Assembly manual

Product line vision

iPQ-Check
iPQ-View
webvideo_star TTB

© BST eltromat International GmbH 2014

Heidsieker Heide 53
33739 Bielefeld
Germany 969790505002
 vision TOC

Table of Contents

1 General Assembly Instructions ________________________________ 1

1.1 Structure of the Assembly Manual _______________________ 1
1.2 General Instructions ___________________________________ 1
1.3 Qualified Personnel____________________________________ 2
1.4 Designation___________________________________________ 2
1.5 General Conditions ____________________________________ 2
1.6 Structure of the safety instructions ______________________ 3
1.6.1 Warning of danger to persons _______________________ 3
1.6.2 Warning of damage to assets _______________________ 4
1.6.3 Other information _________________________________ 4
1.7 Liability ______________________________________________ 5
1.8 Warranty and guarantee ________________________________ 5

2 System review and safety instructions __________________________ 6

2.1 Components of a web monitoring system
(iPQ-View/webvideo_star TTB)____________________________ 7
2.2 Components of the iPQ-Check system ____________________ 8
2.3 Safety instructions ____________________________________ 9

3 Assembly of the system _____________________________________ 10

3.1 Assembly of the image recording unit (iPQ-Check) ________ 10
3.2 Assembly of the traverse bar with camera ________________ 12
3.3 Assembly of the background plate (optional) _____________ 13
3.4 Assembly of the image processing unit (iPQ-Check) _______ 15
3.5 Assembly of junction box (optional) _____________________ 17
3.6 Assembly of the measuring wheel with shaft encoder
(iPQ-Check) __________________________________________ 18
3.7 Shaft encoder assembly (iPQ-View/webvideo_star TTB) ____ 21
3.8 Control Unit Assembly (option) _________________________ 23
3.9 Mounting Plate Assembly (option) ______________________ 25
3.10 Laying and connecting cables _________________________ 26

4 Remote service and other network functions____________________ 28

4.1 Integration of the BST eltromat router
(INSYS MoRoS Modem ) ______________________________ 28
4.2 Direct network integration of an BST eltromat system _____ 30

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1 General Assembly Instructions

1.1 Structure of the Assembly Manual

The present assembly manual is subdivided into four chapters:

• Chapter 1: This chapter contains general advice and requirements

regarding the assembly of BST eltromat systems. Moreover, the
structure of safety instructions will be explained.
• Chapter 2: This chapter gives an overview of the system components.
Moreover, this chapter lists all safety instructions, which indicate
possible dangers.
• Chapter 3: This chapter describes the assembly process. In addition,
the chapter contains cross-references to other assembly instructions
of other manufacturers, whose products are part of the described
BST eltromat system.
• Chapter 4: This chapter describes the integration of the BST eltromat
system into a network (required for remote service and other network
functions).

1.2 General Instructions

The present assembly manual describes the operating routines for the
safe and proper installation and commissioning / start-up of the system.
For this purpose, adhere to the step-by-step operating sequence.

• This assembly manual describes the product families iPQ-View/

webvideo_star TTB and iPQ-Check. However, some parts of the
operating manual are only valid for one of the two product families.
These chapters and sections are marked by the coloured writing iPQ-
View/webvideo_star TTB and/or iPQ-Check.

• Reading this assembly manual attentively is indispensable for effec-

tive and fault free assembly of this system.

• Ensure that this assembly manual is available to all persons assem-

bling this system. Observe all relevant information and instructions.

• Ensure that this assembly manual is always complete and in a

perfectly legible condition.
• Only operate the system when in a perfect condition.This system is
designed as a unit to be fitted to a complete machine line. Do not
start up this machine within CENELEC member states until the
complete machine is approved to meet the EC machine directives.

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1.3 Qualified Personnel

Only allow qualified personnel to install and service the system. For the
purpose of this documentation these are persons who:

• are familiar with the general safety regulations (in particular with the
accident prevention regulations),
• are trained for installation and commissioning of mechanical and
electrical components,
• have familiarised themselves with this assembly manual
• If the system is applied in explosive areas, please make sure that
this person has also

1.4 Designation

• The contents on the type plate clearly identifies the system.

• Refer to the enclosed EC Conformity Declaration for the CE symbol
of identification.

System manufacturer: BST eltromat International GmbH

Heidsieker Heide 53
D-33739 Bielefeld
Service: Tel.: +49 - 52 08 - 987 - 680
Fax: +49 - 52 08 - 987 - 349
E-Mail: service@eltromat.de

1.5 General Conditions

• Only operate the system in accordance with the intended use stated
in the documentation. Expressly agree any exceptions with BST
eltromat.
• Perfect and safe operation of the system requires the correct trans-
port, erection and installation as well as careful operation and correct
maintenance and repair.
• Installation, commissioning / start-up and operation are only permis-
sible in closed production facilities.
• Only use original BST eltromat spare parts. Only this will ensure that
function safety is maintained.
• Unauthorised modifications (mechanical / electrical) are expressively
forbidden. The warranty will automatically become null and void if
the system is modified in any way.

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• For installation, commissioning / start-up and operation of this system

adhere to the current valid safety and accident prevention regulations.
• Electrical components may only be assembled in de-energized con-
dition.
• Motors must be assembled in accordance with the assembly method
(flange / foot assembly) the motor manufacturer stipulates / provides
in his own assembly manual.
• All components of the incomplete system must be assembled so that
they do not affect the free moving space of the staff and of other
machine components.
• The incomplete machine may not be started before all mounted parts,
in particular all covers, safety elements (e.g. emergency stops etc.)
and safety sensors have been assembled and an operational check
has been carried out.

1.6 Structure of the safety instructions

The safety instructions in this assembly manual are of a uniform structure

in accordance with the following examples.

Signal word! Information text

• The pictograph indicates the type of danger.

• The signal word indicates the severity of the danger.
• The information text describes the individual danger and provides
instructions on how to avoid danger.

1.6.1 Warning of danger to persons

Pictographs

Warning of a dangerous point

Warning of dangerous electrical voltage

Warning: danger of entanglement

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Signal words

DANGER! Warns of imminent danger. Consequences of non-observance: death or

serious injury.

WARNING! Warns of a possibly very dangerous situation. Possible consequences of

non-observance: death or serious injury.

CAUTION! Warns of a possibly dangerous situation. Possible consequences of non-

observance: Slight, minor injuries.

1.6.2 Warning of damage to assets

Pictograph

STOP Warning of possible damage to assets.

Signal word

STOP! Warns of possible damage to assets. Possible consequences of non-

observance: Damage to the plant or its surroundings.

1.6.3 Other information

Pictographs

Additional information, instructions and tips.

Cross reference to further and / or related chapters with details of the

chapter number and chapter heading.

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1.7 Liability

The supplied documentation was created with utmost care. Deviations,

however, may occur due to the continuous development of the described
products. If errors are detected in the documentation or in the event of
update according to the technical progress, we reserve the right for
modifications at any time and without prior announcement. No claims
can be made for modification or correction on products already delivered.

Furthermore, the General Sales and Delivery terms of BST eltromat apply.

1.8 Warranty and guarantee

The General Sales and Delivery terms of BST eltromat as well as the
terms of the individual order apply.

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2 System review and safety instructions

Review This chapter gives a review of the components of the system. Moreover,
this chapter contains an overview of all safety instructions which must
be observed for the assembly of the system.

This assembly manual describes the product families iPQ-View/webvi-

deo_star TTB and iPQ-Check. However, some parts of the operating
manual are only valid for one of the two product families. These chapters
and sections are marked by the coloured writing iPQ-View/webvideo_star
TTB and/or iPQ-Check.

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2.1 Components of a web monitoring system

(iPQ-View/webvideo_star TTB)

A web monitoring system consists of the following components:

• Operating elements and data processing hardware

as single components or built into a control unit,
• Camera(s) on traverse bar(s),
• shaft encoder,
• Junction box for easy cabling (optional)

In addition, different terminal boxes are provided in case the web

monitoring system is used in an explosive area. It is possible to have the
construction groups delivered on mounting plates instead of in a control
unit. The following image shows an example of the different assembly /
installation locations of a web monitoring systemthe iPQ-Check system.
The displayed printing press is a general example and propably does not
conform to the assembly of your printing press.

Fig. 2.1

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2.2 Components of the iPQ-Check system

A web monitoring system consists of the following components:

• Operating elements as single components or built into a control unit,

• image recording unit,
• image processing unit,
• Camera(s) on traverse bar(s) (optional),
• shaft encoder,
• Junction box for easy cabling (optional)

In addition, different terminal boxes are provided in case the web

monitoring system is used in an explosive area. It is possible to have the
construction groups delivered on mounting plates instead of in a control
unit. The following image shows an example of the different assembly /
installation locations of a web monitoring systemthe iPQ-Check system.
The displayed printing press is a general example and propably does not
conform to the assembly of your printing press.

Fig. 2.2

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2.3 Safety instructions

The following safety instructions must be observed for the assembly of

the system:

WARNING! Guarantee security at the components assembly location

before starting the assembly works. During the entire assembly works,
the printing press must be fully stopped and secured against restart.
Possible consequences of non-observance can be death or serious injury.

WARNING! Elecrical voltage! Guarantee security at the connection

points by means of de-energizing the circuits and secure them against
recharge of voltage! Death or serious injury can be consequences of non-
observance.

CAUTION! Attention: Do not expose the cables to mechanical forces

(e.g. pulling, folding, crushing, stretching or twisting)!

CAUTION! In order to avoid accidents or damages, a second person is

needed to transport and to assemble the traverse bar.

CAUTION! Danger of crushing! Danger of injury, ensure that no body

parts are within the danger zone of the traverse bars.

CAUTION! Never transport the control unit, the image recording unit
and the system cabinet of the image processing unit by means of pure
muscle strength. Use only appropriate means of transport such as fork
trucks, elevating trucks and truck cranes. Back damages and other
injuries can be consequence of non-observance.

STOP! In order to avoid damages on the system, never cover the

ventilators and fences of the control unit!

STOP! Affix the back plane of the system cabinet of the image processing
unit to a massive wall or another surface being likewise solid. Therefore
use the four included wall mount holders. If the system cabinet is not
fixed, the system cabinet has no save position if the doors are opened.

STOP! Be careful when transporting and assembling the shaft encoder.

Protect the shaft encoder against impacts and do not put weight on the
encoder shaft to avoid damages. Consider the maximum offsets in order
to avoid a damage on the shaft encoder coupling.

When choosing the assembly location, consider the respective compo-

nents machine category!

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3 Assembly of the system

Review This chapter describes the assembly of all components of the system.
All requirements the assembly / installation location needs to fulfill will
be cited. Moreover, important safety instructions will be given and, if
necessary, the action steps in particular will be described.

This assembly manual describes the product families iPQ-View/webvi-

deo_star TTB and iPQ-Check. However, some parts of the operating
manual are only valid for one of the two product families. These chapters
and sections are marked by the coloured writing iPQ-View/webvideo_star
TTB and/or iPQ-Check.

3.1 Assembly of the image recording unit (iPQ-Check)

Review The image recording unit is an important component of the 100% print
inspection. It contains multiple cameras for recording the web as well
as one ore more LED rows for illumination. The image recording unit is
mounted across the web on the machine stand. An optional transillumi-
nation unit is available for the illumination of translucent materials. This
transillumination unit is mounted opposite to the image recording unit,
thus the printed web runs between the image recording unit and the
transillumination unit. For easy alignment of the image recording unit,
alignment tools are provided to fix the image recording unit to the
machine stand. The number of the alignment tools depends on the
number of the holding brackets on the image recording unit.

Fig. 3.1

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Safety instructions

WARNING! Guarantee security at the assembly location of the image

recording unit before starting the assembly works. During the entire
assembly works, the printing press must be fully stopped and secured
against restart. Possible consequences of non-observance can be death
or serious injury.

ATTENTION! Never transport the image recording unit by means of pure

muscle strength. Use only appropriate means of transport such as fork
trucks, elevating trucks and cranes. Back damages and other injuries
can be consequence of non-observance.

IMPORTANT! For detailed information on mounting the imaging recor-

ding unit, refer to the separate operating manual IMAGE RECORDING
UNIT iPQ-Check. This document is enclosed with the system both in
printed form and on CD-ROM. Familiarize with this document before
assembling the image recording unit! The operating manual IMAGE
RECORDING UNIT iPQ-Check covers the following topics amongst
others:

• detailed assembly instructions of the image recording unit

(chapter ASSEMBLY AND COMMISSIONING)
• instructions concerning the cooling of the image recording unit
• instructions concerning the cleaning and the maintenance of the
image recording unit
• warning of residual risks during the operation of the imaging recording
unit

Cooling of the system The maximum operating temperature of the image recording unit is 42
°C (without condensation). Usually this temperature is provided by the
internal ventilation. In case of a higher environment temperature it is
necessary to assure this operating temperature by means of an active
cooling. In this case there are two options:

You can find further advice in the manufacturer documentation of the

provided heat exhanger/the existing cooling system at the assembly
location.

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3.2 Assembly of the traverse bar with camera

The traverse bar and the camera are part of the standard scope of supply
of the iPQ-View/webvideo_star TTB system. However these components
are optional for iPQ-Check system.

Review The traverse bar serves to assemble the camera and is set across the
web on the machine stand. By means of a sled, the camera can be slid
over the entire traverse bar width and thus capture an optional position
on the web.

Safety Instructions

WARNING! Guarantee security at the traverse bar assembly location

before starting the assembly works. During the entire assembly works,
the printing press must be fully stopped and secured against restart.
Possible consequences of non-observance can be death or serious injury.

ATTENTION! In order to avoid accidents or damages, a second person

is needed to transport or to assemble the traverse bar.

CAUTION! Danger of being crushed! Danger of injury, ensure that no

body parts are within the danger zone of the traverse bars.

IMPORTANT! For detailed information on mounting the camera and the

traverse bar, refer to the separate operating manual WEBVIDEO CAMERA
WSC_XXX AND TRAVERSE BAR ELT-ZA.x. This document is enclosed
with the system both in printed form and on CD-ROM. Familiarize with
this document before assembling the camera and the traverse bar! The
operating manual covers the following topics amongst others:

• detailed assembly instructions of the camera and the traverse bar

(chapter ASSEMBLY AND COMMISSIONING)
• instructions concerning the cleaning and the maintenance of the
traverse bar
• warning of residual risks during the operation of the traverse bar

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3.3 Assembly of the background plate (optional)

Review A background plate can be assembled to guarantee a shadowless

illumination of transparent printing substrates over the entire traverse
bar width.

Safety instructions

WARNING! Guarantee security at the background plates assembly

location before starting the assembly works. During the entire assembly
works, the printing press must be fully stopped and secured against
restart. Possible consequences of non-observance can be death or
serious injury.

CAUTION! In order to avoid accidents or damages, a second person is

needed to transport and to assemble the background plate.

Assembly Conduct the following action steps in order to assemble the background
plate:

• Loosen the holding brackets on the background plate until they can
be displaced.
• Adapt the background plate in the installation location and tempo-
rarily fix it by means of the vices.
• Precisely align the background plate and check that it is installed at
right angles and has the correct distance to the printed web.
• Mark the holes for all holding brackets of the background plate.
• Remove the background plate again.
• Drill 4 M8 holes and cut M8 threads.

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• Adapt the background plate in the installation location and lightly

fasten with 2x M8 on both sides using the holding brackets.
• Align the background plate according to the adjacent sketch (hori-
zontally at right angles, parallel to the printed web, distance 20 to
max. 40 mm).
• Tighten the background plate using the 4 M8 screws.
• Retighten the holding brackets on the background plate.

Repeat this procedure for each additional camera (optional).

If shadow formation occurs on the monitor image during system opera-

tion: reduce the distance between background plate and printed web
(to min. 20 mm)!

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3.4 Assembly of the image processing unit (iPQ-Check)

The recorded image data is sent from the image recording unit to the
image processing unit for further processing. The image recording unit
is delivered in an ventilated or air-conditioned system cabinet (see figure
below).

Fig. 3.2

Detail information to the measures of the system cabinet can

be found in the chapter MECHANICAL DRAWINGS in the customer
documentation.

Safety

ATTENTION! Never transport the system cabinet by means of pure

muscle strength. Use only appropriate means of transport such as fork
trucks, elevating trucks and truck cranes. Back damages and other
injuries can be consequence of non-observance.

The system cabinet may only be used in non-explosive areas.

Assembly Location The assembly location has to fulfill the following requirements:

• The dust or humidity load should be as small as possible.

• In case of using a ventilated system cabinet, the surrounding
temperature may not exceed 42°C.
• In case of using an air-conditioned system cabinet the surrounding
temperature may not exceed 50°C.
• The system cabinet may not be exposed to vibrations when the system
is running.
• The floor of the assembly location should be flat and solid and should
have an appropriate load capacity.
• The maximum cable length between image recording unit and the
image processing unit is 7 m. By using the optional available optical
fiber for signal transfer a larger distance is possible.

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Assembly Advice In addition, you should consider the following points for the system
cabinet assembly:

• Consider the length of the provided cables.

• Make sure that each door of the system cabinet is accessible.
• Make sure that the system cabinet is duly grounded.

STOP! In case of using an air-conditioned system cabinet: Affix the back

plane of the system cabinet to a massive wall or another surface being
likewise solid. Therefore use the four included wall mount holders. If
the system cabinet is not fixed, the system cabinet has no save position
when the doors are opened.

STOP! In order to avoid damages on the system, never cover the

ventilators and fences of the system cabinet!

If the provided cables are longer than required, store the non-laid cable
sections, if possible, in the cable box of the system cabinet.

For further information on the system cabinet, please see the provided
documentation.

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3.5 Assembly of junction box (optional)

For easy cabling, the scope of delivery for certain systems includes a
junction box.

Fig. 3.3

Detailed information on the measures of the junction box can

be found in the customer documentation under MECHANICAL DRAWI-
NGS.

Safety instructions

The junction box may only be used in non-explosive areas.

Carry out the following action steps in order to assemble the junction box:

ff • Mark the drillholes at the assembly location (for drill measure, see
mechanical drawings)
• Drill the holes and cut the corresponding threads.
• Tighten the junction box.

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3.6 Assembly of the measuring wheel with shaft encoder

(iPQ-Check)

In order to take a current image of the running web via the camera, the
system has to be synchronised with the web. A shaft encoder is used for
this synchronisation being fed with signals from a measuring wheel,
which is attached to the web. The shaft encoder and the measuring
wheel are mounted at a hinged arm. The hinging arm can be mounted
at an included profile rail or directly at the machine stand.

Fig. 3.4

Safety instructions

WARNING! Guarantee security at the shaft encoder assembly location

before starting the works. During the entire assembly works, the printing
press must be fully stopped and secured against restart. Possible
consequences of non-observance can be death or serious injury.

STOP! Be careful when transporting and assembling the shaft encoder.

Protect the digitizer against impacts and don’t put weight on the encoder
shaft to avoid damages.

The shaft encoder may only be used in non-explosive areas.

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Assembly location To guarantee the correct function of the shaft encoder, a uniform contact
with the printed web must always be ensured. For this reason the
assembly location must enable the web being guided between the
measuring wheel and a guide roller of the printing machine. The wrap
angle at this guide roller must not exceed 90° (see figure above). In
addition it is important, that the assembly location is located as close
as possible to the image recording unit.

Assembly advice

Some important advice concerning the assembly is provided in this

chapter. A detailed description of the shaft encoder assembly is provided
in the included manufacturer documentation.

• Profile rail: The shaft encoder is to be assembled using the included

profile rail. Affix the profile rail across the web to the macine stand
using 2 x 2 M8 screws.
• Installation of the bracket for the hinged arm: Fasten the hinged arm
(A) on the machine so that the moving arm fits precisely parallel in
relation to the printed web and the running direction (no incorrect
angle to the printed web!). Place the bracket for the hinged arm in
the profile rail so that a uniform contact with the printed web is
always ensured (uniform follow-up, no web unnevenness).
• Shaft encoder connections: When routing the electrical shaft encoder
connections ensure that the movements of the hinged arm are not
impaired and it is not subject to traction forces.

• Setting the contact pressure: Set the contact pressure on the

measuring wheel so that the print product is not damaged.Carry out
the following operation steps, to set the contact pressure:

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Carefully undo the centre screw on the hinged arm. The

measuring wheel slightly makes contact to the printed
web during this.
Insert the screwdriver into the hole in the setting wheel
intended for this purpose (D) and set the contact pressure
by turning the setting wheel by approx. one engagement
cycle (10 ... 30 N). The contact pressure can be set to a
max. of 40 N (this corresponds to the admissible radial
shaft load of the shaft encoder).

Retighten the centre screw. Ensure that the hinged arm

moves smoothly.

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3.7 Shaft encoder assembly (iPQ-View/webvideo_star TTB)

In order to be able to take a current image of the running web via camera,
a flash must be released in the right moment. A shaft encoder which is
used for synchronizing the flash with the print cylinder position is
assembled on the print unit. There is a shaft encoder model which may
only be operated in non-explosive areas and another one which may be
operated in zone 1.

Safety Instructions

WARNING! Guarantee security at the shaft encoder assembly location

(if necessary, terminal boxes assembly location, too) before starting the
works. During the entire assembly works, the printing press must be fully
stopped and secured against restart. Possible consequences of non-
observance can be death or serious injury.

STOP! Be careful when transporting and assembling the shaft encoder.

Protect the digitizer against impacts and don’t put weight on the encoder
shaft to avoid damages.

STOP! Mount the shaft encoder only directly on the shaft. Do not mount
any machine elements like drives and gear belts between shaft encoder
and shaft to avoid damages on the shaft encoder.

For shaft encoder application in explosive areas:

The shaft encoder falls in machine category 2G and may only be used
in zone 1, zone 2 and in non-explosive areas.

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Assembly Instructions • Mount the shaft encoder, depending on the type of drive, on the main
drives or on the counter pression cylinders shaft.
• The shaft encoder must be mounted in a transmission ratio corres-
ponding to the application (e.g. 1:1).
• The shaft encoder must be mounted so that no slip can occur.

Assembly Conduct the following steps in order to mount the shaft encoder:

• Mount the shaft encoder flange (A, not included in the eltromat scope
of delivery) on the machine side.
• Plug the shaft encoder coupling (B) on the cylinders shaft end (or
on the deviation rolls end) and tighten it.

• Plug the shaft encoders shaft (C) in the shaft encoder coupling.
• Adjust the shaft encoder axially aligned and tighten it on the shaft
encoder flange.

STOP! Consider the maximum offsets in order to avoid a damage on

the shaft encoder coupling:

• radial: max. arbour offset 0.2 mm

• axial: max. arbour offset 1 mm
• angle offset: max. 2°

• Tighten the shaft encoder coupling on the shaft encoder shaft.

• For further advice on mounting the shaft encoder and the coupling,
please see the provided documentation.

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If you use the shaft encoder in an explosive area, you have to install a
terminal box, to which the shaft encoders cables are connected.

The terminal box falls in the machine category 3G and may only be used
in zone 2 and in non-explosive areas.

• Loosen the screws and remove the cover of the terminal box.
• Fix the terminal box with 2x M4 screws.
• Fix the protective earth conductor of the terminal box terminal on
the machine stand.

After cable connection:

• Close the cover of the terminal box by means of the four screws.

For further advice on mounting the terminal box, please see the provided
documentation.

3.8 Control Unit Assembly (option)

It is possible to accommodate the system controls (monitors and

optionally keypad with joystick) into a control unit. Depending on the
system configuration the data processing hardware (e.g.industrial PC)
can also be integrated into a control unit.

The system webvideo_star TTB is delivered with an ergonomic desktop

housing. If not specified else, the following advice is also valid for this
desktop housing.

All relevant information on your web monitoring systems control

unit type can be found in the customer documentation under MECHA-
NICAL DRAWINGS.

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Fig. 3.5

The following safety instruction exclusively applies to the systems iPQ-

View and iPQ-Check :

ATTENTION! Never transport the control unit by means of pure muscle

strength. Use only appropriate means of transport such as fork trucks,
elevating trucks and truck cranes. Back damages and other injuries can
be consequence of non-observance.

The control unit may only be used in non-explosive areas.

Assembly Location The assembly location has to fulfill the following requirements:

• The dust or humidity load should be as small as possible.

• The surrounding temperature may not exceed 40°C. Otherwise, a
housing with climate control must be used.
• The control unit may not be exposed to vibrations when the system
is running.
• The floor of the assembly location should be flat and solid and should
have an appropriate load capacity.

Assembly Advice In addition, you should consider the following points for the control unit
assembly:

• Consider the length of the provided cables.

• Make sure that each door of the control unit is accessible.
• Place the control unit ergonomically for the user.
• Make sure that the control unit is duly grounded.

STOP! In order to avoid damages on the system, never cover the control
units ventilators and fences!

If the provided cables are longer than required, store the non-laid cable
sections, if possible, in the control units cable box.

For further information on the control unit, please see the provided
documentation.

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3.9 Mounting Plate Assembly (option)

It is possible to purchase the hardware of the web monitoring system

without control unit. In this case, the mere construction groups are
delivered on mounting plates. The layout and the number of these
mounting plates depends on the customers needs. The following image
shows exemplarily the sectioning into energy supply module, main
control panel and output module:

Fig. 3.6

All relevant information on the mounting plates of your web

monitoring system can be found in the customer documentation under
MECHANICAL DRAWINGS.

Assembly Carry out the following steps to assemble the mounting plates:

ff • Mark the drill-holes on the back wall of the console or the tall cupboard
(see the mechanical drawings for boring measures)
• Drill the holes and cut the correspondent windings.
• Tighten the mounting plates on the back wall.

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3.10 Laying and connecting cables

This chapter gives only basical advice on how to lay and to connect the
provided cables. For further information on electrical installation works,
see chapter E-CAD plans in the customer documentation

Laying cables

ATTENTION! Attention: Do not expose the cables to mechanical forces

(e.g. pulling, folding, crushing, stretching or twisting)!

The cables are clearly marked. The following image shows:

• the standard cable list with cable designations as well as

• an example of a cable label with reference mark (according to DIN
EN 61346-2).

Fig. 3.7

For further information on electrical installation works, see chapter E-

CAD plans in the customer documentation!

Connecting cables

WARNING! Electrical voltage! Ensure safety at the connection points by

means of de-energizing the circuits! Death or serious injury can be
consequences of non-observance!

STOP! De-energize the concerned circuits in order to avoid damages on

the system!

Basic principle for all cables: Plug in jack / coupling and screw / secure it!

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Installing cables Consider the following advice when installing the cables in the control
cabinet:

Insert the cables through the cable entry in the socket of

the control cabinet.

Fix the cables at the strain relief rail to protect the cables
from mechanical stress.

Connect the shield with the ground bar and fix it with a
cable clamp.

Fig. 3.8

For further information on electrical installation works, see chapter E-

CAD plans in the customer documentation!

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4 Remote service and other network functions

BST eltromat systems can be connected to the network (LAN) of the

customer.This allows the following system functions:

• Remote service
• by building up a VPN tunnel to BST eltromat in Germany.
• by building up an encrypted TeamViewer connection to BST
eltromat in Germany by means of a relay server.

• Calling up the reel products when using the optional event_logger.

• Exchanging data when using the optional function extensions PDF
plate_auditor and Snapshot gallery.

The connection of a BST eltromat system to the customer's network, is

established either directly via an Ethernet connection or indirectly via
the BST eltromat router as an interface. In the following subsections
operation and requirements of both versions are described.

4.1 Integration of the BST eltromat router (INSYS MoRoS Modem )

The BST eltromat router (INSYS MoRoS Modem) serves as an interface

between the BST eltromat systems on site and the customer network
(LAN). It allows a remote service connection with the highest safety
standards. The following figure shows an example of integrating the BST
eltromat router into a customer LAN.
Fig. 4.1

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Remote service
When using the remote service, a VPN tunnel to BST eltromat in Germany
is built up as required (initiated by push button) via the customer LAN
and, thus, via his/her internet access

Requirements The following requirements must be provided by the customer to

integrate the
BST eltromat router:

1. fixed IP address allocated to the BST eltromat router in the customer

network
2. corresponding netmask
3. Standard Gateway address in the customer LAN

The following two settings are only required for the remote service
function and not for the use of the event_logger and plate_auditor
modules:

4. Port 1194/UDP (openVPN) must be open from the inside to the

outside in the firewall
The target address for this firewall rule can be limited to
62.156.180.114 if required.

5. Port 123/UDP (NTP) must be open from the inside to the outside in
the firewall
The target address for this firewall rule cannot be limited!

Alternative If it is not possible to integrate the BST eltromat router into the customer
network, a separate ADSL access including ADSL modem can be
provided alternatively by the customer. In this case, the BST eltromat
router operates as an ADSL router.

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4.2 Direct network integration of an BST eltromat system

Using this variant, the BST eltromat system on-site is directly connected
to the network (LAN) of the client. The software TeamViewer is used for
remote service: The TeamViewer client is installed on both the BST
eltromat system and on the computer of the BST eltromat service
employee. When using the remote service both TeamViewer Clients
connect to a relay server in the Internet. The relay server connects both
clients with each other and thus enables a direct connection between
your BST eltromat system and the computer of the BST eltromat service
employee.
Fig. 4.2

Requirements The following requirements must be provided by the customer to

integrate the BST eltromat system:

1. fixed IP address allocated to the BST eltromat router in the customer

network Alternatively a dynamic IP address (DHCP) can be used for
remote service (not recommended for event_logger and plate_audi-
tor).
2. corresponding netmask
3. Standard Gateway address in the customer LAN

The following settings is only required for the remote service function
and not for the use of the event_logger and plate_auditor modules:
4. Port 80, 443 or 5939 must be open from the inside to the outside
in the firewall.
Alternative If it is not possible to integrate the BST eltromat system into the customer
network, a separate ADSL access including ADSL modem can be
provided alternatively by the customer.

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