EcoGuide Operating-Manual 04 en

Compact web guide control
Installation and
operating instructions
EcoGuide
MD.464.EN.04
Translation of the original instructions

BST eltromat International GmbH
Heidsieker Heide 53
D-33739 Bielefeld
Tel.: +49 (0) 5206 999 0
Fax: +49 (0) 5206 999 999
E-mail: [email protected]
Internet: www.bst-international.com
This document is protected by copyright. The translation as well as reproduction and distribution in any form is forbidden without the approval of
the rights holder. Violations will be pursued under civil and criminal law. Subject to technical changes without notice.
Table of contents
Table of contents
1 About this document 6
1.1 What you need to know .................................................................... 6
1.2 Target group...................................................................................... 7
1.3 Storage and distribution ................................................................... 7
1.4 Meanings of the safety instructions and symbols ............................. 7
1.4.1 Safety instructions ............................................................................ 7
1.4.2 Symbols ............................................................................................. 7
1.4.3 Using the keys ................................................................................... 8
1.4.4 Operating states of LEDs ................................................................... 8
1.5 Further information .......................................................................... 8
2 About safety 9
2.1 Intended use ..................................................................................... 9
2.2 Non-intended use ........................................................................... 10
2.2.1 Non-intended infringement of guidelines ....................................... 10
2.2.2 Non-intended operation ................................................................. 11
2.2.3 Non-intended modification of electronic data................................ 11
2.3 Safety instructions .......................................................................... 11
2.3.1 General safety instructions ............................................................. 12
2.3.2 Safety instructions for installation .................................................. 14
2.4 Qualification of personnel ............................................................... 15
2.5 Obligations of the operating company and personnel.................... 17
2.5.1 Obligations of the operating company............................................ 17
2.5.2 Obligations of the personnel ........................................................... 17
2.6 Conduct in the event of danger and accidents ............................... 18
2.7 Personal protective equipment...................................................... 19
2.8. Guarantee and liability .................................................................... 19
2.8.1 Exemption of liability ...................................................................... 19
2.8.2 Exceptions to the disclaimer ........................................................... 20
2.8.3 License and liability for software supplied ...................................... 20
3 Design and function 21

3.1 System description .......................................................................... 21
3.1.1 System design ................................................................................. 21
3.1.2 Functional principle......................................................................... 22
3.1.4 Connectable components ............................................................... 22
3.2 Terms used ...................................................................................... 23
3.2.1 Sensor 1 / Sensor 2 ......................................................................... 23
4 Technical specifications 24
4.1 Standard sizes ................................................................................. 24
4.1.1 Size 1-3 ............................................................................................ 24
4.2 Ambient conditions ......................................................................... 25
4.3 Protection class ............................................................................... 25
4.4 Voltage supply ................................................................................. 25
4.5 Sensors ............................................................................................ 25
4.5.1 Edge sensors ................................................................................... 25
4.6 Power pack ...................................................................................... 27
4.7 Emissions ......................................................................................... 27
4.8 RoHS Conformity ............................................................................. 27
5 Transport, delivery and storage 28

5.1 Transport ......................................................................................... 28
EcoGuide compact web guide control 3/70

Table of contents
5.2 Scope of delivery ............................................................................. 29

5.3 Unpacking the delivery ................................................................... 29
5.4 Storage ............................................................................................ 30
6 Installation 31
6.2 Selecting the installation location ................................................... 32
6.3 Space requirement.......................................................................... 32
6.4 Tools and auxiliary material ............................................................ 33
6.4.1 Tools and auxiliary material for EcoGuide ...................................... 33
6.5 Recommendations for installation .................................................. 34
6.5.1 Alignment of the compact web guide control ................................ 35
6.5.2 Deflection pulleys ........................................................................... 36
6.6 Installation positions ....................................................................... 37
6.7 Installation of the compact web guide control ............................... 37
6.7.1 General............................................................................................ 37
6.7.2 Securing hole template ................................................................... 39
6.8 Changing the mounting position of the controller.......................... 40
6.9 Changing the mounting position of a sensor /
mounting an additional sensor ....................................................... 43
6.9.1 Preparing the mounting rail ............................................................ 44
6.9.2 Removing sensor and sensor holder ............................................... 44
6.9.3 Preparing the sensor holder ........................................................... 45
6.9.4 Mounting the Sensor ...................................................................... 46
7. Electrical connection 48
7.2 Cable routing ................................................................................... 49
7.3 Connecting the cables ..................................................................... 50
7.4 Ensuring equipotential bonding ...................................................... 51
7.5 Cable connections ........................................................................... 53
7.5.1 Cable connections for the EcoGuide size 1-3 .................................. 53
7.6 Voltage supply................................................................................. 54
7.6.1 Requirements of the supply grid ..................................................... 54
7.6.2 Connecting the voltage supply ........................................................ 54
7.7 Remote control (Option) ................................................................. 55
7.7.1 General............................................................................................ 55
7.7.2 Connecting the remote control....................................................... 55
8 Commissioning 56
8.2 Requirements .................................................................................. 57
8.3 Settings for commissioning ............................................................. 57
8.4 Further information on setting up the ekr CON 100 ....................... 57
9 Operation 58
9.1 Threading in the material web. ....................................................... 58
9.2 Operating the ekr CON 100 controller ............................................ 60
10 Maintenance and cleaning 61

10.2 Maintenance table .......................................................................... 62
10.3 Maintenance and cleaning work ..................................................... 62
10.3.1 Cleaning the housing of the compact web guide control ............... 62
10.3.2 Cleaning the pivoting frame ............................................................ 62
4/70 EcoGuide compact web guide control

Table of contents
10.3.3 Cleaning the sensors ....................................................................... 63

10.3.4 Cleaning the control panel .............................................................. 63
11 Troubleshooting 64
12 Accessories and spare parts 65
12.1 Order address.................................................................................. 65
13 Customer Service 66
14 Shutting down and disposal 67
Index 68
Declaration of incorporation 70

1 About this document

1.1 What you need to know
These instructions help you to work with the system in a safe,
simple and successful manner.
The following instructions must be observed in order to avoid
hazards and incorrect operation:
■ You are only permitted to install and commission the EcoGuide
after first acquainting yourself with the associated installation
and operating instructions. This will help to avoid hazards and
prevent damage to the compact web guide control due to im-
proper installation or operation.
■ The EcoGuide compact web guide control is an incomplete ma-
chine in compliance with EC Machinery Directive 2006/42/EC.
The installation instructions describe the conditions that must
be fulfilled when installing the incomplete machine so that it
can be correctly assembled with other parts to form a complete
machine and without influencing the safety and health of other
persons.
■ These installation and operating instructions must be read and
applied by every person who is involved in the installation,
commissioning, operation and maintenance of the EcoGuide
compact web guide control.
■ Before beginning installation and commissioning work it must
be established, in particular by those responsible for the instal-
lation, that the safety instructions specified in chapter 2 of
these installation and operating instructions have been read
and understood.
■ Modifying or adding firmware to the integrated controller of
the compact web guide control must only be carried out by BST
eltromat staff or by other persons specifically authorized by
BST eltromat for this purpose Non-observance of this warning
may result in the warranty rights being invalidated!
■ The settings and details shown in these installation and operat-
ing instructions (e.g. in the screen display of the control panel)
are only provided as examples, unless the text explicitly states
otherwise.

About this document 1
1.2 Target group
These instructions are directed to all persons that work with or on

the system. The operating company of the entire system and su-
pervising personnel must also be familiar with these instructions.
1.3 Storage and distribution

These instructions must be stored at the workplace in such a
manner that the user has access to them at all times.
These instructions and all other applicable documents are a com-
ponent of the product and must be handed over to the operating
company of the system.
1.4 Meanings of the safety instructions and symbols

1.4.1 Safety instructions
DANGER
Danger that will be fatal or lead to severe injuries!
► Here you can read how dangers can be avoided.
WARNING
Danger that may be fatal or lead to severe injuries!
CAUTION
Danger that may be lead to medium or slight injuries!
NOTE
Danger that may be lead to material damage!
There is no risk of injury here.
1.4.2 Symbols
Information that is essential for successful operation.
Information that makes operation easier.
Action requirements may include the following symbols:
1. Requirement for you to take actions. And ...

2. …in the sequence specified.

► Requirement for you to take actions –- without any certain se-
quence.
1.4.3 Using the keys
Use of the keys is represented by the following symbols in these

installation and operating instructions:
Press key.
Key combinations, keys have to be pressed simultaneously.
1.4.4 Operating states of LEDs
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 illuminated = active phase
LED flashing
1.5 Further information

► Accompanying documents (e.g. order confirmation) for this sys-
tem and the operating instructions of the entire plant must be
observed.
The latest version of the installation and operating instructions for
the EcoGuide compact web guide control in all available languages
can be found at:
www.bst-eltromat.com

About safety 2
2 About safety
The system has been designed according to the state of the art
and fulfills the latest safety standards.
When using the system, risks may occur that could threaten your
life or health or lead to material damage. In order to avoid these
risks, all instructions in these instructions concerning safety and all
relevant documentation of the entire system must be observed.
This chapter describes the safety guidelines that must imperative-
ly be observed when installing, commissioning, operating and
maintaining the EcoGuide compact web guide control.
2.1 Intended use

The EcoGuide is a microprocessor controlled compact web guide
control with removable control panel. The compact web guide
control must only be used for
■ Web edge guiding (control of either the right or the left web
edge)
■ Web center-line guiding
The EcoGuide compact web guide control has been designed for
installation in another machine or for combining with other ma-
chines to form a machine in the sense of the directive 2006/42/EC
(Machinery Directive). Commissioning of the compact web guide
control is forbidden until the user / operating company has de-
termined that the machine, in which the system is installed, con-
forms to the conditions of this directive.
You are only allowed to use the BST eltromat web guide control
system to correct the position of web-shaped materials (e.g. those
made from paper, film, cardboard, rubber, etc.).
The EcoGuide compact web guide control must only be operated
using the "Connectible components“ specified in chapter 3.1.3 of
these installation and operating instructions. BST eltromat Inter-
national GmbH will not be liable for any damage that results from
operation using third party components (e.g. components of other
BST eltromat systems or from other manufacturers).
The values for the permissible ambient conditions, the maximum
web tension and the voltage supply of the compact web guide
control specified in these installation and operating instructions
must be strictly observed (see chapter 4 "Technical specifica-
tions").
The EcoGuide compact web guide control must not be installed
and used in potentially explosive areas.
BST eltromat web guide controls have been designed and built in
accordance with state-of-the-art standards and the recognized

2 About safety
safety rules. Nevertheless, their use may constitute a risk to life

and limb of the user or of third parties or cause damage the BST
eltromat web guiding systems and other equipment. Therefore
BST eltromat web guide control systems must 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 immediate-
ly. Only original spare parts are to be used for this purpose. We
cannot guarantee that parts from third parties have been de-
signed and manufactured in line with the safety and load re-
quirements. In this case any guarantee claims made against the
BST eltromat web guiding system will be invalidated. Only quali-
fied personnel who have been trained on the system are allowed
to undertake any work required on the BST eltromat web guiding
system (i.e. installation, commissioning, operation, maintenance,
etc.). Intended use also includes adhering to the instructions given
in this instruction manual. Use for any other purposes other than
those mentioned above is considered as contrary to the intended
use. BST eltromat International GmbH does not accept liability for
any damage resulting from this type of use.
2.2 Non-intended use

Every use is considered non-intended that is not described in the
chapter "Intended use" or does not comply with the guidelines
specified there (see chapter 2.1 Intended use on page 9).
2.2.1 Non-intended infringement of guidelines
■ Infringement of operating, maintaining or installation instruc-

tions
■ Unsuitable, incorrect or unauthorized use of the product
■ Operating the product in an environment not intended for its
use
■ Operating the product in breach of the legal safety guidelines
relevant at the location of use
■ Neglecting the warning and safety instructions in the relevant
documents for the product
■ Operating the product under faulty safety and protective condi-
tions

About safety 2
2.2.2 Non-intended operation
■ Private use of the product or its components

■ Operation by unauthorized or insufficiently qualified personnel
■ By-passing, disassembling, switching off or manipulation of
safety equipment
■ Incorrect or negligent handling by the customer
■ Any intervention, modifications or conversions to the product
without explicit approval of BST eltromat International GmbH
■ The use of unsuitable operating materials or spare parts
■ Operation of the product near to sources of interference, e.g.
electro-magnetic fields (high voltage lines) or sources of heat
■ Operation of the product under the influence of chemical, elec-
tro-chemical or electrical factors
2.2.3 Non-intended modification of electronic data
■ No virus scanners, firewalls or similar items may be installed on

any products from BST eltromat International GmbH. Virus
scanners or other scan or registration programs must not (be
able to) access BST eltromat products via networks.
■ Writing, deleting and editing of system data / files on BST el-
tromat products is not permitted. Excepted from this is service
work carried out at the instruction of BST eltromat Internation-
al GmbH.
■ Access of any external software to BST eltromat products via
networks is not permitted.
■ USB memory sticks may only be used together with BST el-
tromat products if they are free of viruses and harmful soft-
ware.
■ Products or supplied software from BST eltromat International
GmbH must never be modified without permission.
■ All software supplied is protected by copyright and must not be
edited, copied or made available to third parties. Except where
explicit approval has been sought from BST eltromat Interna-
tional GmbH or the respective owner of the copyright.
2.3 Safety instructions

Every user must read and follow the safety instructions in these
instructions before working with or on the system.
The following contains general safety instructions that always
have to be observed. Special safety information that must be ob-
served for certain work will be specified at the start of the respec-
tive chapter of these instructions.

2 About safety
When installing and operating the EcoGuide compact web guide

control, do not only observe the safety instructions in these instal-
lation and operating instructions, but also the generally applicable
safety relevant information in accordance with DIN EN ISO 13857,
DIN EN 349 and the industry-specific accident prevention regula-
tions (UVV).
Non-observance of the safety instructions listed in the following
chapters can lead to personal injuries or to damage to the
EcoGuide compact web guide control.
2.3.1 General safety instructions
DANGER
Danger of death when operated in potentially explosive areas!
► The system must never be installed or operated in potentially
explosive areas.
DANGER
Mortal danger from electric shock!
Life threatening injuries caused by incomplete switching off or re-
sidual current.
► With defective insulators or live parts, switch off the power
supply immediately and have the repairs carried out by a quali-
fied electrician.
► Switch the system off completely, switch free of voltage and
wait 10 minutes before carrying out any maintenance, repair,
cleaning or installation work.
► Secure the system against being switched back on.
DANGER
Mortal danger caused by moving machine parts!
Parts of your body could be crushed, cut, scraped, wound up,
caught, drawn in or hit.
► Never reach in-between the area containing moving rolls or
machine parts.
► Do not wear any necklaces, scarves or similar near to moving
rolls / parts of the machine.
► Never stay in the pivoting / traversing area of moving machine
parts or reach into the section.
► Before setting up / operating the system, ensure that no other
person is in the working area of the moving machine parts.

About safety 2
WARNING
Risk of cutting on sharp edges of the material web!
Severe cutting injuries from the edges of the running material
web.
► Never touch the edges of running material webs.
WARNING
Danger of death from actuator movements!
When the position controller is switched on, the actuator can car-
ry out positioning movements independently when operating in
manual mode.
► Make sure that no persons remain in the vicinity of the pivot-
ing / traversing area of machine components that are posi-
tioned by the actuator.
WARNING
Risk of falling and damage to property from climbing on system
components!
Climbing on system components (e.g. traverses or camera hous-
ings) can lead to fatal falls and destruction of the components.
► Never climb on or walk on system components.
WARNING
Mortal danger from missing emergency stop equipment!
There is a risk of severe injuries if emergency stop equipment
(emergency stop button) is not fitted on the entire system. Only
emergency stop equipment can stop the system immediately in
the event of an emergency. Operation of the entire system is for-
bidden without emergency stop equipment.
► If not installed, have emergency stop buttons and emergency
stop equipment installed by the operating company before op-
erating the system.
WARNING
Serious injuries due to of lack of knowledge / neglecting the
emergency stop equipment and safety instructions!
► Before starting work, familiarize yourself with the emergency
and rescue equipment of the entire system, e.g. emergency
stop button.
► Before starting work, make sure that all safety guidelines and
instructions are observed.
► Cable connections between the individual components of the

web guide control must only be disconnected after the com-
pact web guide control has been disconnected from the power
supply. Any infringements will result in the warranty claim be-
ing invalidated.

2 About safety
NOTE
Damage to electronic parts due to ESD (electrostatic discharge)!
Destruction / loss in performance of electronic components by
making contact with electrostatically charged persons / objects.
► Open the device only at a workplace suitable for ESD (accord-
ing to DIN EN 61340-5-1).
► If there is no ESD-suitable workplace, ESD protective measures
must be implemented (according to DIN EN 61340-5-1), so that
electrostatic charges are discharged in a controlled manner.
► When returning electronic components, adhere to DIN EN
100015 ("Protection of electrostatically sensitive compo-
nents").
► For transporting electrostatic components, use only appropri-
ately labeled electrically conducting ESD packaging.
BST eltromat International GmbH is not liable for any damage

caused by non-observance of the ESD protective measures de-
scribed here.
2.3.2 Safety instructions for installation
Before starting installation work:

► Read the safety instructions in the production machine operat-
ing manual in which the compact web guide control is to be in-
stalled as well as in the operating manual of the manufacturer
of third party components supplied.
► When installing the EcoGuide compact web guide control, ob-
serve the overall safety concept of the production machine.
► Cordon off the work area to prevent access by unauthorized
persons (e.g. by erecting a protecting fence).
► Establish the voltage-free condition of the production machine
and secure the machine against being turned back on acci-
dentally. Risk of injuries caused by the starting production ma-
chine.
► Before carrying out any drilling work, cover up moving parts of
the production machine with film or cardboard Dust and chip-
pings from drilling can lead to malfunctions or damage to the
machine.
► Before installation, make sure that the machine frame on
which the EcoGuide compact web guide control is to be
mounted has the respective load bearing capacity.

About safety 2
During installation work:

► Observe all safety and hazard warnings on the BST eltromat
components and on the production machine.
► Make sure that no small parts (screws, washers, tools, etc.) can
fall into the production machine. Parts falling down can lead to
malfunctions or damage to the machine. If necessary, cover up
moving parts of the production machine with film or cardboard
► Do not use the EcoGuide compact web guide control or ma-
chine frame as a climbing aid or a stepladder.
► Keep the specified safety distances between the BST eltromat
equipment and the machinery already installed on-site (such as
safety distances to machine panels, building structures, etc.).
► Ensure that sufficient free headroom is observed. If the free
passage height is restricted, the relevant building components
causing the height restrictions must be padded and danger-
warning signs (yellow / black) must be attached to them.
► When installing the EcoGuide compact web guide control into
the production machine, never remove any safety equipment.
Never decommission safety equipment. If the removal of safety
equipment is necessary for installing the compact web guide
control, the re-installation of the safety equipment must be
carried out immediately after completing the installation work.
After completing installation work:

► Remove all tools and auxiliary aids used from the production
machine.
► Reinstall all safety equipment and covers that had to be re-
moved for the installation work.
2.4 Qualification of personnel
WARNING
Assembly, installation, commissioning, operating and mainte-
nance carried out by unqualified personnel
may cause death or lead to severe personal injuries.
► Only deploy qualified specialist personnel for the assembly,
installation, commissioning, operating and maintenance of the
compact web guide control.
The EcoGuide compact web guide control must only be transport-

ed, installed, connected, commissioned, operated and serviced by
qualified and trained specialist personnel and after they have read
the corresponding installation and operating instructions!
The qualifications required by the personnel are defined as fol-
lows:

2 About safety
Instructed personnel have been instructed comprehensively by

the operating company and informed about the following points:
■ Tasks assigned
■ Possible hazards when carrying out the tasks
■ Possible hazards in the event of incorrect conduct
■ Measures for avoiding the hazards
Qualified personnel also have sufficient experience or practice in

the safe implementation of the tasks assigned.
Specialists with the following tasks by themselves due to their

training, knowledge and experience as well as knowledge in the
relevant regulations:
■ Carrying out the tasks assigned to them
■ Recognizing possible hazards
■ Undertaking appropriate measures for avoiding the hazards
Specialists must only carry out tasks according to their profession-
al training.
Qualified electricians also have an electrical engineering training

according to the applicable guidelines (in Germany, DIN VDE 1000-
10).
Moreover, all personnel must satisfy all requirements that are de-
rived from the following documentation or directives:
■ Operating instructions for the entire system
■ National guidelines, laws and applicable guidelines for protect-
ing employees, general safety at workplaces and for accident
prevention

About safety 2
2.5 Obligations of the operating company and personnel
2.5.1 Obligations of the operating company
The operating company of the entire system is responsible for

safety in the workplace as well as for the information and training
of the personnel. In particular, for the entire life-cycle of the sys-
tem and the entire plant, the operating company must ensure
that:
■ All relevant legal safety, accident prevention and environmental
guidelines are maintained
■ All hazards are determined that result from the special operat-
ing conditions at the operating location of the system and from
the construction of the entire system
■ All hazards determined are avoided. This means, in particular:
- Constructive prevention of hazards
- Installation of protection and safety equipment and checking
that these are working properly
- Mounting of warning signs at hazard sites and checking their
correct condition
- Information and training of the personnel for safe conduct,
intended use, safety equipment, prevention of hazards and
conduct in the event of emergencies
- Provision of the necessary personal protective equipment
- Supervision of the personnel with regard to safety-relevant
conduct
■ The system is integrated into the safety concept of the entire
system
■ The system is stopped immediately if the safety of people or
the environment is endangered or changes occur that could
impair the safety
■ All employees have read and understood these instructions be-
fore working on or with the system
■ Only personnel are assigned that are qualified and trained for
the respective task
■ The responsibility of the personnel is determined for the task to
be completed and that the personnel are informed
2.5.2 Obligations of the personnel
Each and every employee is responsible for their own safety. In

particular, each and every employee must abide by the following
instructions:
► Read these instructions completely before working on or with
the system and follow all safety instructions.

2 About safety
► Observe all warning instructions on the system and entire

plant.
► Observe the operating instructions for the entire system and
the separate machines as well as all safety instructions included
in it.
► If required, wear the necessary personal protective equipment.
► Before starting work, check if the safety equipment is intact.
► Stop the system immediately if the safety of people is at risk
and secure against being switched back on unintentionally.
► The system must be visually inspected for any recognizable
damage or problems at least once per shift.
► If sections of these instructions are unclear, inform your super-
visor and ensure for clarification.
2.6 Conduct in the event of danger and accidents

Preventative Measures
Emergency and rescue equipment must be ready for use in every
company. These include, for example, emergency stop buttons,
fire extinguisher, first aid kit and equipment for reporting acci-
dents.
► Always be prepared for emergencies, accidents and fire.
► Familiarize yourself as to where the emergency and rescue
equipment is located and how to use it.
► Keep emergency and rescue equipment at hand and ready for
use.
► All access routes for rescue vehicles and escape routes must be
kept free.
If an emergency is impending or has occurred

1. Press the emergency stop button immediately.
2. Make sure that the system cannot be switched on again.
3. Rescue the persons from the danger zone if your personal safe-
ty is not at risk.
4. Initiate first aid measures.
5. Warn the emergency doctor and / or fire brigade.
6. Inform the responsible person at the operating location.
7. Clear the access route for the emergency vehicles.

About safety 2
2.7 Personal protective equipment
When carrying out certain activities, you have to wear personal

protective equipment in order to avoid accidents and injuries.
Personal protective equipment includes, depending on the activi-
ty:
■ Protective clothing
■ Hard hat
■ Safety shoes
■ Protective gloves
■ Safety goggles
■ Ear protection
► Observe the safety information in these instructions and the in-
formation signs on the system for personal protective equip-
ment.
2.8. Guarantee and liability

The guaranty terms are specified in the sales documentation.
2.8.1 Exemption of liability
BST eltromat International GmbH is not liable for damage or de-

fects to their products that originate from non-intended use (see
Non-intended use, page 10).
Liability for defects does also not apply if the fault originates from
one or more of the following causes:
■ Catastrophic events and force majeure
■ Natural wear
■ Incorrect operation of the product resulting from the effect of
connected or neighboring third party devices
■ Malfunction of the product due to unsuitable operating re-
sources, spare parts, chemical, electro-chemical or electrical
factors.
■ Unsuitable or faulty execution of the maintenance work de-
scribed by the operating company, see Maintenance and Clean-
ing 61.
■ Infringement of operating, maintaining or installation instruc-
tions
■ Unsuitable, incorrect or unauthorized use of the product
■ Operating the product in an environment not intended for its
use
■ Operating the product not observing the legal safety guidelines
relevant at the location of use

2 About safety
■ Non-observance of the warning and safety instructions in all

relevant documents for the product
■ Operating the product under faulty safety and protective condi-
tions
■ Incorrect operation of the product resulting from the effect of
connected or neighboring third party devices
■ Incorrect or negligent treatment by the customer
■ Interventions in the product made by the customer or third
parties
2.8.2 Exceptions to the disclaimer
In the cases listed above BST eltromat International GmbH shall

also not be liable (claims for damages) unless:
■ The damage results from a willful or grossly negligent breach of
duty on the part of BST eltromat International GmbH or its legal
representatives or vicarious agents
■ The damage is associated with injury to life, body or health and
results from a willful or grossly negligent breach of duty on the
part of BST eltromat International GmbH or its legal representa-
tives or vicarious agents
■ The form of damage can usually and typically be insured against
by means of third-party liability insurance taken out by BST el-
tromat International GmbH under reasonable conditions
This applies in particular to claims for damages associated with
fault or negligence occurring before or upon conclusion of the con-
tract, the infringement of secondary obligations and claims associ-
ated with impermissible actions; this does not affect claims as-
serted in accordance with the German Product Liability Act or
those associated with a guarantee.
Otherwise, the specific terms of license of BST eltromat Interna-
tional GmbH apply.
2.8.3 License and liability for software supplied
Software supplied that has not been produced by BST eltromat In-
ternational GmbH underlies the respective liability and license
agreements of the manufacturer.

Design and function 3
3 Design and function

3.1 System description
3.1.1 System design
General
The EcoGuide compact web guide control consists of the following
components:
■ Pivoting frame with two deflection pulleys
■ Housing
■ Controller with keyboard
■ Actuator
■ One or two edge sensors (optical sensors or ultrasonic sensors)
3
2
4
1
7
4
5
Fig. 1: EcoGuide
① Controller with keyboard

② Top frame
③ Deflection pulley
④ Edge sensor
⑤ Sensor adjustment unit
⑥ 24V DC (on the back panel of the controller)
⑦ Base frame
The compact web guide control is delivered ready for connection.

All cable connections between the individual components has al-
ready been carried out in the factory.

3 Design and function
Compact web guide control with control panel fitted

The operation of the compact web guide control is carried out via
the control panel that is factory-fitted to the operating side of the
housing as specified in the order.
Web running
direction
Operating side Operating side

left right
Fig. 2: EcoGuide with control panel fitted
3.1.2 Functional principle
In automatic mode, one or two edge sensors detect the current

position (ACTUAL position) of the material web and transmit the
respective information to the integrated controller.
The controller compares the ACTUAL recorded position against
the default SETPOINT position. The controller will send a relevant
correction signal to the actuator if a deviation is found to exist be-
tween the two values.
The actuator pivots the movable pivoting frame suspended on the
housing of the compact web guide control around a rotating point
in the material web infeed until the material web is located back
in its SETPOINT position at the outfeed.
3.1.4 Connectable components
A list of connectable components is to be found in the documen-

tation of the ekr CON 100 controller.

Design and function 3
3.2 Terms used
3.2.1 Sensor 1 / Sensor 2
In this instruction manual, the sensors of the compact web guide

control are designated as "Sensor 1" and "Sensor 2".
According to the BST eltromat definition, the following relationship
applies between the selector switches and the scanning type for the
sensors:
Symbol: Designation: Position:
Sensor 1 Left web edge
Sensor 2 Right web edge
The following is valid for the sensor installation positions:

The sensor that is located on the left of the web in the web run-
ning direction (viewed from the top of the material) is Sensor 1.
Sensor 1
Sensor 2
Fig. 3: Sensor positions
The sensors are connected in the factory as follows:
Sensor: Connector
1 X101
2 X102

4 Technical specifications
4.1 Standard sizes
4.1.1 Size 1-3
Fig. 4: Dimensional drawing EcoGuide
Size Width Y Roll length L Correction Rolls Ø D Controllable Max. web

[mm] [mm] length C [mm] error [mm] tension
[mm] [N]
180
150
200
1 280 180 60 ± 15 300

200
250
250
300
180
200
350
2 400 250 60 ± 15 300
300
400 250
450
3 580 300 60 ± 15 300
550

Technical specifications 4
4.2 Ambient conditions
DANGER
explosive areas.
Ambient conditions Permissible values

Working temperature 0 to +45 °C
Storage temperature -10 to +70 °C
Humidity during operation 5 to 90 %
4.3 Protection class
Protection class IP 40
4.4 Voltage supply
Connector X100
Voltage 24 V⎓ ±10% (including ripple)
Current Max. 2.5 A
Connection 4-pin micro-style connector M8
Max. length of connecting 20 m
cable (with wire cross section 0.5 mm2)
4.5 Sensors
4.5.1 Edge sensors
Optical edge sensor IR 2011

Fork width 40 mm
Measuring range 24 mm (±12 mm) digital operation
12 to 30 V⎓
Supply voltage
(including ripple)
Current consumption 20 mA (24 V⎓)
Opto-transmitter wave length 630 nm
Output signal (digital opera-
BST eltromat CAN bus
tion)
Polarity reversal protection
yes
(supply)

Optical edge sensor IR 2011

Short circuit protection
yes
(analog output)
Operating display LED (2 colored)
Electrical connection M8 plug, 4-pin
Ambient temperature during 0 to +60 °C
operation
Noise generation < 70 dB
Weight < 400 g < 500 g
Housing dimensions See separate product data sheet
Complies with RoHS Yes
BST eltromat order number 3SEOP156765
Ultrasonic edge sensor US 2010

Fork width 40 mm
Measuring range 12 mm (±6 mm)
Supply voltage 12 to 30 V⎓ (including ripple)
Current consumption 40 mA (24 V⎓)
Ultra-sonic frequency 164 kHz
Output signal (digital opera-
BST eltromat CAN bus
tion)
Polarity reversal protection
yes
(supply)
Short circuit protection
yes
(analog output)
Operating display LED (2 colored)
Electrical connection M8 plug, 4-pin
Ambient temperature during 0 to +60 °C
operation
Noise generation < 70 dB
Weight < 400 g < 500 g
Housing dimensions See separate product data sheet
Complies with RoHS Yes
BST eltromat order number 3SEOP157271

Technical specifications 4
4.6 Power pack
Only the following power packs may be used for the voltage sup-
ply of the compact web guide control:
Power pack from Puls GmbH

Type ML 100.100
BST eltromat order number 1ELNT103837
or
Power pack from Mean Well

Type CLG-100-24
BST eltromat order number 1ELNT137535
or
Power pack with the following specifications

24 V⎓ ± max. 10 %
Output voltage
(including ripple)
Power output Min. 100 W
Special properties No hiccup
The power packs must fulfill the requirements of the IEC 61010-1
for energy limited current circuits. When being used in countries
that have defined deviations to IEC 61010-1, these must also be
observed.
The 0 V connection of the power pack must be connected with
the protective conductor system (see requirements IEC 60204-1).
The power pack is not included in the compact web guide control
scope of delivery.
4.7 Emissions
The A-rated equivalent continuous sound level of the equipment
is less than 70 dB(A).
4.8 RoHS Conformity

This product complies with the EU Directive 2011/65 (the so-
called RoHS* Directive). The limits values for hazardous substanc-
es in electrical and electronic equipment specified there are not
exceeded by this product.
* EU Directive for limiting the use of certain hazardous substanc-
es in electric and electronic devices, "RoHS Directive" (Re-
striction of Hazardous Substances).

5 Transport, delivery and storage

5.1 Transport
The EcoGuide compact web guide control is intended to be in-
stalled in a production machine for web-type materials.
The equipment will be shipped in accordance with the details
stipulated in the order:
■ Completely installed and connected to the production machine
■ As a ready to use separate device in a standard box
The compact web guide control must only be transported in the
original BST eltromat transport packing.
NOTE
Improper transportation
can cause damage to the surface of the compact web guide con-
trol.
► Transport the packing units only in the position marked.
► Avoid causing damage to the packaging. Replace damaged
packaging with appropriate new packaging in order to avoid
subsequent damage to the compact web guide control.
BST eltromat International GmbH will not be liable for damages

to the compact web guide control, that are caused by incorrect
transport packaging!
For loading and unloading, and for the transport of the compact
web guide control, use a lifting cart, forklift or suitable lifting gear
(e.g. hall crane).
When transporting, observe the following safety measures in all
cases:
WARNING
Danger of death and material damage caused by incorrect trans-
portation!
Death and crushing from transported goods falling.
► Do not fix the lifting gear on the handles.
► Never remain under suspended loads.
► Never stand in the area of movement of the goods being
transported.
► Transport to be carried out by qualified and trained personnel
only.

Transport, delivery and storage 5
CAUTION
Risk of injury from carrying weight being too high!
► Lift maximum 15 kg (females) or 25 kg (males) per person.
► Use handles.
The following personal protective equipment is required for

transporting:
■ Protective gloves
■ Safety shoes
■ Safety helmet when using lifting gear
► Observe the applicable guidelines (e.g. accident prevention
regulations).
► Always wear personal protective equipment.
► Use only suitable lifting gear (e.g. lifting straps, chains) and lift-
ing devices according to the type and weight of the goods to be
transported.
► Attach the lifting gear only at the intended fixing points and on-
ly when using suitable slings. Do not fix the lifting gear on the
handles.
► Secure the bearing ropes so that they cannot slip.
► Transport the system components only in the original packag-
ing and in the position marked on the packaging.
► If transport restraints have been supplied, always transport the
system components using transport restraints.
► Secure the goods to be transported on the transport device so
that they cannot slip, fall-over, knock or fall down. E.g. secure
using lashing straps and edge protectors.
► Lift and put the transport goods down carefully.
5.2 Scope of delivery

Obtain the scope of delivery from the delivery documents or con-
firmation of order.
5.3 Unpacking the delivery

Upon delivery, immediately check the shipment for completeness
and any transport damage.

NOTE
Damaged packaging
can cause damage to system components.
► Remove the damaged packing in the presence of a representa-
tive of the shipping company and check the contents for dam-
age.
Unpack the components in a dry room immediately before com-

mencing with the installation.
The parts supplied will depend upon your order.
► Before starting with the installation work, check that all com-
ponents required are available. For this purpose, arrange all
packages / cartons delivered as part of your order in front of
you. Open the packages / cartons one after another and care-
fully take out the packaging material and components. Pay par-
ticular attention to the small parts, such as cables and addi-
tional parts, which may be packed in the packaging / cartons.
► Check the components supplied for damage /e.g. dents,
scratches, loose parts, defective cables, etc.). Defective or de-
formed components must be replaced immediately as trouble
free function of this part cannot be guaranteed over a longer
period.
► In the event that you wish to forward the components, keep
the original packaging. The transport must only be carried out
in the original BST eltromat transport packing. Otherwise dis-
pose of the packaging in accordance with local disposal regula-
tions.
5.4 Storage
NOTE
Damage caused to the system due to incorrect storage!
► Do not store the system and components outdoors.
► The following conditions for storage must be observed.
The system and components must be stored as follows:

■ In a well ventilated and dry room
■ In the original packaging
■ On palettes or on a shelf to protect against moisture on the
floor
■ Protected against dust and dirt (e.g. covered with film)
For permissible ambient temperatures and humidity, see chapter
Ambient conditions on page 25.

Installation 6
6 Installation
WARNING
Danger of death and material damage caused by incorrect instal-
lation!
► Have the installation carried out only by qualified personnel
that have been instructed by BST eltromat service personnel or
authorized personnel.
DANGER
Danger of death caused by the machine starting up!
Parts of your body could be crushed, cut, drawn in or hit.
► Switch off the machine completely and secure it against it be-
ing switched back on.
NOTE
Damage to the system from drilling dust and loose parts!
Drilling dust, splitter and loose parts may damage the machine.
► Before carrying out drilling or installation work, cover the af-
fected area of the machine with film or paper.
► After installation work, check that the bolts are screwed tight.
Before starting with the installation work

► Read the safety instructions in the operating instructions of the
machine in which the BST eltromat components are to be in-
stalled.
► Observe the complete safety concept of the machine.
► Cordon-off the work area in order to prevent access by unau-
thorized persons (e.g. by setting up barriers).
► Make sure that all parts of the machine where the BST eltromat
components have to be installed have a sufficient load bearing
capacity.
During installation work

► Observe all safety instructions and hazard warnings on the BST
eltromat components and the machine.
► Do not deactivate or remove any protection and safety equip-
ment belonging to the machine. If the protection and safety
equipment has to be removed for the installation of the BST el-
tromat components, these must be re-installed immediately af-
ter completing the installation work.
► Escape routes and access to safety equipment must not be
blocked by the installation of BST eltromat components.

6 Installation
► Make sure that no parts (e.g. screws, washers, tools) can fall in-
to the machine. Cover the affected area of the machine with
film or paper. Parts falling down may damage the machine.
► Do not climb onto or walk on BST eltromat components or un-
suitable parts of the machine.
► Ensure that there is sufficient free headroom. If the free head-
room is restricted, the relevant components causing the height
restrictions must be padded and danger-warning signs must be
attached to them (yellow / black).
After completing the installation work

► Install all safety equipment and protective covers that had to
be removed for the installation work.
► Check that the bolts are screwed tight.
► Remove all tools and auxiliary aids used from the machine.
► Before commissioning, remove any transport locks present
from the BST eltromat components.
6.2 Selecting the installation location
DANGER
explosive areas.
In addition to the basic ambient conditions (see Ambient condi-

tions, page 25), the following conditions also have to be fulfilled:
■ Installation location dry, vibration-free and level
■ Ergonomic positioning of the control panel
■ No direct light irradiation onto the display of the control panel
■ Minimum clearance of 100 mm to electro-magnetic fields (en-
ergy sources or high voltage lines)
■ No sources of heat in the immediate vicinity
6.3 Space requirement

The dimensions for the compact web guide control can be ob-
tained from chapter 4.2. (Standard sizes) or the installation draw-
ing supplied.
Allow enough space around the installed compact web guide con-
trol so that there is no risk to persons or material from the pivot-
ing frame in both end positions.

Installation 6
The compact web guide control must be easy to access for

maintenance work. Sufficient space for removal must be provided
for the purpose of removing defective components during
maintenance work.
6.4 Tools and auxiliary material

For the installation of a EcoGuide compact web guide control in
the standard version in the production machine, you need the fol-
lowing tools and auxiliary material:
6.4.1 Tools and auxiliary material for EcoGuide
■ Drilling machine
■ ø 9 mm metal drill bit
■ 13 mm open-ended / ring spanner
■ Phillips screwdriver
■ Try square
■ Steel rule

6 Installation
6.5 Recommendations for installation
When installing the compact web guide control into the produc-
tion machine, please observe the following points:
2
Si Se
3
1 4
Fig. 5: Recommendations for installation
1 Last fixed roll before the infeed roll

The wrapping angle of the web on the last fixed roll before
the infeed roll should be between 45° and 135°. The opti-
mum wrapping angle is 90°.
2 Pivoting frame
3 Sensor
The sensor should be positioned at the very end of the
first third of the outfeed path.
4 Last fixed roll after the outfeed roll
The wrapping angle of the web on the first fixed roll after
the outfeed roll should be between 75° and 105°. The
optimum wrapping angle is 90°. The roll should have a
non-slip surface to allow the corrected position of the web
to remain at the outfeed.
5 Web running direction
Observe the specified web running direction ! The web
running direction is marked by an arrow on the pivoting
frame.

Installation 6
Si Infeed path
For an optimum correction of the web position, the infeed
path must be approx. 0.5 to 1x the maximum web width.
Se Outfeed path
For an optimum correction of the web position, the out-
feed path must be approx. 0.5 to 1x the maximum web
width.
C Correction length
The correction length is already determined when project-
ing the compact web guide control and can no longer be
changed. The correction length should be 0.7 to 1 x the
maximum web width.
6.5.1 Alignment of the compact web guide control
Observe the precise alignment of the compact web guide control !

The support surface on which the compact web guide control is
going to be mounted must be precisely parallel to the run of the
web.
Deviations between the support surface and web running level
must be compensated by aligning the support surface.
The center of the pivoting frame must correspond with the center
of the web run in the production machine.
The angle between the housing of the compact web guide control
and the web run in the production machine must be precisely 90°.
Material web
Center pivoting frame = Center web run
Fig. 6: Vertical alignment

6 Installation
Last fixed roll

before the infeed roll
ekr CON 100

First fixed roll
after the outfeed roll
Fig. 7: Horizontal alignment
6.5.2 Deflection pulleys
Fixing screws Deflection
Fig. 8: Position of the deflection pulleys

Installation 6
Both deflection pulleys of the pivoting frame are aligned precisely

to the housing of the compact web guide control ex-factory.
The position of the deflection pulleys must never be changed.
The fixing screws (see fig. 8) of both deflection pulleys must not
be loosened!
6.6 Installation positions

The compact web guide control can be mounted in different posi-
tions.
Figure 20 shows the permissible installation positions.
Horizontal installation Vertical installation
Fig. 9: Permissible installation positions
When delivered from the factory, the compact web guide control
is prepared for installation in installation position W1U1. The ekr
CON 100 controller is mounted at the operating side of the hous-
ing specified in the order.
Other installation positions are mounted ex works according to
the order.
6.7 Installation of the compact web guide control

6.7.1 General
The fastening of the compact web guide control to the machine

frame is carried out using four M8 screws. For this the base plate
of the base frame is fitted with four M8 fastening screw threads
(see fig. 10).

6 Installation
View from below
M8 fastening screw threads
Fig. 10: Position of the fastening screw threads
The drilling distances for fixing the compact web guide control can
be obtained from the securing hole template in chapter 6.7.2.
NOTE
Damage to the system from drilling dust and loose parts!
Drilling dust, splitter and loose parts may damage the machine.
► Before carrying out drilling or installation work, cover the af-
fected area of the machine with film or paper.
► After installation work, check that the bolts are screwed tight.

Installation 6
6.7.2 Securing hole template
The following distances depicted below are valid for the four se-
curing boreholes for the standard sizes 1-3 of the compact web
guide control (see also the following table).
Securing hole template
EcoGuide
(Bottom view)
Maximum screw depth

from the underside of the base plate 10 mm
Fig. 11: Securing hole template for EcoGuide sizes 1-3
Size Housing width Y [mm] Correction length C [mm] Borehole distance Y-30 [mm]
180
200
1 280 250
250
300
180
200
2 400 370
250
300
3 580 300 550

6 Installation
6.8 Changing the mounting position of the controller
Fig. 12: EcoGuide with a controller mounted on the left side
If it is necessary to change the mounting position of the controller,

please go through the steps as follows:
1. Disconnect all cable connections from the controller (see pos. 1
in fig. 13).
2. Remove the cable tie (see pos. 2 in fig. 13) from the assembly
bracket of the controller. Use pliers to cut the cable tie.
Fig. 13: Remove cables and cable tie
3. Remove the two fixing screws of the controller mounting

bracket (see fig. 14) and remove the controller from the
mounting plate.

Installation 6
Fig. 14: Remove fixing screws
4. Set the controller mounting bracket to the desired new mount-

ing position and fix it in position by means of the two fixing
screws (see fig. 15).
Fig. 15: Fix the controller pass through the cables
NOTE
Damage caused by top frame bumping against the controller!
If the controller is mounted too close to the top frame, it may
bump against the controller housing.
► Please make sure that the top frame is able to move freely
when mounting the controller.
► The minimum distance between top frame and controller has
to be 60 mm (see fig. 16).

6 Installation
Fig. 16: Distance Controller – Top Frame
5. Pass through the connecting cables to the controller (see fig

15).
6. Connect all connecting cables to the controller again (see fig.
17).
Fig. 17: Connecting the cables
7. Fix the connecting cables to the controller mounting bracket by

means of a cable tie (see fig. 18).

Installation 6
Fig. 18: Fixing the connecting cables with a cable tie
6.9 Changing the mounting position of a sensor / mounting an additional sensor
Fig. 19: EcoGuide with a sensor mounted on the left side
If it is necessary to change the mounting position of a sensor or to

mount an additional sensor, please go through the steps de-
scribed in the following chapters.

6 Installation
6.9.1 Preparing the mounting rail
Before mounting the sensor the mounting rail has to be set to the
outmost position.
If the mounting rail is already in the outmost position,

please continue with chapter 6.9.2 "Removing sensor and
sensor holder".
Please go through the steps as follows:

1. Remove the two fixing screws (see pos. 1 in fig, 20) of the sen-
sor mounting rail (see pos. 2 in fig. 20).
2. Move the mounting rail to the outmost position determined by
the threaded holes marked with position 3 in fig. 20.
2
1
3
Fig. 20: Moving the mounting rail (example for the right side)
6.9.2 Removing sensor and sensor holder
To change the mounting position sensor and sensor holder have

to be removed from their previous position.
If you just want to mount a second sensor but don't want

to change the position of the existing sensor, please con-
tinue with chapter 6.9.4 "Mounting the sensor".
Please go through the steps as follow:

1. Remove the fixing screw (see pos. 1 in fig. 21) of the sensor and
then remove the sensor from the sensor holder.

Installation 6
1
2
Fig. 21: Removing the fixing screw of the sensor
2. Remove the connecting cable from the sensor.

3. Loosen the locking screw (see pos. 2 in fig. 21) and pull off the
sensor holder from the mounting rail outwards.
6.9.3 Preparing the sensor holder
Before you can mount the sensor in a new mounting position the
sensor holder needs to be prepared.
Please go through the steps as follows:
1. Remove the t-slide (see pos. 1 in fig. 22) from the locking screw
(see pos. 2 in fig. 22).
2. Remove the locking screw from the sensor holder (see pos. 3 in
fig. 22).
3
1
Fig. 22: Sensor holder configured for the left side
3. Turn over the sensor holder and put the locking screw into the
sensor holder, as shown in fig. 23.

6 Installation
Fig. 23: Sensor holder configured for the left side
4. Screw the t-slide together with the lockingg screw, as shown in

fig. 23.
6.9.4 Mounting the Sensor
To mount the sensor, please go through the steps as follows:

1. Slide the sensor holder onto the mounting rail (see fig. 24).
2. Slide the sensor holder to the desired position on the mounting
rail and fix it by means of the locking screw.
Fig. 24: Sliding the sensor onto the mounting rail and fixing it
3. Put the sensor onto the sensor holder and fix it with the fixing
screw (see pos. 1 in fig. 25).
4. Pass through the sensor connecting cable to the sensor and
connect it to the sensor (see pos. 2 in fig. 25).

Installation 6
Fig. 25: Mounting the sensor

7 Electrical connection
7. Electrical connection
DANGER
sidual current.
► Switch the machine off completely, switch free of voltage and
wait 10 minutes before carrying out the electrical connection.
► Check that the unit is voltage-free.
► Secure the machine against being switched back on.
► Cover or fence off any adjacent parts that are still live.
WARNING
Mortal danger and property damage caused by incorrect electric
connections / insufficient PE connection!
Life-threatening electric shock and destruction of system compo-
nents caused by short-circuits.
► Have electrical connections carried out by qualified electricians
only.
► Carry out PE connections for all live system components pro-
fessionally.
► Use suitable safety equipment (RCD switch) upstream for all
live system components.
NOTE
Damage to components resulting from incorrect voltage connec-
tion!
Damage to components caused by connecting to the wrong mains
voltage, incorrect terminal connection or from incorrect polarity.
► Before connecting, observe the connecting diagram and cable
lettering.
► Before connecting, make sure that the mains voltage corre-
sponds with the details specified on the nameplate of the
components.
► Select the correct terminals and polarity when connecting the
power supply.

Electrical connection 7
7.2 Cable routing
WARNING
Severe injuries and property damage caused by routing the ca-
bles incorrectly!
► Route the cable free of tension and well anchored.
► Ensure that no tripping or catching points are created.
► Do not kink the cable; observe the minimum bending radius.
► Maintain a minimum distance of at least 25 mm between the

cables and moving parts of the machine.
► Route the cables so that they do not rub or become crushed,
cut or caught.
► Tighten up the securing screws in the plug connections.
► Route signal cables separately from supply cables as signal ca-
bles are sensitive to interference.
Fig. 26: Separate routing of signal and supply cables
① Cable duct
② Signal cable
③ Supply cable
► Establish cable connections between the components accord-

ing to the connecting diagram.

7.3 Connecting the cables
Cables up to 0.75 mm2

Use conductor end sleeves with collar (DIN 46228/Part 4) for con-
necting the cables.
■ The crimping must be carried out gas tight (no cross-crimping).
■ There must be no gaps between the conductor and the core
end sleeve
■ The length of the metal sleeves fitted on the core end sleeve
must be at least 8 mm.
For crimping, we recommend the crimping pliers VarioC-

rimp-4-Zange 206-204 from Wago.
Cables from 0.75 mm2 to max. 1.5 mm2

Connect the cables without core end sleeve.
■ In the case of fine and multi-core cables and fine-wired cables,
whose kink resistance is not sufficient due to the small diame-
ter, the clamp must be properly opened using a screwdriver to
overcome the contact force of the clamping springs.
► After connecting, in both cases check the correct fit of the ca-
ble.

7.4 Ensuring equipotential bonding
Electrostatic charges (ESD) must not discharge via the system. De-
vices for discharging must be installed before and after (in the
web running direction) the installed system.
In the contact areas of connections, remove the paint as this acts
as an insulator and prevents equipotential bonding.
► Install conducting connections that permit equipotential bond-
ing of low and high frequencies between the individual ma-
chine parts or cable ducts.
► Install ESD discharge devices before and after the installed sys-
tem.
► Connect all components of the system with the same earth that
is connected to the machine.
► In the case of screwed connections, use serrated washers to
ensure a conducting connection with the unpainted surface
(see figure 13).
► Remove the paint coating in the contact area.
Through hole Threaded hole
Fig. 27: Use of fan-type washers
① Screw
② Nut
③ Fan-type washer
④ Washer
⑤ Earthing cable

Fig. 28: Flat connector for the equipotential bonding on the controller and bottom frame
Establish the equipotential bonding on the controller

For the connection of a cable ① for the equipotential bonding
(wire cross-section 1.5 – 2.5 mm2), please use the push-on con-
nector ② on the flat connector ( ) on the back of the controller.
Establish the equipotential bonding on the bottom frame

For the connection of a cable ③ for the equipotential bonding
(wire cross-section 1.5 – 2.5 mm2), please use the push-on con-
nector ④ on the flat connector of the bottom frame (see Fig. 28).

7.5 Cable connections
7.5.1 Cable connections for the EcoGuide size 1-3
On the back panel of the ekr CON 100 controller integrated in the
EcoGuide the following sockets can be accessed:
5 1
3 2
Fig. 29: Connections of the controller
① Sensor 1 (edge sensor)

② Sensor 2 (edge sensor)
③ Network (Ethernet)
④ Motor actuator
⑤ Power supply

7.6 Voltage supply
7.6.1 Requirements of the supply grid
The voltage supply of the EcoGuide compact web guide control is

carried out via an external power pack (Specification see chapter
4.6).
NOTE
Incorrect voltage supply
can cause damage to the surface of the compact web guide con-
trol.
► Before connecting the voltage supply, make sure that the pow-
er pack used fulfills the requirements according to chapter 4.6.
7.6.2 Connecting the voltage supply
The voltage supply is connected to the ekr CON 100 controller in-
tegrated in the EcoGuide using a 4-pin micro-style connector M8.
Contact assignment in the plug connector
Connector
Coupling
Fig. 30: Contact assignment in the plug connector
Contact Signal Wire color Note

1 +24 V⎓ brown Power supply
2 reserved
3 GND blue Ground
4 reserved

7.7 Remote control (Option)
7.7.1 General
The remote control inputs of the compact web guide control allow
the remote control of the functions via external switches or PLC
signals.
Attention!
External switches block opposite function keys of the con-
trol panel.
If a remote control signal is set at the relevant terminals then you

can no longer switch over the assigned functions from the control
panel!
The truth table for the remote control inputs can be obtained in
the documentation of the ekr CON 100 controller.
7.7.2 Connecting the remote control
The connection procedure for the remote control can be obtained

in the documentation of the ekr CON 100 controller.

8 Commissioning
8 Commissioning
WARNING
Danger of death and material damage caused by incorrect com-
missioning!
► Have the installation and commissioning carried out by BST el-
tromat service personnel or authorized personnel only.
DANGER
DANGER
sidual current.
► Electrically isolate the controller.
► Secure the power supply against being switched back on.
► Earth the controller.
► Open the housing of the EcoGuide compact web guide control

only at zero potential.
WARNING
Danger of death from actuator movements!
During function tests, parts of your body may be crushed, cut or
hit.
► Before starting commissioning work, make sure that no per-
sons remain in the vicinity of the pivoting / traversing area of
machine components that are positioned by the actuator.
► Cordon off the work area before starting the commissioning
work to prevent access by unauthorized persons.

Commissioning 8
8.2 Requirements
■ The compact web guide control is connected to the voltage

supply.
8.3 Settings for commissioning

All necessary settings for the commissioning of the EcoGuide are
carried out ex works. Normally they only have to be checked or
corrected in exceptional cases (e.g. replacement of components).
If alterations of the setup are necessary, they have to be done on
the ekr CON 100 controller integrated in the EcoGuide. Infor-
mation on the procedure is to be found in the documentation of
the controller.
8.4 Further information on setting up the ekr CON 100

A detailed description of all setting up processes and settings of
the ekr CON 100 controller integrated in the EcoGuide can be
found in the separate operating manual ekr CON 100 (EDP no.
MD.461).

9 Operation
9 Operation
9.1 Threading in the material web.
WARNING
Threading in the material web when the production machine is
running
can lead to death or crushing, cutting, entrainment, winding, pull-
ing in, trapping and impacts of limbs.
► Thread the material web into the compact web guide control
only when the production machine is stopped.
► Make sure that the production machine cannot start again.
Procedure
The following points describe the procedure for threading the ma-
terial web in when the compact web guide control is equipped
with two edge sensors for web center-line guiding. With web edge
guiding (control on the left or right web edge), the position of the
respective edge sensor must be set.
1. Stop the production machine and secure against being

switched back on.
2. Press the Center positioning button on the control panel.

The pivoting frame moves to the central position.
NOTE
Manual adjustment of the pivoting frame
can cause damage to the spindle of the actuator.
► Move the pivoting frame to the central position only using the
motor (see step 2).
3. Undo the clamping screws on the sensor adjustment unit and

push the sensors outside in the direction of the arrow.
Clamping screws
Fig. 31: Undo the clamping screws and move the sensors outwards

Operation 9
4. Carefully thread the material web into the compact web guide
control. The arrow on the pivoting frame marks the web run-
ning direction. See the figure below with regard to the possible
web threading options.
U threading Z threading
Fig. 32: Threading types
5. Move the material web to the desired nominal position manu-

ally. Ideally, in its nominal position, the material web runs cen-
trally over both deflection pulleys of the pivoting frame.
Material web
Web edge in the center of the sensor measuring range
Fig. 33: Thread in the material web
6. Carefully push the sensors inwards until the web edges are lo-
cated in the center of the sensor measuring range.
The display screen of the relative cover of the respective sensor
shows the value of "50%".
7. Tighten up the clamping screws of the sensor adjustment units.

9 Operation
9.2 Operating the ekr CON 100 controller
The general operation of the ekr CON 100 controller is described

in detail in the operating manual ekr CON 100 (EDP no. MD.461).

Maintenance and cleaning 10
10 Maintenance and cleaning

Maintenance and cleaning work must be carried out as
described in the following. Otherwise increased wear and
system failures may occur.
Claims on the warranty and claims for damage are invalid if

maintenance and cleaning work have not been carried out or not
been carried out correctly.
DANGER
DANGER
sidual current.
► Electrically isolate the controller.
► Secure the power supply against being switched back on.
► Earth the controller.
WARNING
Risk of injury and material damage caused by incorrect mainte-
nance / cleaning!
► Have the maintenance and cleaning carried out only by quali-
fied personnel that have been instructed by BST eltromat ser-
vice personnel or authorized personnel.
► Carry out the maintenance and cleaning as described in the
following chapters.
► With particularly intensive stress / soiling, reduce the specified
maintenance intervals.

10 Maintenance and cleaning
10.2 Maintenance table
The following table gives you an overview of the necessary

maintenance tasks and intervals.
The maintenance intervals specified are reference values. With
particularly intensive stress / soiling, the intervals must be re-
duced.
Carry out the respective maintenance and cleaning as described in
the following chapters.
Component Maintenance work Maintenance Interval See chapter

Housing ■ Cleaning the housing Weekly 10.3.1
Pivoting frame ■ Clean the surface of the deflection 4 weeks 10.3.2
pulleys
Sensors ■ Clean the measuring lenses Weekly 10.3.3
■ Optical sensors ■ Clean the transmission / receiver Prior to each material
■ Ultrasonic sensors capsules setup
Control panel ■ Cleaning the housing Weekly 10.3.4
10.3 Maintenance and cleaning work

10.3.1 Cleaning the housing of the compact web guide control
Cleaning the housing

► Clean using a dry, clean and soft cloth.
► Use a commercially available liquid cleaner in the event of in-
tensive soiling.
► Observe protection class IP 40 of the compact web guide con-
trol.
10.3.2 Cleaning the pivoting frame
NOTE
Manual adjustment of the pivoting frame
can cause damage to the spindle of the actuator.
► Move the pivoting frame for maintenance purposes only using
the motor.
Cleaning the deflection pulleys

Both deflection pulleys of the pivoting frame have ball bearings
with life-long lubrication and are therefore maintenance-free.
► For the processing of materials with intensive dust accumula-
tion, clean the surfaces of the deflection pulleys of dust and
dirt every four weeks.

Maintenance and cleaning 10
► Use commercially available roller cleaner to clean the optional-

ly available rubber deflection pulleys.
Deflection pulleys
Fig. 34: Cleaning the deflection pulleys
10.3.3 Cleaning the sensors
Cleaning the measuring lenses and transmission / receiver cap-

sules
► To achieve the best possible control results, the measurement
lenses of optical sensors or the transmission / receiver capsules
of ultrasonic sensors must be cleaned once a week.
► A material set-up must be run after the measuring lenses or
transmission and receiver capsules have been cleaned (see
Chapter 8.3).
10.3.4 Cleaning the control panel
Cleaning the housing

The control panel is a maintenance-free unit.
► The cleaning of the housings should be carried out once a week
with a dry, clean and soft cloth.
► A commercial liquid cleaner may be used in the event of inten-
sive soiling. Observe protection class IP 40!

11 Troubleshooting
11 Troubleshooting
WARNING
Danger of death and material damage caused by incorrect trou-
bleshooting!
► Have the troubleshooting carried out only by qualified person-
nel that have been instructed by BST eltromat service person-
nel or authorized personnel.
► Only have the faults rectified by BST eltromat customer ser-
vices with the following measures or according to their instruc-
tions.
► All safety instructions in the chapter Maintenance and cleaning

must be observed, see safety instructions, page 61.
A detailed description of typical faults, their possible causes and

measures for their rectification can be found in the instruction
manual ekr CON 100 (EDP no. MD.461).
► For further information, please contact BST eltromat customer

services, address see customer services, page 66.
64/70 CompactGuide compact web guide control

Accessories and spare parts 12
12 Accessories and spare parts

12.1 Order address
Accessories and spare parts can be purchased under the following
address:

Heidsieker Heide 53
D-33739 Bielefeld
Germany
Tel.: +49 (0) 5206 999 767

Fax: +49 (0) 5206 999 0
http: www.bst-international.com
CompactGuide compact web guide control 65/70

13 Customer services
13 Customer Service
Do you have any questions about this product? Or for other prod-
ucts or services from BST eltromat International?
Then please contact the following address.
In order to be able to reply to your request as soon as possible,
please provide us with the following data (where available):
■ Product name
■ Job number
■ EDP number and software version
■ Serial number and date of manufacture (see name plate)
Customer Services address

Service
Heidsieker Heide 53
D-33739 Bielefeld
Germany
Tel.: +49 (0) 5206 999 767

http: www.bst-international.com
66/70 CompactGuide compact web guide control

Shutting down and disposal 14
14 Shutting down and disposal

When shutting down and disposing of the system, the applicable
national laws and guidelines must be observed.
Moreover, the safety concept of the entire system must be ob-
served in which the system is installed. The necessary procedure
must be prepared by the manufacturer of the machine.
To a great extent, the system is made from electric / electronic
components and materials that, depending on the compilation,
are returned for recycling. Also note the legal regulations as well
as local recycling guidelines for this purpose.
Returning the system to BST eltromat International GmbH is gen-
erally possible. For this purpose and all other questions, please
contact BST eltromat customer services, page 66.

Index
Index
A G
Ambient conditions ......................................... 25 Guarantee ....................................................... 19
Automatic mode .............................................. 22 Guarantee terms ............................................. 19
C H
Cable connections ........................................... 53 Housing width ................................................. 39
Cable duct ........................................................ 53
Cable routing ................................................... 49 I
Commissioning ................................................ 56 Iits intended purpose ........................................ 9
Requirements .................................................57 Infeed path ...................................................... 35
Components .................................................... 22 Installation ................................................... 9, 31
Connectable components................................ 22 Alignment....................................................... 35
Control panel ............................................. 21, 63 Auxiliary material ........................................... 33
Display ............................................................32 Installation location requirements ................ 32
Installation......................................................37 Installation positions ...................................... 37
Protection class ..............................................63 Recommendations for installation ................ 34
Controller Safety ............................................................. 31
Changing the mounting position ....................40 Securing hole template .................................. 39
Correction length ....................................... 24, 35 Space requirement ........................................ 32
Customer services ........................................... 66 Tools ............................................................... 33
Installation location requirements .................. 32
D Installation positions ....................................... 37
Deflection pulleys ............................................ 37
K
Disclaimer ........................................................ 19
Display ............................................................. 32 Keyboard block ................................................ 22
Display screen .................................................. 59
L
E Last fixed roll after the outfeed roll ................ 34
Edge sensors .................................................... 25 Last fixed roll before the infeed roll ................ 34
Electrical connection ....................................... 48
M
Electrostatic discharge .................................... 14
Emissions ......................................................... 27 Maintenance ................................................... 61
Equipotential bonding ..................................... 51 Control panel ................................................. 63
ESD ................................................................... 14 Housing .......................................................... 62
ESD protection................................................14 Maintenance table ......................................... 62
Pivoting frame................................................ 62
F Sensors ........................................................... 63
Firmware............................................................ 6 O
Adding firmware...............................................6
Functional principle ......................................... 22 Operating display ............................................ 26
Further information ........................................... 8 Operating instructions
Use ................................................................. 14
Operating mode

Index
Automatic ...................................................... 22 Ultrasonic ...................................................... 26

Optical sensors ................................................ 25 Set position ..................................................... 59
Outfeed path ................................................... 35 Settings for commisoning ............................... 57
Shutting down and disposal ............................ 67
P Standard sizes ................................................. 24
Personal Storage ............................................................ 30
Qualification ................................................... 15 Supply voltage ................................................. 25
Personal protective equipment ....................... 19 Symbols used .................................................... 7
Potentially explosive areas .............................. 25 System design ................................................. 21
Power pack ...................................................... 27
Power supply ................................................... 25 T
Protection class ............................................... 25 Technical specifications................................... 24
Terms used in this manual .............................. 23
R Thread in the material web ............................. 58
Remote control................................................ 55 Transport ......................................................... 28
RoHS ................................................................ 27 Troubleshooting .............................................. 64
Roll diameter ................................................... 24 Truth table....................................................... 55
Roll length........................................................ 24
U
S Ultrasonic sensors ........................................... 26
Safety ................................................................. 9 Unpacking........................................................ 29
Safety instructions ........................................... 11
Commissioning ............................................... 56 V
Electrical connection ...................................... 48 Voltage supply
General........................................................... 12 Connecting the voltage supply ...................... 54
Installation ..................................................... 14 Requirements of the supply grid ................... 54
Maintenance and cleaning............................. 61
Scope of delivery ............................................. 29 W
Securing hole template ................................... 39 Web center-line guiding .................................... 9
Sensor Web edge guiding ............................................. 9
Changing the mounting position ................... 43 Web running direction .........................23, 34, 59
Mounting ....................................................... 46 Web tension ................................................ 9, 24
Sensors ............................................................. 25 Weight ............................................................. 26
Definition Sensor 1 and 2................................. 23 Wiring sleeves
Optical ............................................................ 25 Use ................................................................. 50
Technical specifications ................................. 25

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Compact web guide control

Translation of the original instructions

3 Design and function 21

5 Transport, delivery and storage 28

EcoGuide compact web guide control 3/70

5.2 Scope of delivery ............................................................................. 29

10 Maintenance and cleaning 61

4/70 EcoGuide compact web guide control

10.3.3 Cleaning the sensors ....................................................................... 63

EcoGuide compact web guide control 5/70

1 About this document

6/70 EcoGuide compact web guide control

1.2 Target group

These instructions are directed to all persons that work with or on

1.3 Storage and distribution

1.4 Meanings of the safety instructions and symbols

Information that is essential for successful operation.

Information that makes operation easier.

Action requirements may include the following symbols:

1. Requirement for you to take actions. And ...

EcoGuide compact web guide control 7/70

2. …in the sequence specified.

1.4.3 Using the keys

Use of the keys is represented by the following symbols in these

Key combinations, keys have to be pressed simultaneously.

1.4.4 Operating states of LEDs

LED illuminated = active phase

1.5 Further information

8/70 EcoGuide compact web guide control

2.1 Intended use

EcoGuide compact web guide control 9/70

safety rules. Nevertheless, their use may constitute a risk to life

2.2 Non-intended use

2.2.1 Non-intended infringement of guidelines

■ Infringement of operating, maintaining or installation instruc-

10/70 EcoGuide compact web guide control

2.2.2 Non-intended operation

■ Private use of the product or its components

2.2.3 Non-intended modification of electronic data

■ No virus scanners, firewalls or similar items may be installed on

2.3 Safety instructions

EcoGuide compact web guide control 11/70

When installing and operating the EcoGuide compact web guide

2.3.1 General safety instructions

12/70 EcoGuide compact web guide control

► Cable connections between the individual components of the

EcoGuide compact web guide control 13/70

BST eltromat International GmbH is not liable for any damage

2.3.2 Safety instructions for installation

Before starting installation work:

14/70 EcoGuide compact web guide control

During installation work:

After completing installation work:

2.4 Qualification of personnel

The EcoGuide compact web guide control must only be transport-

EcoGuide compact web guide control 15/70

Instructed personnel have been instructed comprehensively by

Qualified personnel also have sufficient experience or practice in

Specialists with the following tasks by themselves due to their