FMS BKS309.MS User manual

Operating Manual BKS309.MS
Digital Web Guide Controller
with Master-Slave Function
Version 2.40 08/2018 NS
Firmware Version V2.43
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Table of Contents
1 Safety Instructions ..................................................................................... 4
1.1 Description Conditions 4
1.2 List of Safety Instructions 4
2 System Description .................................................................................... 5
2.1 Functional Description Standard Web Guide Controller 5
2.2 Web Guide Controller with Master-Slave Functionality 5
2.3 Steering Frame or Actuator 6
2.4 Electronic Control Unit 6
2.5 Sensors 6
3 Quick Installation Guide ............................................................................ 7
3.1 Preparations for Set-up 7
3.2 Installation Procedure 7
3.3 Adjustment of the Sensors 7
4 Installation .................................................................................................. 8
4.1 Mounting the Steering Frame 8
4.2 Mounting the Actuator to your Unwind or Rewind Station 8
4.3 Mounting the Sensors 8
4.4 Mounting the Electronic Control Unit 9
5 Wiring Diagrams ....................................................................................... 10
5.1 Wiring a Steering Frame with BKS309.R / .S or .W Controller 10
5.2 Connecting webMASTERs BKS015 or BKS020 11
5.3 Connecting a winderGLIDE BKS.D.3 or a webMASTER BKS030 11
5.4 Connecting a winderGLIDE BKS.D.6 11
6 Configuring the System ........................................................................... 13
6.1 Power up the BKS 309.MS 13
6.2 Relays Outputs 14
6.3 Digital Inputs 14
6.4 Differences between Standard and Master-Slave Electronics 15
7 Operation .................................................................................................. 16
7.1 Operation Panel 16
7.2 Operating the Web Guiding System via the Front Panel 16
7.3 Automatic Operation 17
7.4 Manual Operation 18
7.5 Saving the Travel Limits 18
8 Parameter Setting over the Front Panel ................................................ 19
8.1 Basic Instructions for Parameter Setting 19
8.2 Setting of Operation Parameters 19
8.3 Setting of System Parameters 24
8.4 List of Operation Parameters 25
8.5 Description Operation Parameter 27

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8.6 Setting of System Parameters 38
8.7 Reset to Default Parameter Set 40
9 Parameter Setting via a PC ..................................................................... 41
9.1 Parameterization in a Network via Web Browser 42
9.2 Parameterization via a PC (peer-to-peer connection) 47
10 Mechanical Dimensions .......................................................................... 51
11 Trouble Shooting ...................................................................................... 54
12 Technical Specification ............................................................................ 55

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1 Safety Instructions
1.1 Description Conditions
a) Danger of health injury or loss of life
Danger
This symbol refers to high risk for persons to get health injury or loss life. It has to
be followed strictly.
b) Risk of damage of machines
Caution
This symbol refers to information, that, if ignored, could cause heavy mechanical
damage. This warning has to be followed absolutely.
c) Note for proper function
Note
This symbol refers to an important information about proper use. If not followed,
malfunction can be the result.
1.2 List of Safety Instructions
Some contacts on the power supply board are under 230V tension! Mortal danger!
Disconnect power supply before open the housing!
Proper function of the FMS web guide is only guaranteed with the recommended
application of the components. In case of other arrangement, heavy malfunction
can be the result.
Local installation regulations are to preserve safety of electric equipment. They are
not taken into consideration by this operating manual. However, they have to be
followed strictly.
Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the control unit! It is vital to ensure that proper earth
connection is done.
The processor board is mounted directly behind the operation panel. Improper
handling of the electronic boards may cause damage to the fragile equipment!
Don’t use rough tools such as screwdrivers or pliers! Operators handling the
electronic boards must wear a well earthed bracelet in order to discharge static
electricity

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2 System Description
2.1 Functional Description Standard Web Guide Controller
Figure 1 shows a typical web guiding system with its basic components.
The sensors measure the position of the web edge and send this information as an
analogue signal to the web guide controller BKS309. This electronics compares the
position feedback signal with the reference. If the difference of these two values is
higher then the stored dead band value, the steering frame will be adjusted.
Fig. 1: Basic system arrangement with BKS309 web guide controller K309003e
2.2 Web Guide Controller with Master-Slave Functionality
For the lamination of two webs Chase & Follow Control Systems are often used. This
control system enables the exact positioning of two webs one above the other. The
BKS309.MS web guide controller with Master-Slave functionality measures the
position of a first web (Master) and guide a second web (Slave) so that both webs
exactly match each other. Chase & Follow guiding requires at least one steering
frame (or actuator) and two material sensors.
The material sensors are mounted on the same side of the corresponding webs.
Either both on the left, or both on the right hand side.

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Fig. 2: System with Master-Slave Functionality (BKS309.MS) K309003e
2.3 Steering Frame or Actuator
The steering frame consists of a fixed lower and a moveable upper frame that
supports the rollers. The upper frame is activated by a stepper motor. The rollers are
manufactured and balanced according to customer specification. End positions are
controlled via a linear potentiometer. A location rail for easy sensor attachment is
integrated to the steering frame. For rewind und unwind stands a stepper motor
based drive acts as actuator.
2.4 Electronic Control Unit
The micro-processor based electronic control unit handles all calculations and
communications. Three buttons and a five key wind-rose serve as the man-machine
interface. Parameter setting can be performed via the front panel keys or via a web
interface. The BKS309 controller series works in combination with FMS steering
frames of the series webMASTER BKS020, BKS040, webDIRECTOR BKS041/42,
and actuators of the winderGLIDE BKS.D.3 and winderGLIDE BKS.D.6 series.
2.5 Sensors
Optical sensors (AZS01/04), ultrasonic sensors (US01/4B) and a digital line sensor
(DLS) are available from FMS. These sensors provide a signal of 0...10V. With them,
edge, center and line guiding applications can be covered.

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3 Quick Installation Guide
The installation and set-up instructions in this operation manual refer to the
BKS309.MS controller with Master-Slave functionality.
3.1 Preparations for Set-up
• Read the Operation Manual of your web guide or actuator system.
• Check your system requirements such as:
− Operation with steering frame or with actuator
− Unit system (metric, imperial)
− Relay or digital input requirements of your set-up
• Draw the wiring diagram for your configuration (ref. to chapters 5.1 to 5.6)
• If required, determine special parameters (ref. to 8“Parameter Setting over the
Front Panel”)
3.2 Installation Procedure
1. Mount and ajust your material sensors to the Slave Web (steering frame) and
Master Web (ref. to chapter 4.3)
2. Mount the steering frame or actator to the machine
3. Wire the sensors to the electronic unit (ref. to chapter 5)
4. Wire the steering frame to the electronic unit (ref. to chapters 5.1 to 5.6)
5. If using an external web guide controller, mount the electronics on a place where it
can be easily reached by the operator
6. Make sure the power supply voltage is in the range 18 to 30V DC (Vnom= 24V)
7. Power your system on and check if the electronics starts up (LCD turn on)
8. Install your webs in the machine and align the edge sensors to the material (ref.
3.3 “Adjustment of the Sensors”).
9. If necessary, continue with the configuration of your system (ref. to chapter 6)
3.3 Adjustment of the Sensors
Align sensor axis to the web edge: Loosen the
fixing nut on the bracket and adjust the
sensor. Fix the sensor in the new position.
The sensor will be positioned properly if the
web edge goes through the sensor axis
(center of active window (ref. to Fig. 3).
Fig 3: Alignment of the sensor axis to
the web edge K100004e

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4 Installation
Caution
Proper function of the FMS web guides and actuators is only guaranteed with the
recommended application of the components. Other arrangements, can cause
heavy malfunctions. Therefore, the installation instructions on the following pages
must strictly be followed.
Caution
Local installation regulations are to preserve safety of electric equipment. They are
not taken into consideration by this operating manual. However, they have to be
followed strictly.
4.1 Mounting the Steering Frame
The mounting orientation of the steering frame (indicated by an arrow), must
correspond with the web running direction. The lower frame is mounted with four M8
screws to the machine frame. The machine must be prepared to accept the M8
mounting screws.
4.2 Mounting the Actuator to your Unwind or Rewind Station
The static part of the winderGLIDE actuator must be mounted to the machine frame
e.g. to the spherical rod end on the gearbox. The moving rod end is mounted to the
winding stand. For other assembly forms consult the operation manual of the
BKS.D.3 respectively BKS.D.6. The BKS.D.3 / D.6 are designed for horizontal
mounting positions. The machine frame must be prepared to accept the mounting
devices of the winderGLIDE.
4.3 Mounting the Sensors
The sensors will be mounted with brackets to the rail of the steering frame or to the
sensor arrangement of the Master Web (refer to operation manual AZS01, US01 or
DLS). The sensors have to be installed after the steering frame if seen in running
direction of the web. They have to be mounted so that the narrow side is closer to the
steering frame (see Fig. 4).
Caution
The material sensors for the Master Web and for the Slave Web must both be
mounted on the same side (either left or right side).

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Definition of Left and Right:
Left and right are always seen in direction of the running web (see Fig. 4).
Fig. 4: Position of the sensors according to the web K400005e
Note
Make sure that the sensors are connected properly to the electronic unit by means
of the delivered cables. For left / right orientation please refer to Fig. 4. If the
connections are crossed over, malfunction can be the result.
Note
For optimum control results, the sensors have to be placed next to the exit roller of
the steering frame. If the sensors are placed far from the steering frame, control
dynamics will deteriorate.
4.4 Mounting the Electronic Control Unit
The BKS309.MS series is available in four different housing options:
1. Rail mount housing (electrical connections via screw terminals)
2. Rail mount housing (electrical connections via connectors)
3. Wall mount housing
4. Panel mount housing
The mechanical dimensions can be seen in chapter 10 “Mechanical Dimensions”.

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5 Wiring Diagrams
Use the original FMS cables to connect the steering frame respectively the actuator
to the BKS309.MS controller. The connector end of the cable is connected either to a
steering frame or a BKS.D.3 / D.6 actuator. The open ends of the cables must be
wired to the cable terminals in the controller according to the wiring diagrams below
(ref. also to Fig. 5 or Fig. 7)
5.1 Wiring a Steering Frame with BKS309.R / .S or .W Controller
Sensor right = Master sensor
Sensor left = Slave sensor
Please note that both sensors must be installed either on the right or the left side of the
webs.
Fig. 5: Connection terminals BKS309.MSBKS309.ai

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5.2 Connecting webMASTERs BKS015 or BKS020
5.3 Connecting a winderGLIDE BKS.D.3 or a webMASTER BKS030
The illustration show a BKS.D.3 as sample. A BKS030 is equally wired.
5.4 Connecting a winderGLIDE BKS.D.6
Caution
Bad earth connections may cause electric shocks to persons, malfunction of the

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total system or damage of the control unit! It is vital to ensure that the earth
connection is properly done.

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6 Configuring the System
After having mounted and wired the web guiding equipment on the machine, the
system can now be configured to the specific requirements of the application.
6.1 Power up the BKS 309.MS
1. Make sure the power supply voltage is in the range 18…30 VDC (Vnom= 24V)
2. Check, if the web is in the detection range of the sensors.
3. Switch-on your power supply
4. The web guide controller starts-up in Manual Operating Mode.
5. A web guiding system using BKS309.MS is pre-set to control a chase & follow
application with the master web being connected to the left sensor input (see
wiring diagrams Fig. 5 to 7). If required by the application the asignment of the
master web sensor can be changed by the parameter [MastrInp] (ref. to 8.2
“Setting of Operation Parameters”, Fig 15)
6. If required re-configure the programmable relay outputs (see chapter 6.2)
7. If required re-configure the digital inputs (see chapter 6.3)

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6.2 Relays Outputs
The BKS309 controller provides 2 programmable relay outputs. The outputs are
software controlled. Electrically they are potential-free. Each relay output can be
configured individually and can perform an assign special function. The outputs are
configured in the Parameter Setting Mode. Following functions can be assigned to
each output:
• Indicate centre position of web edge
• Indicated if web edge is detected
• Indicate if web edge is detected and Automatic Mode on
• Indicate if no web edge is detected and Automatic Mode on
• Indicate if Automatic Mode was chosen
• Indicate if steering frame or actuator is centred
For more details about the functions refer to chapter 7.4 “Description Operation
Parameter”.
Hardware access via screw terminals (see Fig. 3)
Signal Name Terminal #
Relay 1/1 9
Relay 1/2 10
Relay 2/1 11
Relay 2/2 12
6.3 Digital Inputs
The BKS309 controller provides 4 digital inputs for special functions.
The digital inputs are edge or level triggered. An impulse of 100ms or longer
activates the event. Each digital input can be configured individually and can perform
an assign special function. The digital inputs are configured in the Parameter Setting
Mode. Following function can be assign to each digital input:
• Toggle between Manual and Automatic mode (edge triggered)
• Toggle between Manual and Automatic mode (level triggered)
• Go to centre position
• Decrease reference value in 0.1mm steps in (deactivated for BKS309.MS)
• Move actuator in 0.1mm steps to the left
• Increase reference value in 0.1mm steps (deactivated for BKS309.MS)
• Move actuator in 0.1mm steps to the right
• Lock steering device (steering frame or actuator)
• Reset reference value (deactivated for BKS309.MS)
For more details about the functions refer to chapter 8.4 “Description Operation
Parameter”.

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Caution
If the function “Toggle between Manual and Automatic mode” is controlled via the
digital inputs, the corresponding key on the operation panel will be
deactivated.
Hardware access via screw terminals (see Fig. 9)
Signal Name Terminal #
Dig.In 1 5
Dig.In 2 6
Dig.In 3 7
Dig.In 4 8
.
6.4 Differences between Standard and Master-Slave Electronics
Due to its use in the special field of chase & follow applications the BKS309.MS
Master-Slave unit has a slightly different parameter set if compared with the
standard web guide controller BKS309. Several functions aren’t any more available
with the BKS309.MS. Parameters connect to these functions are displayed and can
be modified without having any influence in the application. Following function are
not available in the BKS309.MS unit:
• Reset of the frame reference position via digital inputs or the keys and on
the operation panel.
• Setting the Reference Value over the parameter [Ref Pos]
• Determination of the Reference Position is deactivated and thus the parameter
[Ref Mod] has no impact. The Reference Position is always defined by the Master
Web Position.
• A change of the Reference Position in automatic operation via the digital inputs or
via the web interface is not possible.

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7 Operation
7.1 Operation Panel
Fig. 11: View of the Operation Panel K309039e
7.2 Operating the Web Guiding System via the Front Panel
Key Key function during operation
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.
Centre guiding mode is deactivated for BKS309.MS
To enter the Parameter Setting Mode, hold the key for longer then 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 (ref. to 6 “Parameter Setting over the Front Panel”)
Automatic, Manual. With this key you can select 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.

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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: Adjust Reference Position (left) is deactivated
for BKS309.MS.
In Setup-Position and independent if the device is in manual or automatic
mode, pressing the button increases continuously the 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: Adjust Reference Position (right) is deactivated
for BKS309.MS
In Setup-Position and independent if the device is in manual or automatic
mode, pressing the button increases continuously the parameter value.
Note
If DLS (digital line sensors) are 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 the line anymore. The LED above the
.key will start blinking and indicate to operator that the line quality is bad.
7.3 Automatic Operation
• Start automatic mode with key or digital input. Reference position is taken
from the middle of the sensor detection band (Fig. 12). Using center guide,
reference position is in the middle between the 2 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 using digital inputs (step
width 0.1 mm). Using the key, the web
moves out of the sensor; using the
key, the web moves in Using center guide,
this description refers to the right sensor.
• Terminate the automatic mode by using
the key again.
Note
If the web leaves the sensor detection band, control is no longer effective. Hold
the web edge strictly inside the sensor detection band.
Fig. 12: Position at automatic start K
100005e

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Note
If web is not running, it can’t be guided properly to the reference position! The steering
frame moves in the limit-of-travel position and may damage the web. Start automatic
mode only when web is slowly running.
7.4 Manual Operation
In manual mode, possibilities as follows are available:
• Center position :The steering frame will return to center position.
• Frame position and :The steering frame can be adjusted in 0.1mm
steps. If key is held, steering frame is moving continuously. These functions
can also be carried out via the digital inputs (see 4.7 “Digital Inputs”).
7.5 Saving the Travel Limits
There are two possibilities to alter the limits for 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 parameter changing mode or you drive manually
to the desired position and save it. The procedure for is then as follows:
1. Enable the change of the travel limits by pressing the two keys at the same
time. The LED above the key will light.
2. Travel with the actuator to the desired position with the keys .
3. Press the key. The LED above the key starts to flash and expects the
definition of the setting.
4. The definition is done with for the Home Position, for the Maximal Position
and for the Middle Position
5. On the displayed following comments will report completion.
Display first line: [Save Pos]
Display second line: [Done] or [Invalid]
In the case of [Invalid] the display flashes. 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 Parameter Setting over the Front Panel
8.1 Basic Instructions for Parameter Setting
The web guide controller has three operator modes:
• Operation mode
• Parameter Setting mode (parameter selection)
• Change mode (set or change chosen parameters)
The parameter setting can be performed via the keys on the front panel or via a web
browser. When using the front panel, the user can toggle between these modes by
pressing a key or a combination of keys. The keys have the following functions:
Key Key function during parameter setting
Enter
Change the selections or increase / decrease the values
8.2 Setting of Operation Parameters
To enter the Parameter Setting Mode the web guide controller must be in the Manual
Mode. In the Automatic Mode only the reference value can be changed.
Press the key for longer then 3 sec. The LED will light and the first parameter
will appear on the LCD display. With the .keys the parameter list can be
scrolled up and down. By pressing the key again you will enter the parameter
setting mode. The select parameter on the display flashes indicating that it can be
changed.
The following state diagrams will help you to navigate through the Parameter Setting
menu.
Notes for the following state diagrams:
1) Permanent pressing of the keys expedites the changing speed.
2) The display shows the unit of measure that was previously selected.
3) Parameter only used in winderGLIDE (actuator) applications
4) This parameter change requires a restart of the web guide controller.

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Fig. 13: State Diagram Operation Parameters (1) K309009e