instructed p e r s o n n e l only.

1.3 S a f e t y i n s t r u c t i o n s

N e v e r touch the e d g e s of running w e b s .

2 .

F u n c t i o n T h e E+L infra-red e d g e s e n s o r FR 5001/FR 5021 s c a n s the e d g e s of o p a q u e materials ( t h r e a d s / s t r i p e s / m e s h ) s u c h a s paper, c a r p e t s o r tightly knit textiles without touching. T h e Infra-red e d g e s e n s o r should only be u s e d - in perfect technical condition, - for u s e as intended, - in a c c o r d a n c e with the operating instructions.

2.1 I n t e n d e d u s a g e

2.2 D e s i g n

Lens

LED strip display Socket

Membrane keyboard

..Operational" LED

Securing drill holes

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Infra-red e d g e s e n s o r FR 5001/FR 5021 2.3 O p e r a t i n g p r i n c i p l e T h e e d g e s e n s o r o p e r a t e s on a light-sensitive barrier principle and u s e s an infra-red LED as light s o u r c e . This infra-red LED projects light onto the micro-prism reflector loc a t e d behind the w e b via a mirror. T h e reflector reflects back the light according to a retroreflecting principle, d e p e n d i n g on how far the web c o v e r s the m e a s u r i n g r a n g e . T h e reflected light is reflected onto the C C D array via the telecentric optical unit. T h e CCD e l e m e n t s can c o p e with a higher signal level w h e n t h u s illuminated. T h e signal is converted in the microprocessor into an output value proportional to the position of the w e b e d g e a n d conveyed to the CAN bus. This output value can be u s e d to e.g. trigger a digital w e b controller. At the s a m e time, the current w e b position in the measuring r a n g e is indicated on the LED strip display. If the LED b e s i d e the strip of LEDs lights up green, the e d g e s e n s o r is signalling that it is operational. nnnnnnnnnnnnnnnn O di Edge sensor measuring range T h e e d g e s e n s o r measuring r a n g e is 10 mm and h a s a resolution of 512. T h e e d g e s e n s o r outputs the w e b e d g e position value for this range.

Measuring range +10 mm

Edge sensor measuring range

3 .

A s s e m b l y Mount the e d g e s e n s o r on the first third of the w e b guider exit path ( s e e actuator description). T h e w e b must run at a 90 angle to the e d g e s e n s o r ( s e e fig. below). Web Edge sensor

3.1 E d g e s e n s o r with r e f l e c t o r bracket

Edge sensor

Reflector bracket

T h e w e b height during travel may c h a n g e to any d e g r e e with e d g e s e n s o r FR 5001 but must not however touch the e d g e s e n s o r or reflector. With e d g e s e n s o r FR 5021 the w e b should be 140 -160 mm (as m e a s u r e d from the lens) a w a y from it. At a d i s t a n c e of 0 140 mm, reliable w e b e d g e (narrow thread) detection is limited.

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Infra-red e d g e s e n s o r FR 5001/FR 5021 3.2 S e p a r a t e e d g e s e n s o r a n d reflector Mount the e d g e s e n s o r a n d reflector on t h e first third of the w e b guider exit path ( s e e actuator description). Mount the e d g e s e n s o r so that the w e b runs at a 90 angle to the e d g e s e n s o r . Mount the reflector parallel to the e d g e sensor. To avoid any self reflection c a u s e d by the w e b , the e d g e s e n s o r must be tilted t o w a r d s the reflector by 10 to 15. T h e w e b must run parallel to the reflector.

3.2.1 FR 5001 m o u n t i n g clearances

Flat, h o m o g e n o u s w e b e d g e T h e d i s t a n c e b e t w e e n t h e e d g e s e n s o r lens and the reflector may b e 20 to 500 mm. T h e height at which t h e w e b travels b e t w e e n the e d g e s e n s o r a n d reflector may vary to a n y extent but must not touch the e d g e s e n sor or reflector.

3.2.2 FR 5021 m o u n t i n g clearances

Thread(stripe) or mesh-type w e b edge T h e d i s t a n c e b e t w e e n the e d g e s e n s o r lens a n d the reflector must be 2 4 0 to 3 2 0 mm. T h e reflector must n o t be mounted in the 0 - 2 4 0 mm a r e a . This dimensional restriction d o e s not apply to permanently m o u n t e d E+L reflector brackets (section 3.1). T h e optimum w e b position is a c l e a r a n c e of 180 mm. T h e w e b height during travel may c h a n g e to any d e g r e e in the s h a d e d grey a r e a (140 - 2 4 0 mm). T h e w e b should not be located outwith this r a n g e a s otherwise reliable w e b e d g e (narrow thread) d e t e c tion is limited.

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Infra-red e d g e s e n s o r FR 5001/FR 5021 3.3 C l e a r i n g d e v i c e (optional) T h e optional clearing device must be c o n n e c t e d to the c u s t o m e r ' s c o m p r e s s e d air supply using a service unit with a submicron filter. T h e service unit must m e e t the following conditions: - Oil-free - Operating p r e s s u r e 2 bar - P o r e size < 5um

If the clearing device is mounted at the customer, the nozzle openings m u s t be aligned with the s e n s o r and reflector.

InStdlldtiOn

~* ' leads.

3 r o t e c t s

'9

n a l

leads and run apart from heavy current-carrying

-* Pull off the union nut on the s e n s o r cable. T h e s e e n s u r e that the e d g e s e n s o r housing and the signal lead insulation a r e conductively c o n n e c t e d . -* S e c u r e the signal lead with a c a b l e clamp. If the w e b is subject to a high d e g r e e of static charging we recomm e n d you link the e d g e s e n s o r housing to the m a c h i n e frame.

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Infra-red e d g e s e n s o r FR 5 0 0 1 / F R 5021 5 . C o m m i s s i o n i n g On c o m p a c t units, no adjustment to the e d g e s e n s o r is n e e d e d on first-time commissioning. If you h a v e ordered t h e s e control c o m p o n e n t s separately and wish to construct your own o p e r a b l e control loop or if e d g e s e n s o r s a r e s u p plied but not pre-mounted you m u s t perform the s t e p s described in section 5.1 and 5.2.

5.1 S e t t i n g g r o u p a n d d e v i c e numbers

E d g e s e n s o r on right in w e b direction of travel, unit n u m b e r 1 " E d g e s e n s o r on left in w e b direction of travel, unit n u m b e r 2 " II Direction of w e b travel = P r o c e s s i n g direction for the entire s y s t e m

T h e group n u m b e r d e p e n d s on the digital controller (identical to the group n u m b e r of the w e b guider to which it belongs, s e e block diagram). -> S e t the controller to "center position" m o d e . Edge sensor on left of web direction of travel Unit number 2 Group number 0 - P r e s s the "GRP" a n d "DEV" buttons on the e d g e s e n s o r at the s a m e time. After a b o u t 6 s e c o n d s the group a n d unit n u m b e r s on the LED display will start to flash. After approx. a further 20 s e c o n d s the e d g e s e n s o r switches into s e t u p m o d e . T h e LEDs stop flashing a n d stay on permanently and the group n u m b e r (GRP button) and unit n u m b e r (DEV) can be c h a n g e d . If t h e GRP" a n d DEV" keys a r e not p r e s s e d for longer than a p prox. 20 s e c o n d s , the g r o u p and device n u m b e r s a r e stored and s e t u p m o d e quit again. Processing direction for the entire system

Group number 0 Unit number 1 Edge sensor on right of web direction of travel Example: setting the group and unit numbers

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Infra-red e d g e s e n s o r FR 5001/FR 5021 5.2 C a l i b r a t i n g t h e e d g e s e n sor P l e a s e o b s e r v e the following w h e n calibrating the e d g e sensor: the s e n s o r must be mounted mechanically correctly, clean the lens a n d reflector with a soft dry cloth, no w e b or reflector joints should be located in the s e n s o r visual r a n g e . -> Enter the e d g e s e n s o r group and device n u m b e r s on the comm a n d station. -> Select p a r a m e t e r 3 a n d e n t e r value 10. Select p a r a m e t e r 4. T h e e d g e s e n s o r calibrating p r o c e s s is initiated by changing p a r a m e t e r s . During calibration, the yellow strip LEDs 0-7 and 1-8 will flash in alternation a n d the "Operational" LED will light up red. When calibration is finished the "Operational" LED will light up green and the yellow strip LEDs 0-7 will go on. If the "Operational" LED lights up red t h e r e must h a v e b e e n a error during calibration, repeat calibration a n d check the error m e s s a g e in p a r a m e t e r ..9. .

6.

O p e r a t i o n LEDs 7 and 1 are on

Positioning the e d g e s e n s o r With the help of the row of LEDs on the receiver, the e d g e s e n s o r can be manually positioned at the w e b e d g e . -> S e t the w e b offset on the digital controller to 0". -> Position the e d g e s e n s o r manually: If the w e b is in its set position, locate the e d g e s e n s o r on the web so that only the LEDs in the middle, 1 and 7, only light up. If the w e b is not in its set position or no w e b is available, locate the e d g e s e n s o r so that middle of the scanning r a n g e is on the w e b e d g e set position.

Web edge set position

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Infra-red e d g e s e n s o r FR 5001/FR 5021 7 P a r a m e t e r s ' P d e s e t u p p a r a m e t e r s can b e displayed and t o a certain extent, c h a n g e d . To e n t e r s e t u p m o d e from the e d g e sensor, you will n e e d a c o m m a n d device DO .... or RT ....
n s e t u m

7.1 P a r a m e t e r list

T h e p a r a m e t e r n u m b e r s a r e listed in t h e No. field of the table, in the N a m e field the abbreviation. T h e Default field indicates the s t a n d a r d settings, Min. a n d Max. a r e the permissible limit values respectively. T h e unit is indicated in the Unit field. T h e D e s c r i p t i o n explains the p a r a m e t e r function. If a dot () c o m e s after the p a r a m e t e r n u m b e r this indicates that it is a display parameter, the value of which cannot be changed. T h e p a r a m e t e r list applies for the CAN d a t a protocols PR 1 and PR 2. T h e fields indicate w h e t h e r e a c h p a r a m e t e r is u s e d in the related CAN d a t a protocols. You can s e e which CAN data protocol is u s e d from the n u m b e r in p a r a m e t e r "..4. FR 5 0 0 1 " .

No. ..0. ..1. .2.

Name edit device edit group reset settings

Default XX XX 0

Min X.1 ox 0

Max XF 7.X 2

Unit hex hex

..3.

start service

199

..4. ..4. .5.

FR 5001 FR 5001 mounting norm/rev

1.1 4.3 0

1.0 4.0 0

1.1 4.3 1

PR PR Description 1 2 X X Device number (see block diagram) X X Group number (see block diagram) X X Works setting 0 = no function 1 = E+L basic settings 2 = internal value specification (default) X X Starting a function 0 = no function 1 = reset 2 = save parameters 10 = perform sensor calibration X - Software version X Software version X X Edge sensor mounting "0" = standard M M

"1" = scanning direction turned (edge sensor turned by 180) ..6. .7. ..8. resolution abs. range +/position 1024 10.00 0 1024 10.00 -10.00 1024 10.00 10.00 mm mm X X X X X X Available sensor measuring range in pixels Available sensor measuring range in mm Actual edge position in mm

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Infra-red e d g e s e n s o r FR 5001/FR 5021 No. .9. Name error code Default 0 Min 0 Max 299 Unit PR PR Description 1 2 X X Error messages "..0" = no error "..1" = lens or reflector damaged or soiled "..2"= edge sensor under-exposed (lens or reflector soiled) "..3" = edge sensor over-exposed (direct sunlight on lens) "..4" = CCD chip error "..5" = operating temperature exceeded or not attained (temperature < 0 C or > 60 C) Calibration errors: ".4." = dark threshold too high (send in sensor) ".5." = white threshold too low (repeat calibration) ".6." = error during saving (send in sensor) "1.." = sensor not calibrated X X Display brightness 0 = minimum brightness 15 = maximum brightness X X Display mode 0 = normal display (web edge is displayed as deviation from the sensor center) 1 = web edge is displayed as illuminated band X X Edge sensor interior temperature in C X X Transmitter brightness 0 = maximum brightness 255 = minimum brightness X X Infra-red diode 0 = ON 1 = OFF X X Reverse sensor signal 0 = normal 1 = reversed X X Maximum brightness value X X Infra-red edge sensor FR 5001/FR 5021 0 = Flat, homogenous web edge 1 = Thread(stripe) or mesh-type web edge X X Sensitivity of thread detection 10 = sensitive 100 = insensitive Note! High sensitivity level also means a high level of sensitivity to soiling. Dirt deposits are detected as a web edge. X X Web guider blocking 0 = blocking OFF 1 = blocking ON. The web guider is blocked if there is no web edge in the scanning range, (invalid state signal is emitted by the CAN) Distance between sensor and reference point X X Entry for the support address The position of the support is added to the sensor signal and the value sent over the CAN bus. X Entry for the support address The position of the support is inverted and added to the sensor signal, and the value sent over the CAN bus.

.1.0.

display brightness display mode

15

.1.1.

.1.2. temperature .1.3. transm. brightness .1.4. IR LED on/off

0 0

-60 0

150 255

.1.5.

position norm/rev

.1.6. maximum pixel .1.7. thread detection .1.8. diff. - limit

0 0

0 0

255 1

30

10

100

.1.9.

invalid state flag

.2.0. .2.1.

mount position use supportadr

0 0.0

-3276.8 3276.7 F.F 0.0

mm hex

.2.2.

invert support pos

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Infra-red e d g e s e n s o r FR 5001/FR 5021 No. .2.3. Name disable expos Ctrl Default 0 Min 0 Max 1 Unit PR 1 X PR Description 2 X Deactivate the exposure controller If this value is set there is no automatic exposure control. This parameter will not be saved and must be set if required.

7.2 E r r o r m e s s a g e s .9.

Error c o d e (parameter 9) Any e d g e s e n s o r errors that may occur a r e displayed in p a r a m e t e r 9. T h e main error m e s s a g e s a r e listed below.

Brightness values 1/3 2/3 1 21 92 53 23 84 5 Pixel Alien object

E r r o r m e s s a g e : ..1 Lens/reflector soiled An alien object (e.g. grain of s a n d , thread, plastic splinter etc.) located in the e d g e s e n s o r scanning r a n g e in addition to the w e b e d g e is r e p r e s e n t e d as a dark spot on the s c a n . If the d e g r e e of brightness is l e s s than 2/3 of the total brightness (<67 brightness value) and brightness contrast e x c e e d s a width of more than 3 pixels, a " . . 1 " error shall be emitted. W h a t t o d o : clean the e d g e s e n s o r lens a n d reflector. II Error m e s s a g e ..1 h a s no function for e d g e s e n s o r FR 5 0 2 1 .

Error message 1

Brightness values 1 0 0 '

1 21 92 53 23 84 55 15 76 4 Pixel

E r r o r m e s s a g e : ..2 "Edge s e n s o r u n d e r - e x p o s e d " The transmitter brightness is regulated so that the receiver e l e m e n t s that a r e not covered by the w e b reach an approx. brightness value of 100. If a brightness value of 100 ( p a r a m e t e r 16) given maximum transmitter brightness ( p a r a m e t e r 13 = 0) is not achieved, error "..2" is output. Every s e c o n d LED on the illuminated LED band flashes. W h a t t o d o : clean the e d g e s e n s o r lens a n d reflector.

E r r o r m e s s a g e : ..3 "Edge s e n s o r o v e r - e x p o s e d " If a brightness value of 100 ( p a r a m e t e r 16) is e x c e e d e d given minimum transmitter brightness ( p a r a m e t e r 13 = 255), error " . . 3 " is output. Every s e c o n d LED on the illuminated LED band flashes. W h a t to d o : shield the e d g e s e n s o r from external light (e.g. sunlight, artificial lights). Error message 2 and 3

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Infra-red e d g e s e n s o r FR 5001/FR 5021 Output range for error messages Bright- 8 7 ness " 6 2 values = T h e following a p p l i e s t o all e r r o r m e s s a g e s : For error m e s s a g e s to be output, error 5 s must be available and the w e b e d g e positioned within a r a n g e of 0 % to 80 % of the sensor m e a s u r i n g a r e a .

1 21 92 53 23 84 53 ^5 76 4

Pixel

Output range for error messages

8 .

M a i n t e n a n c e

Maintenance work s h o u l d only be performed w h e n the proc e s s i n g m a c h i n e i s s w i t c h e d off. - Depending on the a m b i e n t conditions, clean the lens and reflector regularly with a dry or d a m p cloth. - D a m a g e d reflectors must be replaced.

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Erhardt + Leimer GmbH Postfach 10 15 40 D-86136 Augsburg Telephone (0821)24 35-0 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com 9 . T e c h n i c a l d a t a Operating voltage Nominal value Nominal r a n g e (incl. residual ripple) Current input S c a n n i n g frequency Measuring r a n g e Measuring r a n g e resolution Fabric a n d stripe thickness FR 5001 FR 5021 Ambient t e m p e r a t u r e Storage temperature C a b l e length Reflector to e d g e s e n s o r d i s t a n c e FR 5001 FR 5021 Protection c l a s s Weight Dimensions

24 VDC 2 0 - 30 V DC approx. 80 mA 2 0 0 Hz 10 mm 0,02 mm (64 pixels x 16 subpixels)

min. 0,2 mm +10 C to +50 C -20 C to +80 C max. 8 m 20 - 140 mm / 2 4 0 - 500 mm 2 4 0 - 320 mm max. IP 6 5 with suitable connector inserted ca. 3 0 0 g s e e a t t a c h e d dimensioned drawing <5 urn

Operating p r e s s u r e clearing device 2 bar Pore size Technical data subject to modification without notice