Description B Edge Sensor FR 0801/0901 (infrared) Function Mounting Commissioning Operation Troubleshooting Maintenance Spare parts Wiring diagram Dimensions 10 Technical data FR 0801 en 6 7 8 FR 0901 BEA 084840-EN-03 Edge Sensor FR 0801/0901 Function 1.1 Purpose The FR 0801/0901 infra-red sensor senses the position of a web edge The magnitude and direction of any deviation is output in the form of a signal voltage When properly set, the sensor will detect web deviations of less than 0,1 mm 1.2 Mode of Operation The FR 0801/0901 edge sensor works according to an optoelectronic principle It emits infra-red light, which is reflected by a reflector The edge of the web passes between the edge sensor and the reflector Depending on how far the web protrudes into the light beam, the sensor picks up a greater or lesser amount of the reflected light (measurement of light quantity) The integral amplifier converts this „residual light“ received from the reflector into a positive or negative signal voltage The level and polarity of the signal voltage therefore indicates the position of the web edge Operating principle of the FR 0801/0901 edge sensor FR 0901 infra-red edge sensor FR 0801 infra-red edge sensor Web Web Reflector 1.3 Design The FR 0801/0901 edge sensor comprises a combined light source and receiver with built-in amplifiers The reflector is either a signal film or a triple film For instructions on replacing the reflector, refer to the section on maintenance The FR 0801 and FR 0901 edge sensors differ in design in terms of their lenses; the mode of operation is the same With its lens, the FR 0901 has a larger working range than the FR 0801 edge sensor Refer to the „Technical Data“ section B page BEA 084840-EN-03 Edge Sensor FR 0801/0901 Mounting The edge sensor and reflector are rigidly connected by a bracket; they can also be mounted separately The FR 0801/0901 edge sensor is largely insensitive to ambient light Nevertheless, when installing the sensor always make sure that neither artificial light nor sunlight shines directly into the sensor lens External light will result in a weaker output signal and thus impair the accuracy of the sensor Mounting: angle of inclination in relation to web Please also ensure that the FR 0801/0901 edge sensor is mounted at an angle of at least 5° with respect to the web (see diagram below) If the sensor and reflector are linked, they will both be tilted If they are mounted separately, you not need to adjust the reflector Edge sensor Angle with respect to web 5°, Web if surface is highly reflective, 20° Reflector mounted separately Reflector Signal film Reflector linked to sensor If the edge sensor is to be used for sensing a web with a highly reflective surface, you must angle the sensor at about 20° to the web (see diagram above) In this way you will avoid light being reflected from the web into the sensor and interfering with the sensor signal A sufficient amount of light is reflected to the sensor up to an angle of approximately 20° In this case, too, if the sensor and reflector are linked, they will be tilted together If they are mounted separately, you not need to adjust the reflector On mounting, observe the following distances: Tripel film Edge sensor to web: at least 10 mm Signal film to web: at least 20 mm Triple film to web: at least 40 mm Edge sensor to signal film: between 50 and 400 mm Edge sensor to triple film: between 50 and 1200 mm BEA 084840-EN-03 B page Edge Sensor FR 0801/0901 FR 0801 FR 0901 Min 10 mm Signal film: 20 mm Triple film: 40 mm Reflector Signal film 50 to 400 mm Triple film 50 to 1200 mm Mounting: angle and distances Connection Connect the edge sensor to the switch panel with the spiral cable Note: Commissioning The sensor housing must be electrically connected to machine ground (for example by the metal sensor bracket) If you receive your FR 0801/0901 edge sensor together with a system from Erhardt + Leimer, and if the edge sensor and reflector are already mounted, you not need to make any adjustments on the sensor You can put the sensor into operation immediately (see section on operation) Important: 3.1 Setting the amplification factor for the sensor signal B page BEA 084840-EN-03 If you mount the edge sensor on the system yourself, or if you change the distance between the sensor and reflector, you must re-adjust the sensor You not have to make this setting unless you are using a triple film as the reflector and the distance between the edge sensor and triple film is less than 400 mm Edge Sensor FR 0801/0901 Distance from sensor to triple film Greater than 400 mm Less than 400 mm On the edge sensor, unscrew the lid on which the LED is fitted The VK 2601 amplifier card is beneath the lid (see diagram on left) Set the amplification with the aid of bridge X If the distance between the edge sensor and the triple film is less than 400 mm, you must remove bridge X from position (factory setting) and insert it in position Bridge X Important: If the distance between the sensor and the reflector is increased, the proportional band is also increased, thus making correction less precise VK 2601 amplifier card beneath the sensor lid 3.2 ������������������������� Adjusting the sensor output signal The output signal is dependent on the strength of the light that is reflected from the reflector, and is therefore also dependent on the distance from the sensor to the reflector Adjust the sensor output voltage with a multi-function instrument (multimeter; internal resistance 3,3 kW/V) according to the following instructions: Potentiometer R 10 Potentiometer R Potentiometer R 10 Potentiometer R Adjustment of the output signal on the FR 0801/FR 0901 sensor - Switch on the edge sensor It is ready for operation immediately after it is switched on - Clean the lens of the sensor and the reflector with a soft, clean cloth - Connect the multimeter at the free cable end between V (white core) and signal output (brown core) - On the side for the plug there are two bores through which you get to the potentiometers R and R 10 with the help of a screw driver These potentiometers are used to set the sensor output voltage First set the positive signal output voltage using potentiometer R 6, (see diagram on left) To this, the light beam from the edge sensor must be allowed to strike the reflector in full Turn the metal screw on the potentiometer until the output voltage is +8 V Turn the screw slowly, because the sensor signal has a reaction time lag - Now set the negative output voltage To make this adjustment, insert a piece of material between the reflector and the edge sensor; the light beam to the reflector must be fully blocked off Set the negative output voltage with potentiometer R 10 This potentiometer is located on the VK 2601 amplifier card alongside the LED (see diagram on left) Turn the metal screw until the output voltage is -8 V Turn the screw slowly, because the sensor signal has a reaction time lag - Check the output voltage once more by passing a test sample in and out of the light beam If you not obtain readings of +8 V and -8 V, you may need to make re-adjustments BEA 084840-EN-03 B page Edge Sensor FR 0801/0901 Operation Off Web Green Setting the sensor to the edge of the web It is possible to adjust the edge sensor to the edge of the web quickly with the aid of the red/green LED on the lid To this, set your guide unit (guider roller or narrow web guider) to „midway position“ If you have a sensor remote control unit connected, this should be set to „0“, i.e in the centre If the web obscures more than half of the light beam, the LED shows a red light, while if it obscures less than half of the beam, the LED shows a green light (see diagram on left) A deviation of approximately 0,3 mm is sufficient to cause the LED to light up The edge of the web should be precisely in the centre of the optical system In this position the LED does not light up The output voltage is then V, in other words no signal Red Position of the web Troubleshooting If the sensor fails to function correctly, try to find the cause by checking the following in sequence: - - - - - Is the operating voltage connected? Is the edge sensor’s lens clean? Is the reflector clean and in good condition? Is the sensor housing connected to machine ground? Is the edge sensor adjusted correctly with respect to the reflector? - Does the LED light up red or green when you move a piece of paper backwards and forwards through the sensor’s light beam? - Is there a measurable output signal? If the answer to even the last question is „yes“, the fault does not lie in the FR 0801/0901 edge sensor Maintenance To ensure proper function of the sensor, you should clean the lens of the sensor from time to time with a soft, clean cloth Do not use solvents Check from time to time that the reflector is not soiled If necessary, clean it with a dry cloth, or, if greasy, with domestic washing-up liquid B page BEA 084840-EN-03 Edge Sensor FR 0801/0901 Protective film Signal film If the reflector is heavily worn, it must be replaced Proceed as follows: - The reflector consists of a signal film (triple film) and a protective film Remove both films - Clean the base thoroughly, removing all grit, dust and grease Protective film Triple film - Now adhere first the signal film (triple film) to the dry reflector bracket or base Make sure that the sensor axis is aligned with the centre of the film - Finally adhere the protective film on the signal film (triple film), making sure that there are no bubbles or creases The protective film should overlap the signal film (triple film) uniformly (see diagram on left) Replacing the reflector Spare parts OK 0701 023101 VK 2601 023102 Accessories Spiral cable 300 to 1500 mm long 029895 Spiral cable 500 to 2500 mm long 023884 Reflector (comprising triple and protective films, please specify length) 108228 Wiring diagram WS BR GN GE GR RS BL SW +12 V 0V -12 V ±8 V Signal +12 V 0V -12 V white brown green yellow grey pink blue black Socket for FR 0801/0901 BEA 084840-EN-03 B page Erhardt+Leimer GmbH D-86136 Augsburg GERMANY Phone +49 (0)821 2435-0 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com Dimensions FR 0801 edge sensor FR 0901 edge sensor 10 Technical data Signal output voltage -8 V V +8 V (±0,5 V) Proportional band FR 0801 Distance sensor to reflector = 200 mm ±8 mm (±10 %) Proportional band FR 0901 Distance sensor to reflector = 200 mm ±12 mm (±10 %) Ambient temperature max 60° C Protection class IP 40 Subject to technical modifications without notice