Digital controller RK 4004Search for edge:The sensor searches for and follows the web edge until the operatingmode is changed by,e.g.a guider enable.1.4 Control structure with con-In a control structure for proportional actuators the web or tool actualstant controlling for pro-position value is pared with the required set position value and,portional actuatorsin the event of a deviation.it is transmitted to a P position controlleras a control difference.The resultant set speed value is paredwith the actual speed value and transmitted to the PI speed control-ler.The latter emits a pulse width-modulated signal at the outputstage.The following are available as proportional actuators:DRS pivoting frame,WS turning rod,SRS steering roller,WSSwinding station,SVS push roller SVS and VSS positioning and fol-low-up controller.182023172224Control structure legend1 Operating mode15 Counter2 Actuator position controller16 Incremental encoder3 Max.variable actuating speed in manual17 Web position controller4Speed controller18 Max.variable actuating speed in automatic5 Variable current controller19 Memory mand at stop6 Power output stage20 Right edge sensor7 Gearing with spindle21 Left edge sensor8 Right end position22 Sensor selection(right web edge,left web edge,web center)9 Center position23 Web offset10 Left end position24 Oscillation generator11 Right offset25 Current controller12 Left offset13 Actual position memory14 Actual speed value recordingJ Page 4/68BEA-250482-E-25Digital controller RK 40041.5 Control structure with con-In a control structure for a support beam a set speed value is deter-stant controlling for sup-mined on the basis of the sensor signal via the P position controllerport beamsthat is transmitted to the speed controller.The resulting set speedvalue is pared to the actual speed value and transmitted to thePI speed controller.The latter emits a pulse width-modulated signalat the output stage.In"search for edge"or "hybrid"modes the sen-sor is driven to follow-up the web edge.Available as proportional actuator:Support beam VSS12Control structure legend1 Operating mode11 Support beam position controller2 Sensor12 Actual speed value recording3 Counter13 Incremental encoder4 Web offset14 Max.variable actuating speed in search for edge mode5 Edge sensor position controller15 Variable current controller6 Support beam speed controller16 Current controller7 Power output stage17 Variable actuating speed during positioning8 Sensor zero point detector18 Oscillation generator9 Memory for edge position10 Park positionBEA-250482-EN-25J Page 5/68Digital controller RK 40041.6 Control structure with con-In the case of a control structure for integral actuators the web actualstant controlling for inte-position value is pared to the required web set position valuegral actuatorsand,in the event of a deviation,it is transmitted as a control differ-ence to a P position controller.The latter provides the necessary setposition value for the actuator.The cumrent actual actuator positionvalue is pared to the required set position value and transmittedas a control difference to the actuator position controller.The lattergenerates the set speed value which is pared to the actual speedvalue,the difference being fed to the PI speed controller which emitsa pulse width-modulated signal at the output stage.Available integral actuators:SWS segmented roller guider,VGA pivoting roller,BCS edge andwidth spreader2mode19182023172224Control structure legend1 Operating mode14 Actual speed value recordingActuator position controller15 Counter3Max.variable actuating speed in manual16 Incremental encoder4Speed controller17 Web position controller5Variable current controller18 Max.variable actuator speed in automatic6Power output stage19 Memory mand at stop7Gearing with spindle20 Right edge sensor8 Right end position21 Left edge sensor9 Center position22 Sensor selection(right web edge,left web edge,web center)10 Left end position23 Web offset11 Right offset24 Oscillation generator12 Left offset25 Current controller13 Actual position memoryJ Page 6/68BEA-250482-EN-25Digital controller RK 40042.Type overviewThe following table provides an overview of the most mon digitalcontrollers.The individual digital controllers (DC)are listed in the ver-tical column.The crosses mark the ponents belonging to them(AK.,LK....,etc.).TypeRK4004AK4002LK4203RT4019D02000AK4014DC0310DC0311DC0340XDC0341DC0360DC0361XXDC1310DC1340XDC2340DC23413.AssemblyController card RK 40..is usually mounted in a sheet steel housingor E+L device.If the controller card is supplied on its own it should be mounted in acontrol cabi away from heavy current-camying modules.lI The maximum distance to the DC actuator must not exceed 10 m.BEA-250482-EN-25J Page 7/68Digital controller RK 40044.InstallationConnect electrical leads according to the attached wiring diagram.Shield and run signal lines away from heavy current-carryingleads.The connection line between the controller card and DC actuatormay be run in one lead up to a length of 3 m.From a distance of3 m to 10 m the motor and incremental encoder lines must berun separately.The CAN bus must not exceed a total maximum length of 160 mand the SPI bus a total maximum length of 0.2 m.X 5 RightX6 LeftX 12 CAN connectiondigitaldigitalX15 Fansensorwithout LED displaysensorfor internal deviceworkingX7CAN connectionwith LED display回回回for CAN deviceX 21 Supply voltageconnectorfor further E+LX11SPI busmodulesX9serial busX 13 Supply voltagefor further E+LmodulesX8Analogue cardAK4002(only when ana-X1Operating volt-logue sensors are3used)ageX 14 External configu-ration adapterX 10 Optical incre-mental encoderX 2 DC actuatorX3Command sta-X 4 ReferenceX 20 End switchand incre-tion for webswitch,guidermental en-lock and endcoderor signal forposition signalpath-dependentoscillationRK 40..terminal assignmentsThe wiring diagram indicates which connectors are assigned.The guider lock is intended for on-site requirements where the actua-tor is to be stopped in its current position.If the guider lock is closed(make contact)the actuator remains in this position until the contactis open again.J Page 8/68BEA-250482-E-25Digital controller RK 4004X 1 to X 21TeminalNo.InputOutputAssignment1X+24 V DC supply voltage23GroundX21XDC actuatorDC actuatorIncremental encoder on DC actuator track A4Incremental encoder on DC actuator track B5+24V DC6X312Programmable input(default"Web offset or path-dependent")or("Oscillation signal")or("automatic mode signal (for minimum operation only)")3Sensor range limit or range limit for D.C.actuator4(possible only in bination with web offset RE 1721)1Programmable input(default"Guider lock")20 V potential 0 V for controller lock3+24 V DC reference switch4Programmable input(default"Reference switch signal")50 V reference switch6+24V DC7Programmable input(default"Actuator end position signal")8CAN High2CAN Low3LED+4LED-X1012(Index)-3Track A4+5V5+Track BX121CAN High3free4freeX131X2X151+12V2Switch output for additional fanX201+24VProgrammable input(default"Actuator 2nd end position signal")4Programmable output(default"System on stand-by)X211+24V/I max 1.0A2BEA-250482-EN-25J Page 9/68Digital controller RK 40044.2 Setup operationThe three keys and the displays are used as the setup control panel.The key assignment (setup,decrease/increase value)is indicated inthe illustration opposite.The following applications are possible:4.2.1 Setting the controller card device address4.2.2 Current error display4.2.3 Setting parametersSETUP4.2.1 Set controller cardPrior to missioning the device address of controller card RK 4004device addressmust be checked and changed as necessary.Press both keys "decrease value"and "increase value"at thesame time.The group number is indicated via the "decreasevalue"key and the device number via the "increase value"key.If both keys are held down for longer than approx.4 seconds thedevice address will start to flash.If the device address deviates from the required address it may bechanged via the keys.If none of the keys are actuated the device address will be savedafter approx.20 seconds have elapsed and a software reset istriggered.J Page 10/68BEA-250482-EN-25Digital controller RK 40044.2.2 Current error displayIn normal circumstances the display on the controller card indicatesonly three dots.These three dots signal that no errors are present.Aflashing number signals an error.The number indicates the errorcode.If several errors are present at the same time,the error withthe highest priority will be indicated.If this error is no longer present,the display will indicate the next error.Below is a list of possible errors:No.Error display inDescriptionOutput atCANMONterminal X 20.4UDC-power low19.5 VDC operating voltage not attained02UDC-power high30.5 VDC operating voltage exceeded03I motor highset maximum cut-off current exceeded4Temp case highheat sink over 70 oC05encoder faultincremental encoder motor fault6encoder inversincremental encoder motor inverted1sensor R faultno message from right sensor8sensor Lfaultno message from left sensor9gearconstant faultcalculated gear constant produces impermissible value10Motorline faultmotor line interrupted012powerstage defectmotor power stage defective013Motor blockedmotor blocked due to overloading (I max.&n=0)0Attention!output is set after 5 seconds only14ref.switch errorseveral reference switch errors detected.15end switch errorend position proximity switches incorrectly configured1624 V ext.faultext.supply voltage overloaded.023motor protectmotor protection04.2.30 utput X20.4In the case of certain errors (see table)output X 20.4 is switched to"0".The internal switch on the controller card that furnishes a con-nection to ground is opened.The following circuit variants are remended:X20X20+24V-+24Ve-SPSLamp"ON system on stand-byPLC"1"=system on stand-byLamp"OFF"errorPLC "0"=errorBEA-250482-EN-25J Page 11/68Digital controller RK 40044.2.4 Parameter settingAll parameters in the CAN work may be selected and changed bythe three keys.The following flow diagram illustrates basic operationwith the setup editor:Basic operation in setup mode:Para-ParametermetervalueStart setup mode:press the setup and addition-ally the increase value key (press the setup keyfirst).The green LED on the setup key will flashStart setup modeEnter device number:press and hold down thesetup key and select parameter 0 via the increasevalue key.Release the setup key again and enterthe device number via the increase or decreaseEnter device number.0value keys (device number is specified in theblock diagram)Enter group number:press and hold down thesetup key and select parameter 1 via the increasevalue key.Release the setup key again and enterthe group number via the increase or decreaseEnter group numbervalue keys (group number is specified in the blockdiagram)Select and change parameters:press and holddown the setup key and select the required pa-Select parameter△rameter via the increase value key.Release thesetup key again and enter the required parametervalue via the increase or decrease keys.Change parameter value△Incorrect parameter changes may impairthe function of the entire systemMay param-yeseter value bechangednoSelect expanded setup mode:select devicenumber X.5,then press and hold down the setup△key and select parameter 3 by pressing the in-Expanded setup mode0crease value key.Release the setup key againand enter parameter value 42 via the increase ordecrease value keys.SelectfurtheryesparametersnoQuit setup mode:select device number X.5,thenpress and hold down the setup key and select△3parameter 3 by pressing the increase value key.Release the setup key again and enter parameter1 by pressing the increase or decrease value key.Quit setup modePress and hold down the setup key and press the△increase value key once.Release the setup keyagain.ETUP0-X is used as a place retainerJ Page 12/68BEA-250482-EN-25