FMS BKS309 Series User manual

Operating Manual BKS309
Digital Web Guide Controller
Document Version 2.60 07/2019 NS
Firmware Version V3.00
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie Ihren nächstgelegenen FMS Vertreter.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – Alle Rechte vorbehalten.

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1 Table of Contents
1 TABLE OF CONTENTS ............................................................................................................................. 2
2 SAFETY INSTRUCTIONS .......................................................................................................................... 3
2.1 Presentation of safety information ..................................................................................................... 3
2.1.1 Danger that could result in minor or moderate injuries .................................................................. 3
2.1.2 Note regarding proper function ...................................................................................................... 3
2.2 General safety information ................................................................................................................. 3
3 PRODUCT INFORMATION ........................................................................................................................ 4
3.1 Functional Description ........................................................................................................................ 4
3.2 Web guide controller .......................................................................................................................... 4
3.3 Order code and variations of the web guide controller BKS309 ........................................................ 5
3.4 Steering frames, steering rollers or actuators .................................................................................... 6
3.5 Material sensors ................................................................................................................................. 6
4 QUICK INSTALLATION GUIDE ................................................................................................................ 7
4.1 Configuration ...................................................................................................................................... 7
5 INSTALLATION AND WIRING .................................................................................................................. 8
5.1 Installation of a steering frame of the FMS-webMASTER series ....................................................... 8
5.1.1 Installation of the material sensor .................................................................................................. 8
5.1.2 Alignment of the material sensors ................................................................................................. 9
6 ELECTRICAL CONNECTION .................................................................................................................. 11
6.1 Web guide controller BKS309 .......................................................................................................... 11
6.2 Material sensors ............................................................................................................................... 12
6.3 Steering frame BKS020.EE and BKS015.EE with external web guide controller BKS309 ............. 12
6.4 Steering frame FMS-webMASTER BKS030 or actuators FMS-winderGLIDE BKS.D.3 or BKS.D.4
13
6.5 Actuator FMS-winderGLIDE BKS.D.7 .............................................................................................. 13
7 OPERATION AND CONFIGURATION .................................................................................................... 15
7.1 Automatic mode ............................................................................................................................... 17
7.2 Manual mode ................................................................................................................................... 17
7.3 Approaching and saving dedicated positions ................................................................................... 18
8 CONFIGURATION VIA OPERATING PANEL ......................................................................................... 19
8.1 Operating parameters ...................................................................................................................... 19
8.2 List of operating parameters ............................................................................................................ 19
8.3 Description of operating parameters ................................................................................................ 22
8.4 System parameters .......................................................................................................................... 30
8.5 List of System parameters ............................................................................................................... 30
8.6 Description of system parameters ................................................................................................... 31
8.7 Reset to factory settings ................................................................................................................... 34
9 CONFIGURATION VIA WEB BROWSER ............................................................................................... 35
9.1 Peer-to-Peer connection .................................................................................................................. 39
10 DIMENSIONS ........................................................................................................................................... 42
11 TECHNICAL DATA .................................................................................................................................. 45
12 TROUBLE SHOOTING ............................................................................................................................ 46

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2 Safety instructions
All safety related regulations, local codes and instructions that appear in the manual or
on equipment must be observed to ensure personal safety and to prevent damage to
the equipment connected to it. If equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
Do not stress the equipment over the specification limits neither during assembly nor
operation. To do so can be potentially harmful to persons or equipment in the event of a
fault to the equipment.
2.1 Presentation of safety information
The following safety symbols appear in this manual.
2.1.1 Danger that could result in minor or moderate injuries
Danger, warning, caution
Failure to follow wiring instructions in this manual may result in
equipment damage or personal injury.
2.1.2 Note regarding proper function
Note
Note regarding roper operation
Simplification of operation
Ensuring function
2.2 General safety information
The Force Measuring Rollers may not be stressed over the
specification limits neither during assembly nor operation. The
unit’s overload protection value may not be exceeded.
The attachment points for the Force Measuring Rollers on the
machine frame must be properly designed. The bearings need to be
appropriately mounted.
For proper installation and operation, follow the electrical wiring
diagram and instructions in this manual.

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3 Product information
3.1 Functional Description
The sensors measure the position of the web edge and send this information as an
analogue signal to the electronic control unit. In our case a BKS309 web guide
controller.
The control compares the position feedback signal with the reference. If the difference
of these two values is higher than the stored dead band value, the steering frame will be
adjusted.
Figure 1: typical arrangement BKS309_BA_manual.ai
Description
Position Description
1 Steering frame, steering roller, actuator
2 Web, entry side
3 Material sensor(s)
5 Web guide controller
Table 1: designation web guide controller
3.2 Web guide controller
The micro-processor based electronic control unit handles all calculations and
communications. Three buttons and a five-key panel serves as the man-machine
interface. Parameter setting can be performed via the operating panel or via a web
browser. All parameters are stored in a none-volatile memory.

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3.3 Order code and variations of the web guide controller BKS309
Figure 2: order code BKS309_BA_manual.ai
Description
Housing types description
BKS309.W Wall mount, for field installation
BKS309.R DIN
-
rail mount, for cabinet installation
BKS309.S Panel mount, integrated in front panel
Other Options description
.EIP EtherNet/IP interface
(see operating manual BKS309.EIP)
.M To control one or two motorized traverses
(see operating manual BKS309.W.M)
.MS To control Chase
-
and
-
Follow applications
(see operating manual BKS309.W.MS)
.DC To control actuators with DC motor, FMS
-
winderGLIDE BKS.D.7
.ACV Power supply 110 bis 240VAC
Table 2: overview variations

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Variations
BKS309.W BKS309.R BKS309.S For web guide solutions
Standard X X X
BKS015.EE, BKS020, BKS030,
BKS042, BKS.D.3, BKS.D.4
.ACV X X X
BKS020, BKS030, BKS042,
BKS.D.3, BKS.D.4
.EIP X X X
BKS020, BKS030, BKS042,
BKS.D.3, BKS.D.4
.M X
BKS020, BKS030, BKS042,
BKS.D.3, BKS.D.4
.MS X X
BKS020, BKS030, BKS042,
BKS.D.3, BKS.D.4
.DC X X
BKS020, BKS030, BKS042,
BKS.D.3, BKS.D.4, BKS.D.7
Table 3: BKS309 variations and options
3.4 Steering frames, steering rollers or actuators
Steering frames of the FMS-webMASTER series consist of a fixed lower and a moveable
upper frame that supports the rollers. The upper frame is activated by a motor. The
rollers are manufactured and balanced according to customer specification. End
positions are controlled. A location rail for easy sensor attachment is integrated to the
steering frames.
The web guide controller BKS309 can be used for rewind und unwind stations in
combination with actuators of the FMS-winderGLIDE series.
The combination with steering rollers of the FMS-webDIRECTOR series is also possible.
3.5 Material sensors
Optical sensors, ultrasonic sensors and a digital line sensor are available from FMS.
Adjustment is done automatically.
These sensors provide a signal of 0 to 10VDC. With them, edge, center and line guiding
applications can be covered.
Retrofit a digital line sensor
If you retrofit a sensor to an existing controller you have to restart
the controller after the installation of the sensor. This will allow the
controller to detect sensor correctly.

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4 Quick Installation Guide
The set-up of the BKS309 web guide controller and corresponding web guide is limited
to only mounting the devices on the machine frame, wiring and powering up system.
4.1 Configuration
- Read the operating manual of your web guide or actuator system.
- Check your system requirements such as:
o Desired guiding form (edge, centre or line guiding)
o Unit system (metric, imperial)
o Relay or digital input requirements of your set-up
- Draw the wiring diagram for your configuration
- Mount and adjust your material sensor(s) to the steering frame (see p. 8ff)
- Mount the steering frame or actuator to the machine
- Wire the sensor(s) to the electronic unit (see p. 12ff)
- Wire the steering frame to the electronic unit (see p. 11ff)
- Mount the electronic unit on a place where it can be easily reached by the operator
- Install 24VDC (18 to 30VDC)
- If required, determine special parameters (see p. 19ff)

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5 Installation and wiring
5.1 Installation of a steering frame of the FMS-webMASTER series
The mounting orientation of the steering frame (indicated by an arrow), must
correspond with the direction of the moving web. The lower frame is mounted with four
M8 screws to the machine frame. The machine must be prepared to accept the M8
mounting screws.
The steering frame must be grounded. Connect the ground wire to the machine ground.
5.1.1 Installation of the material sensor
The material sensors will be mounted with brackets to the rail of the steering frame or to
the sensor arrangement of the unwind/rewind stand (see installation instruction of the
material sensors).
The installation side "left" and "right" of the material sensor is defined by the direction of
the moving web.
Figure 3: direction of the moving web BKS309_BA_manual.ai

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Description
Position Description
1 Web entry side
2 Web exit side
3 Direction of the moving web
4 Material sensor, sensor axis
5 Material sensor, sensor axis left
6 Web edge left
7 Web edge right
8 Material sensor, sensor axis right
9 Integrated web guide controller BKS309.S (optional)
Table 4: description
Material sensors have to installed on the web exit side
Installation on the entry side of the web will not work of proper
functionality.
Material sensors as close to roller as possible
For optimum control results, the material sensors have to be placed
next to the exit roller of the steering frame.
5.1.2 Alignment of the material sensors
Figure 4: alignment of the material sensors BKS309_BA_manual.ai

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Description
Position Description
1 Web edge
2 Sensor axis
3 Deviation of web edge from sensor axis
4 Detection range of material sensor
5 Center mark of the detection range
Figure 5: Material sensors
- Loosen the clamp
- Align sensor axis to the web edge
- Slide the sensor in the new position.
- The sensor will be positioned properly if the web edge goes through the sensor axis
- Tighten the clamp

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6 Electrical connection
Ground connection
Insufficient ground connection may cause electric shock to persons,
malfunction of the total system or damage of the control unit! It is
vital to ensure that there is a proper and secure earth connection.
6.1 Web guide controller BKS309
Figure 6: electrical connection BKS309_BA_manual.ai

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6.2 Material sensors
Figure 7: electrical connection material sensors BKS309_BA_manual.ai
6.3 Steering frame BKS020.EE and BKS015.EE with external web
guide controller BKS309
Figure 8: electrical connection BKS020.EE and BKS015.EE
BKS309_BA_manual.ai

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6.4 Steering frame FMS-webMASTER BKS030 or actuators FMS-
winderGLIDE BKS.D.3 or BKS.D.4
Figure 9: electrical connection BKS030, BKS.D.3, BKS.D.4 BKS309_BA_manual.ai
6.5 Actuator FMS-winderGLIDE BKS.D.7
Only in combination with BKS309.R.DC or BKS309.W.DC
The use of any other web guide controller will lead to damage or
destruction of the components.

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Figure 10: electrical connection BKS309.DC (.R and .W) BKS309_BA_manual.ai
Figure 11: electrical connection BKS.D.7 BKS309_BA_manual.ai

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7 Operation and configuration
Figure 12: Operating panel BKS309_BA_manual.ai
Description
Position Description
1 LED operating status, on if in automatic mode
2 LCD
3 Center guiding
4 Edge guiding right
5 Edge guiding left
6 Toggle from automatic to manual mode
7 Configuration menu
8 Manually drive right, increase value
9 Manually drive left, decrease value
10 Move to center position
Table 5: operating panel

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Description
button Function
The sensor is mounted on the left side of the frame and controls the
material on the left edge or on the line, if a line sensor is used. One
sensor is necessary. The LED indicates the left edge guiding mode.
The sensor is mounted on the right side of the frame and controls the
material on right edge or on the line, if a line sensor is used. One
sensor is necessary. The LED indicates the right edge guiding mode.
Two sensors are mounted on both sides of the frame. The frame is
controlled in a way that the material position is kept centered with
regard to both sensors position. The LED indicates the center guiding
mode.
To enter the operating parameters menu, hold the key for longer than
3 sec. The LED will light and the first parameter will appear on the
LCD display indicating that you entered the mode. A second press on
the PARA key will cause the parameter to flash. Now it can be
changed
Automatic, Manual. With this key you can toggle between automatic
and manual mode. The LED indicates the automatic mode.
Drive to center position. The frame moves to the center Position.
Function is only available in manual mode.
In manual mode the frame will move to the left in 0.1mm steps by
pressing the button once. By pressing the button longer than 1 sec. it
will continuously move the frame to the left.
In automatic mode the frame set-point will be adjusted to the left in
0.1 mm steps by pressing the button once. Pressing the button longer
than 1 sec. it will continuously move the set-point of the frame to the
left.
In configuration mode this function will decrease the selected
parameter value.
In manual mode the frame will move to the right in 0.1mm steps by
pressing the button once. By pressing the button longer than 1 sec. it
will continuously move the frame to the right.
In automatic mode the frame set-point will be adjusted to the right in
0.1 mm steps by pressing the button once. Pressing the button longer
than 1 sec. it will continuously move the set-point of the frame to the
right.
In configuration mode this function will increase the selected
parameter value.
Table 6: buttons and functions

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Flashing LED with connected line sensor
If a digital line sensor is used, it may happen that the web guide
controller blocks the steering frame. This protective function is
activated when the line is interrupted and impossible to detect
anymore. The LED will start flashing to indicate the bad line quality.
7.1 Automatic mode
Start automatic mode with key or digital input. Reference position is taken
from the middle of the sensor detection band. Using center guide, reference position is
in the middle between the two sensor axis. The controller starts to guide the web to
reference position and to hold this guide point.
The reference position can be adjusted during automatic operation by using the keys
or the digital inputs (step width 0.1 mm). Using the key, the web moves in
the sensor; using the key, the web moves outwards.
Using center guide, this description refers to the moving direction on the right sensor.
Terminate the automatic mode by using the key again.
Material left sensor detection range
The control will stop if the material leaves the detection range of
the material sensor.
Static web
Automatic control can only be provided on a moving web.
7.2 Manual mode
Center position
- The steering frame will return to center position.
Frame position and
- The steering frame can be adjusted in 0.1mm steps.

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- If key is held, steering frame is moving continuously.
- These functions can also be carried out via the digital inputs
7.3 Approaching and saving dedicated positions
There are two possibilities to alter the values of the Home Position, Middle Position and
Maximum Positions of the actuator. Either you modify the parameters [Home Pos], [Mid
Pos] and [Max Pos] in the menu of the operating parameters or you drive manually to
the desired position and save it.
- Enable the change of the travel limits by pressing the two keys at the
same time. The LED above the key will be on.
- Travel with the actuator to the desired position with the keys
- The display will show the actual position with an accuracy of 0.1mm
- Press the key. The LED above the key starts flashing and expects the definition
of the setting.
- The definition is done with
o for the Home Position
o for the Maximal Position and
o for the Middle Position
- On the displayed following comments will report completion.
o Display first line [Save Pos]
o Display second line [Done] or [Invalid]
-
- In the case of [Invalid] the display flashes.
- Possible cause: the position couldn’t be found e.g. because the “home” or
“maximum” position was set over the middle position.

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8 Configuration via operating panel
8.1 Operating parameters
To access the meu for the operating parameters the web guide controller must be in the
manual mode.
Press the key for longer than 3 sec. The LED will be on and the first parameter
will be displayed.
With the buttons the parameter list can be scrolled up and down. By pressing
the button again you will enter the parameter setting mode. The select parameter
on the display flashes indicating that it can be modified with the buttons
To save the changes, press .
8.2 List of operating parameters
Description
Parameter LCD Unit Min Max Selection Factory
Adjust
Reference
Position
Ref Pos mm
-
5.00 +5.00
-
0.00
Set
Reference
Mode
Ref Mode
-
-
-
Manual
Auto
Manual
Save the
Reference
Position
SaveRef
-
-
-
No
Yes
No
Dead
band
DeadBand mm 0.0 2.0
-
0.1

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Description
Parameter LCD Unit Min Max Selection Factory
Relay 1 or
Relay 2
setting
Relay 1
Relay 2
-
-
-
MidSenso
MatFound
Auto&Mat
Aut&Miss
Auto
Centre
Disabled
R1=
MidSenso
R2=
MatFound
Digital
Input 1, 2,
3 or 4
Modes
Input 1
Input 2
Input 3
Input 4
-
-
-
Edge→Aut
Lv→Auto
Centre
- Ref/←
+Ref/→
Lock
ResetRef
Disabled
I1=
Edge→Aut
I2=Center
I3=
-Ref/←
I4= +Ref/→
DLS
Sensor
DLS
-
-
-
none
left
right
none
Password Password
-
-
-
No
Yes
No
Language Language
-
-
-
English
German
English
LCD
-
Contrast
Contrast % 1 100
-
65
Unit
System
Unit Sys
-
-
-
Metric
Imperial
Metric
Gain
Setting
Gain
-
0.02 2.00
-
0.2
Adjust
Correction
Speed
AdjSpeed % 1 100
-
100