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 i n s t r u c -

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

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 per-

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

2.2 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 lo-
c 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
Measuring range controller. At the s a m e time, the current w e b position in the measur-
+10 mm ing 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.

di Edge sensor measuring range

nnnnnnnnnnnnnnnn
O 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.
Edge sensor measuring range

3 . A s s e m b l y
3.1 E d g e s e n s o r with r e f l e c t o r Mount the e d g e s e n s o r on the first third of the w e b guider exit
bracket 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. be-
low).

Edge sensor
Web

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.

BEA-220874-EN-10 B page 3
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 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

reflector 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 Flat, h o m o g e n o u s w e b e d g e

clearances 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 Thread(stripe) or mesh-type w e b edge

clearances 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 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

(optional) 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 open-

ings m u s t be aligned with the s e n s o r and reflector.

3 r o t e c t s n a l
4 InStdlldtiOn ~* ' '9 leads and run apart from heavy current-carrying
leads.
-* 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 conduc-
tively 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 recom-
m 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.

BEA-220874-EN-10 B page 5
Infra-red e d g e s e n s o r FR 5 0 0 1 / F R 5021

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

5 . C o m m i s s i o n i n g
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 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 "

numbers 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 .
-» 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
Edge sensor on left of
web direction of travel 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 -
Unit number 2 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
Group number 0 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 - 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:

sor 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 com-
m 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 initi-
ated 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 cali-
bration 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. .

Positioning the e d g e s e n s o r
6. O p e r a t i o n
With the help of the row of LEDs on the receiver, the e d g e s e n s o r
LEDs 7 and 1 are on 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

BEA-220874-EN-10 B page 7
Infra-red e d g e s e n s o r FR 5001/FR 5021

n s e t u m
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 ....

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 re-
lated 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. Name De- Min Max Unit PR PR Description

fault 1 2
..0. edit device XX X.1 XF hex X X Device number (see block diagram)
..1. edit group XX ox 7.X hex X X Group number (see block diagram)
.2. reset settings 0 0 2 X X Works setting
0 = no function
1 = E+L basic settings
2 = internal value specification (default)
..3. start service 0 0 199 X X Starting a function
0 = no function
1 = reset
2 = save parameters
10 = perform sensor calibration
..4. • FR 5001 1.1 1.0 1.1 - X - Software version
..4. • FR 5001 4.3 4.0 4.3 - - X Software version
.5. mounting 0 0 1 X X Edge sensor mounting
norm/rev

"0" = standard M M

"1" = scanning direction turned

(edge sensor turned by 180°)

..6. • resolution abs. 1024 1024 1024 - X X Available sensor measuring range in pixels
.7. • range +/- 10.00 10.00 10.00 mm X X Available sensor measuring range in mm
..8. • position 0 -10.00 10.00 mm X X 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. Name De- Min Max Unit PR PR Description

fault 1 2
.9. • error code 0 0 299 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
.1.0. display 8 0 15 X X Display brightness
brightness 0 = minimum brightness
15 = maximum brightness
.1.1. display mode 0 0 1 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
.1.2. • temperature 0 -60 150 - X X Edge sensor interior temperature in °C
.1.3. • transm. 0 0 255 X X Transmitter brightness
brightness 0 = maximum brightness
255 = minimum brightness
.1.4. • IR LED on/off 0 0 •1 X X Infra-red diode
0 = ON
1 = OFF
.1.5. position 0 0 1 X X Reverse sensor signal
norm/rev 0 = normal
1 = reversed
.1.6. • maximum pixel 0 0 255 - X X Maximum brightness value
.1.7. thread detec- 0 0 1 X X Infra-red edge sensor FR 5001/FR 5021
tion 0 = Flat, homogenous web edge
1 = Thread(stripe) or mesh-type web edge
.1.8. diff. - limit 30 10 100 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.
.1.9. invalid state 0 0 1 X X Web guider blocking
flag 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)
.2.0. mount position 0 -3276.8 3276.7 mm - X Distance between sensor and reference point
.2.1. use supportadr 0.0 0.0 F.F hex 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.
.2.2. invert support 0 0 1 X Entry for the support address
pos The position of the support is inverted and added to the
sensor signal, and the value sent over the CAN bus.

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Infra-red e d g e s e n s o r FR 5001/FR 5021

No. Name De- Min Max Unit PR PR Description

fault 1 2
.2.3. disable expos 0 0 1 X X Deactivate the exposure controller
Ctrl If this value is set there is no automatic exposure con-
trol.
This parameter will not be saved and must be set if re-
quired.

7.2 E r r o r m e s s a g e s 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.
.9.
T h e main error m e s s a g e s a r e listed below.

E r r o r m e s s a g e : ..1 Lens/reflector soiled

Brightness values
An alien object (e.g. grain of s a n d , thread, plastic splinter etc.) lo-
cated 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
1/3
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
2/3 is l e s s than 2/3 of the total brightness (<67 brightness value) and
12 19 25 32 38 45 Pixel brightness contrast e x c e e d s a width of more than 3 pixels, a " . . 1 " er-
ror shall be emitted.
Alien
object 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 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
100 ' 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"
12 19 25 32 38 45 51 57 64 Pixel 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 mini-
mum transmitter brightness ( p a r a m e t e r 13 = 255), error " . . 3 " is out-
put. 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

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 :
Output range for
error messages 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 sen-
Bright- ™ sor m e a s u r i n g a r e a .
87
ness "
62
values =° 12 19 25 32 38 45 3^ 57 64
Pixel

Output range for error messages

Maintenance work s h o u l d only be performed w h e n the pro-

8 . M a i n t e n a n c e
c 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.

BEA-220874-EN-10 B page 11
 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

Operating voltage
9 . T e c h n i c a l d a t a
Nominal value 24 VDC
Nominal r a n g e 2 0 - 30 V DC
(incl. residual ripple)
Current input approx. 80 mA
S c a n n i n g frequency 2 0 0 Hz
Measuring r a n g e ±10 mm
Measuring r a n g e resolution 0,02 mm
(64 pixels x 16 subpixels)
Fabric a n d stripe thickness
FR 5001
FR 5021 min. 0,2 mm
Ambient t e m p e r a t u r e +10 °C to +50 °C
Storage temperature -20 °C to +80 °C
C a b l e length max. 8 m
Reflector to e d g e s e n s o r d i s t a n c e
FR 5001 20 - 140 mm / 2 4 0 - 500 mm
FR 5021 2 4 0 - 320 mm
Protection c l a s s max. IP 6 5
with suitable connector inserted
Weight ca. 3 0 0 g
Dimensions s e e a t t a c h e d dimensioned
drawing
Operating p r e s s u r e clearing device 2 bar
Pore size <5 urn
Technical data subject to modification without notice