Troubleshooting

WARNING

Danger to life and assets caused by incorrect rectification of malfunctions!

▶Only allow qualified personnel instructed by BST service staff or authorized personnel to rectify malfunctions.

▶Only rectify malfunctions using the following measures or follow the instructions of BST customer service.

▶Observe all safety instructions in the chapter Maintenance and cleaning, see Maintenance and Cleaning.

Typical faults with their possible causes and measures for elimination are specified in the following.

▶For further information, please contact BST Customer Services, address see Customer Services.

Fault
Possible causes	Measures for eliminating the fault

The actuator / the guiding device trembles.
Guiding system overdrive.	Optimize the controller gain. See Optimizing the Controller Gain. Perform material setup. See Performing the Material Setup.

The actuator / the guiding device reacts too slowly or the guiding operates incorrectly.
The controller gain has been set too low.	Optimize the controller gain. See Optimizing the Controller Gain. Perform material setup. See Performing the Material Setup.

The actuator / the guiding device does not carry out any guiding movement.
An incorrect actuator has been selected during commissioning.	▶Check the setting of the DIL switch S4 in the controller. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.
The controller gain has been set too low.	▶Optimize the controller gain. See Optimizing the Controller Gain.

In operating mode Automatic the actuator / the guiding device moves to an end position and remains stationary there (with material web threaded in).
A material setup was not run after the material was changed.	▶Perform material setup. See Performing the Material Setup.
The actuator guiding direction is incorrectly set.	▶Reverse the guiding direction of the actuator. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

In operating mode Center positioning the actuator / the guiding device moves to an end position and remains stationary there.
The actuator guiding direction is incorrectly set.	▶Reverse the guiding direction of the actuator. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.
The servo center transducer used (OMG 4, OMG 8, CK 37) has been installed incorrectly.	▶Check the installation position of the servo center transducer.

	The actuator / the guiding device does not carry out any guiding movement. The warning symbol Motor overcurrent is shown in the display.
The guiding device has moved into an end position or is blocking the electric motor powered actuator.		▶Activate the actuator in the opposite direction. The warning symbol will be deleted automatically.
The guiding device moves with difficulty.		▶Check the ball bearings of the guiding device.
The material setup for the connected sensors has been carried out incorrectly.		▶Perform material setup. See Performing the Material Setup.

	An actuator with position feedback does not carry out any guiding movement. The symbol Limit switch active is shown in the display.
The actuator has reached a software limit switch. Driving the actuator in the corresponding direction is prevented.		▶Activate the actuator in the opposite direction. The symbol is deleted automatically.

	The actuator / the guiding device does not carry out any guiding movement. The warning symbol Controller interlock is shown in the display.
The controller interlock is active.		Deactivate the controller interlock for all operating modes (bridge terminals 1 and 2). Deactivate the controller interlock for the automatic operating mode. See truth table, installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

	The actuator / the guiding device does not carry out any guiding movement. The warning symbol Motor control timeout is shown in the display.
The actuator has been activated uninterrupted in the same direction for more than 50 seconds.		Activate the actuator in the opposite direction. Check the actuator for damage (e.g. broken spindle)
No material web has been threaded in.		▶Thread up the material web.
There is no web tension present.		▶Check the web tension.

	The actuator / the guiding device does not carry out any guiding movement. The warning symbol Faulty bus connection on the actuator is shown in the display.
Fault in the bus connection between the controller and actuator.		▶Check the cable connection between the controller and actuator (Drive Module 160).

	The EMS 23 actuator does not carry out any guiding movement. The warning symbol External motor output stage fault is shown in the display.
The hardware power monitoring of the external motor output stage Drive Module 160 has detected a fault (e.g. overload).	Check the cable connections between the controller, external motor output stage Drive Module 160 and electric motor powered actuator EMS 23. Read the separate operating instructions of the external motor output stage Drive Module 160 (document number MD.359).
The external motor output stage Drive Module 160 is defective.	Check the external motor output stage Drive Module 160 and replace it if necessary. Contact BST customer services.

The EMS 23 actuator does not carry out any guiding movement.

The warning symbol External motor output stage fault is shown in the display.

The hardware power monitoring of the external motor output stage Drive Module 160 has detected a fault (e.g. overload).

Check the cable connections between the controller, external motor output stage Drive Module 160 and electric motor powered actuator EMS 23.

Read the separate operating instructions of the external motor output stage Drive Module 160 (document number MD.359).

The external motor output stage Drive Module 160 is defective.

Check the external motor output stage Drive Module 160 and replace it if necessary.

Contact BST customer services.

The actuator / the guiding device has moved to an end position and the motor switch off does not function. The LEDs of keys or on the control panel and the screen display flash.
As a result of the increased power consumption of the actuator, the supply voltage (24 V⎓) falls below the permissible voltage range.	▶Check the power pack.

The center position of the guiding device is not approached correctly.
When using an actuator with position feedback the servo centre transducer (OMG 4, OMG 8, CK 37) has inadvertently been selected during commissioning.	▶Check the settings of the DIL switches S4.7 and S4.8. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

All the settings for actuator, sensors, servo center transducer, etc. are correct, but the unit does not control.
The controller gain was inadvertently reduced to the minimum value (0.2). No guiding takes place in Automatic operating mode.	▶Set the controller gain. See Optimizing the Controller Gain.

A connected edge sensor is not working.
During commissioning, the incorrect settings have been met for the edge sensor connected.	▶Check the settings of DIL switch S5. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

	An exclamation mark is shown in the sensor symbol of a digital edge sensor in the display.
Malfunctions have occurred several times in the communication between the controller and a digital edge sensor.		Check the cable connection between the controller and edge sensor. To delete the malfunction display switch off the voltage supply of the controller and then switch it back on.

Web edge guiding with Sensor 1 () or Sensor 2 () cannot be switched on.
The respective sensor (Sensor 1 or Sensor 2) was not activated during commissioning.	▶Check the settings of DIL switch S5. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

	The warning symbol Supply voltage is shown in the display.
The supply voltage of the controller is outside the permissible range.		Check the power pack. Check the mains wiring.

	The controller does not react to any operation. A control panel symbol with a padlock is displayed.
The keyboard interlock is active.		▶Deactivate the keyboard interlock (remove the jumper between terminals 17 and 20).

	If the SETUP button is pressed, the SETUP key symbol with a padlock is displayed.
The setup lock is active.		▶Deactivate the setup lock. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

A shifting of the guiding setpoint of the web using the arrow keys on the control panel is not possible.
The optional electronic remote precision adjustment EFE 1 is connected to the controller.	▶Shift the guiding setpoint using the potentiometer of the electronic remote precision adjustment EFE 1. See EFE 1.

	The controller does not react to any operation. The warning symbol Faulty bus connection is shown in the display.
Fault in the bus connection between the controller and control panel.		Check the cable connection between the controller and control panel. Check the correct cable connection on terminal strip X8. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.
The device address of the controller or the control panel has not been set correctly.		▶Check the setting of rotary switch S1 of the controller and the control panel. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.
The internal terminating resistor in the controller and in the control panel is not set correctly.		▶Check the setting of the internal terminating resistor in the controller and in the control panel. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

The controller does not respond to any operation.
A remote control has been connected to the controller. The keys on the control panel are locked.	▶Deactivate the remote control (S5.5 = ON). See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.
The device address of the controller or the control panel has not been set correctly.	▶Check the setting of rotary switch S1 of the controller and the control panel. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

The controller cannot be switched via the remote control function.
The remote control function is deactivated.	▶Check the setting of DIL switch S5.5. See installation and commissioning manual ekr 500 digital Unit Touch, document number MD.497.

Undefined behaviour of the controller.
The length of the connecting cable between the controller and the control panel is more than 20 m.	▶The maximum permissible length of the connecting cable of the control panel must be observed.
The controller or the control panel has been mounted in the immediate vicinity of high-voltage components or lines.	▶Maintain a minimum distance of 100 mm to high-voltage components or lines.

	During line and contrast scanning using the CLS Pro 600 line and contrast sensor an exclamation mark is displayed behind the symbol for Sensor 3.
The printed line / contrast transition to be scanned is not detected by the line and contrast sensor.		Check print for missing print. Repeat the setup on sensor CLS Pro 600 (see the separate operating instructions of the line and contrast sensor).
The printed line / contrast transition to be scanned is located outside the scanning area of the CLS Pro 600 line and contrast sensor.		Correct the position of the CLS Pro 600 line and contrast sensor across the web running direction. Read the separate operating instructions of the CLS Pro 600 line and contrast sensor (document number MD.323).

	During line, contrast or feature scanning using the CLS CAM 100 object sensor an exclamation mark is permanently displayed behind the symbol for Sensor 3.
The guiding criterion to be scanned (printed line, contrast transition or print feature) is not detected by the object sensor.		Check print for missing print. Repeat the setup on sensor CLS CAM 100 (see the separate installation and operating manual of the object sensor).
The guiding criterion to be scanned (printed line, contrast transition or print feature) is located outside the scanning area of the CLS CAM 100 object sensor.		Correct the position of the CLS CAM 100 object sensor across the web running direction. Read the separate installation and operating manual of the CLS CAM 100 object sensor (document number MD.577).
When scanning a print feature, the web does not move or moves very slowly.		▶Increase the web speed. Note: The permanent or long-lasting display of the exclamation mark is not an error in this case!

	With the web edge or the web center-line guiding with CCD camera, an exclamation mark is shown in the display behind the symbol of the CCD camera.
The web edge to be scanned is not detected by the CCD camera.		▶Reconfigure the CCD camera. See separate instruction manual CCD camera CCDPro 30000/5000 (document number MD.167) or CCD CAM 100 (document number MD.465).
The web edge to be scanned is located outside the measuring range of the CCD camera.		Position of the CCD camera perpendicular to the web running direction. Read the separate instruction manual CCD camera CCDPro 30000/5000 (document number MD.167) or CCD CAM 100 (document number MD.465).