FMS BKS309.W.M User manual

Operating Manual BKS309.W.M
Digital Web Guide Controller with Integrated Functions for
Motorized Traverse
Document version 1.30 08/2018 NS
Firmware Version V2.43
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie Ihren nächstgelegenen FMS Vertreter.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Inhalt
1 TARGET GROUPS .................................................................................................................... 3
2 SAFETY INSTRUCTIONS .......................................................................................................... 3
2.1 DESCRIPTION CONDITIONS ............................................................................................................................... 3
2.2 LIST OF SAFETY INSTRUCTIONS .......................................................................................................................... 4
3 SYSTEM AND FUNCTIONAL DESCRIPTION ........................................................................... 5
4 INSTALLATION AND WIRING .................................................................................................. 6
4.1 INSTALLATION OF THE STEERING FRAME –FMS WEBMASTER ............................................................................. 6
4.2 INSTALLATION OF THE ACTUATOR –FMS WINDERGLIDE ..................................................................................... 7
4.3 INSTALLATION OF THE TRAVERSE ....................................................................................................................... 7
4.4 INSTALLATION OF THE SENSORS ......................................................................................................................... 8
4.5 INSTALLATION OF THE CONTROLLER ................................................................................................................... 8
4.6 CONNECTING TERMINAL ................................................................................................................................... 9
4.7 ELECTRICAL CONNECTION OF MATERIAL SENSORS .............................................................................................. 10
4.8 ELECTRICAL CONNECTION OF DIFFERENT FMS STEERING FRAMES AND ACTUATORSFEHLER! TEXTMARKE NICHT DEFINIERT.
5 OPERATION ........................................................................................................................... 12
5.1 OPERATING PANEL ........................................................................................................................................ 12
5.2 DISPLAY ....................................................................................................................................................... 12
5.3 MENU LEVELS ............................................................................................................................................... 13
5.4 INITIAL START-UP AND BASIC SETTINGS ............................................................................................................. 14
6 BASIC FUNCTIONS OF THE CONTROLLER ........................................................................... 16
6.1 AUTOMATIC MODE ......................................................................................................................................... 16
6.2 MANUAL MODE ............................................................................................................................................. 17
6.3 CHANGING AND STORING POSITIONS OF THE ACTUATOR ...................................................................................... 17
6.4 SELECTION OF THE GUIDING LOGICS .................................................................................................................. 18
7 BASIC FUNCTIONS OF THE MOTORIZED TRAVERSE IN MANUAL MODE ......................... 19
7.1 RETRACT THE SENSORS [RETRACT] .................................................................................................................. 19
7.2 AUTOMATICALLY DETECT THE WEB EDGE [DETECT] ............................................................................................. 19
7.3 APPROACHING THE HOME POSITION AS REFERENCE [REFRUN] ............................................................................ 19
7.4 SET AN ABSOLUTE ZERO POINT [SETZERPR] [SETZERPL] .................................................................................. 19
7.5 REPOSITIONING THE TRAVERSES MANUALLY ...................................................................................................... 21
8 OPERATING PARAMETERS .................................................................................................. 23
9 SYSTEM PARAMETERS ........................................................................................................ 32
10 TRAVERSE PARAMETERS AND FUNCTIONS ................................................................... 34
11 RESTORE DEFAULT SETTINGS ......................................................................................... 35
12 SETUP FOR CONNECTION TO A PC OR NETWORK ......................................................... 36
12.1 CONNECTION VIA WEB BROWSER ..................................................................................................................... 37
12.2 SETTING UP A PEER-TO-PEER CONNECTION WITH A PC ........................................................................................ 41
13 TROUBLE-SHOOTING ......................................................................................................... 44
14 DIMENSIONS ..................................................................................................................... 46
15 TECHNICAL DATA .............................................................................................................. 46
16 YOUR SETTINGS ................................................... FEHLER! TEXTMARKE NICHT DEFINIERT.

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1 Target Groups
This manual addresses mechanics who will install and connect the single
components and operators who will setup the machine and put it into operation.
The following skills are required as per target group.
Mechanics (installation, assembly)
Knowledge of electrical and measuring techniques, basic mechanical skills (drilling,
thread cutting, fastening technology, occupational health and safety.
Operator (configuration, start-up, operation)
Knowledge of the manufacturing processes and relevant parameters of the
machine, occupational health and safety, basic knowledge of network technology
(only required for optional LAN connection)
2 Safety Instructions
2.1 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 damaging 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.

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2.2 List of Safety Instructions
Some contacts on the pc board are supplied with a power of 230V!
Mortal danger! Disconnect the power supply before you 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 safety regulations and guidelines for the installation of electric equipment
have to be obeyed. They are not taken into consideration in this operating
manual. However, they have to be followed strictly.
Bad electrical grounding may cause electric shocks to persons, malfunction of the
total system or damage of the control unit! It is vital to ensure that proper
grounding is set.
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
Welding on the machine frame or components can cause defect on the electronic
components. Always disconnect the controller from the power supply before
welding.

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3 System and Functional Description
All instructions given in the manual are only valid for FMS components.
1 Steering frame or actuator 4 One or two sensors
2 Web and moving direction 5 Operating panel of controller
3 Motorized traverse
Illustration 1:Component arrangement
The illustration above shows a complete web guide control system with all required
components. The sensors detect the material position and transfer their measuring
results to the controller. The controller compares the actual measurement values
with the stored reference values. If the deviation reaches a certain threshold value,
the controller triggers the movement of the actuator.
A single sensor can be attached to a traverse. A maximum of two traverses can be
connected to the controller. By means of the electric drives of the traverses, the
sensor positon can be adjusted via the control panel.
The BKS309.W.M controller can be used in combination with steering frames of the
type webMASTER, with steering roller of the type webDIRECTOR and with actuators
of the type winderGLIDE.

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4 Installation and Wiring
Caution
Proper function of the controller is only guaranteed with the recommended
arrangement of the components. Other arrangements can cause heavy
malfunctions. Therefore, the installation instructions on the following pages must
strictly be followed.
4.1 Installation of the steering frame – FMS webMASTER
The mounting orientation of the steering frame (indicated by an arrow), must
correspond with the direction of the moving web. The lower frame part 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 electrically grounded.
Connect the grounding bolt of the steering frame with a corresponding point of the
machine. Use appropriate grounding cable for this connection.
Definition of the sensor alignment and designation of orientation in this manual
The sensors need to be mounted on the discharge side of the steering frame. "Left"
and "right" always refers to the moving direction of the web.
1 Entry side 5 Sensor axis left
2 Exit side 6 Web edge left
3 Moving direction of the web 7 Web edge right
4 Sensor axis left 8 Sensor axis right
Illustration 2: Sensor alignment
Note
Make sure that the sensor(s) are connected properly to the electronic unit by

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means of the delivered cables. For left / right orientation please refer to Fig. 2. 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.
4.2 Installation of the actuator – FMS winderGLIDE
To provide the optimum function of the actuator you should mount it in a horizontal
position. Attach the housing of the actuator to the machine frame. Bolt the moving
part (connection rod) to the winding roll.
Different connectors (fork head, yoke, etc.) are available from the FMS accessories
program.
Dimensions can be taken from the data sheet.
4.3 Installation of the traverse
The traverses have threaded mounting bores (M6) in their main body. You can use
these to bolt the traverse to the machine frame or the steering frame. A drag chain
and a safety guard for the sensor cable are part of the traverse.
If you have submitted the side of installation we have pre-installed all components
to suite the assembly on the correct side of the machine.
If you want to use the traverse on the other side you have to disassemble /
disconnect the following parts and re-install them on the correct side. The entire
hardware is prepared for the mirrored assembly of these parts.
1 M3 screws for guard 2 Guard
3 Drag chain with sensor cable 4 Fixation screw for drag chain
5 Screws for cable support 6 Sensor bracket
7 Screws for sensor (from bottom
side)
8 Sensor
Illustration 3: Motorized traverse
If you apply the motorized traverse on a winding / unwinding station, you have to
provide an appropriate fixation.
Dimensions can be taken from the data sheet of the motorized traverse.

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4.4 Installation of the sensors
The matching installation brackets for the sensors can be ordered from our
accessories program.
Dimensions of the sensors can be taken from the data sheet.
Please follow the instructions in the installation manual of the respective material
sensor.
The DLS2 sensor cannot be combined with this controller.
4.5 Installation of the controller
Make sure that the controller housing is installed in a safe and that the operator can
easily reach. Install the housing on a wall or to a suitable place that provides
enough stability.
You will find the dimensions of the housing on page 14.

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4.6 Connecting Terminal
The connections are located underneath a cover plate on the front side of the
controller. The plate can be lifted after removing the 4 screws.
Illustration 4: Access to the connection termal
Note
First connect the wires of the lower connection terminal (connection 1-15 and 41-
64)
Illustration 5: Connecting terminal BKS_309.ai

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Caution
Bad electrical grounding may cause electric shocks to persons, malfunction of the
total system or damage of the control unit! It is vital to ensure that proper
grounding is set.
4.7 Electrical connection of material sensors
4.8 Connecting FMS winderGLIDEs BKS.D.3, BKS.D.4 or a steering
frame FMS webMASTER BKS030
Illustration 6:Pin assignment of FMS winderGLIDEs BKS.D.3 and BKS.D.4 and
terminal blocks of controller. The illustration shows a BKS.D.3 or BKS.D.4. The
wiring of the BKS030 is similar. BKS309_BA_Manual.ai

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Illustration 7: Wiring diagram for BKS020.EE and BKS015.EE BKS_309.ai
Illustration 8: Wiring diagram for BKS.D.6 BKS_309.ai

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5 Operation
5.1 Operating Panel
LED operation mode
LCD
Traverse control
Edge guiding (right) or
line guiding
Edge guiding (left) or
line guiding
Automatic or manual
mode
Enter, select
Drive/increase
value/scroll parameter
Move to center point
Drive/decrease
value/scroll parameter
Centre guiding
Illustration 9: Operating panel BKS_309.ai
5.2 Display
Illustration 10: Start-up display: upper line with product type, lower line with
firmware version
Illustration 11: Standard display during operation, upper line with feedback of
the actual positon, lower line with reference value
Illustration 12: Menu level, upper line shows selected parameter, lower line
shows parameter value
0.00 mm
Ref Pos
ʌ
I
F
R
V2.33 M
BKS 309

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5.3 Menu levels
The functions and parameters of the controller are arranged in three different
menus.
Menu 1 – system parameters
Menu 2 – operating parameters
Menu 3 – traverse parameters and functions
A complete list of all parameters is printed on page 23.
Key Function
Manual and Automatic Mode
To be able to select the different menus for parametrization, you
have to enable the manual mode. The LED has to be off.
>3 Sec.
System Parameters
If you simultaneously press both keys and hold them for more than
3 sec., the menu for the system parameters will open. The LED is
on and the first parameter is shown in the display.
Press "Para" again briefly and you will enable the selected
parameter. The parameter name starts flashing. This indicates that
you can now change the value of the parameter. You can save the
changes by pressing the "Para" Button again.
If you press and hold the "Para" button for longer than 3 sec. you
will leave the menu and return to manual mode.
>3 Sec.
Operating Parameters
If you press and hold the key for more than 3 sec., the menu for the
operating parameters will open. The LED is on and the first
parameter is shown in the display. Press "Para" again briefly and
you will enable the selected parameter. The parameter name starts
flashing. This indicates that you can now change the value of the
parameter. You can save the changes by pressing the "Para"
Button again.
If you press and hold the "Para" button for longer than 3 sec. you
will leave the menu and return to manual mode.
Traverse Parameters and Functions
If you press the key the menu for the traverse parameters and
functions will open. The LED is on and the first parameter/function
is shown in the display.
Press "Para" briefly and you will enable the selected parameter or
start the function. The parameter name starts flashing. This
indicates that you can now change the value of the parameter. You
can save the changes by pressing the "Para" Button again.
If you press the button briefly again you will leave the menu and
return to manual mode.
Table 1: Access to the menus

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5.4 Initial start-up and basic settings
After applying the correct power (24VDC) the system is in operation. Before putting
the system into operation, you have to set some basic parameters.
Please clarify the following points:
• Steering frame / actuator
o Steering frames of the FMS webMASTER and webDIRECTOR series
are detected automatically
o Actuators of the FMS winderGLIDE series have to be configured
manually. You have to enter the mounting position of the actuator.
• Quantity and type of the applied motorized traverses
• Desired type of control (edge, center, line guiding)
• Units and language displayed on the LCD
• Requirements for the optional relays outputs or digital inputs if you wish to
connect the controller to a superordinated control
• Parameters for an optional integration into your network
After the initial start-up the controller is automatically set to manual mode.
Set language – operating parameter
Key Function
> 3 Sec Enter the menu for changing the operating parameters
Scroll through the list of parameters to the menu point [Sprache] or
[Language]
Changing the parameter: the selected parameter name starts flashing. This
means that you can now change the value of the parameter.
Change the parameter value as desired
Confirm the changes: The selected parameter name stops flashing.
> 3 Sec
Leave the menu for changing the operating parameters. The LED above the
key is now off.
To set the other basic parameters proceed as described above:
• Contrast of LCD [Contrast]
• Mounting side of motorized traverse [Traverse]
• Type of motorized traverse [TvTyp R] and [TvTyp L]

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If you have installed an actuator of the FMS winderGLIDE series, you have to set the
below parameter as well:
WinderGLIDE – system parameter
Key Function
> 3 Sec Enter the menu for changing the system parameters
Scroll through the list of parameters to the menu point [WinderGL]
Changing the parameter: the selected parameter name starts flashing.
This means that you can now change the value of the parameter.
Select the desired type
Confirm the changes: The selected parameter name stops flashing.
> 3 Sec
Leave the menu for changing the system parameters. The LED above the
key is now off.
Mounting side of the actuator – operating parameter
This value indicates the position of the actuator in regards of the rolling direction of
the web.
Key Function
> 3 Sec Enter the menu for changing the operating parameters
Scroll through the list of parameters to the menu point [Actuator]
Changing the parameter: the selected parameter name starts flashing. This
means that you can now change the value of the parameter.
Select the mounting side of the actuator
Confirm the changes: The selected parameter name stops flashing.
> 3 Sec
Leave the menu for changing the operating parameters. The LED above the
key is now off.
Start the reference run of the traverse
To initialize the drives of the traverses the exact position of the sensors on the rail
hast to be set.
Key Function
With the controller being in manual mode, enter the menu for changing
the traverse parameters. The LED above the key will be on and the first
parameter is shown in the display.
Scroll through the list of parameters to the menu point [RefRun]
Confirming the selection will instantly start the reference run.
Leave the menu for changing the traverse parameters. The LED above
the key is now off.
The system is now configured and ready for operation.

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6 Basic functions of the controller
6.1 Automatic mode
In the automatic mode the controller leads the web along the reference value and keeps it
there.
Edge guiding (left or right side)
Reference value (on the LCD "ʌ") = center of sensor range
Center guiding (2 sensors installed)
Reference value (on the LCD "ʌ") = center position of the 2 sensor axis
Key Function
Switch from automatic and manual mode with this key. The LED is on as the
controller is set to automatic mode.
With the controller operating automatically, you can adjust the reference
value in steps of 0.1 mm. This will re-adjust the position of the web.
"-" means that the web moves in direction of the sensor. "+" means a
movement of the web in the opposite direction. If the system is set to center
guiding this information refers to the sensor on the left hand side.
The shift of the reference value is indicated with "ʌ" on the display. The
entire “stroke” that you may use here is ±5 mm.
The LED will be on if you activate the traverse function while the system is in
automatic mode.
enables you to move the web sideways.
The entire stroke of the traverse can be used.
If you have installed 2 sensors, but only 1 traverse it can happen that the
sensor that sits on the traverse may collide with the web.
With activated traverse function in automatic mode you are able to adjust
the web position by moving the traverse with the sensor(s).
"-" means a shift of the web to the left
"+" means a shift of the web to the right
There’s a high risk of a collision between web and sensors or machine
components if you use this kind of control.
If you utilize two traverses and sensors in center guiding, both sensors will
be moved parallel. The menu will offer you a selection. By selecting
“SensR/l” you can choose the right sensor as the leading reference. By
selecting “SensL/r” the left sensor will be leading the movement. When you
confirm the selection with the display will show the distance to the
“home position” of the selected traverse. The sensor on the other side will
follow parallel with equal distance.

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Leave the menu for changing the traverse parameters. The LED above the
key is now off.
The LED is off as you leave the automatic mode.
Note
If the web is not moving the system may not be able to lead the web to the reference
value! The actuator possibly reaches its limit stops and may cause damage to the web.
Only switch to automatic mode when the web is moving slowly.
6.2 Manual mode
The following function are enabled in manual mode
Key Function
+
>3 Sec
Enter the menu for changing the system parameters. The LED is
on.
> 3 Sec Enter the menu for changing the operating parameters. The LED is on.
Enter the menu for changing the traverse parameters. The LED is on.
The actuator approaches the stored center position.
Moving the actuator in 0.1 mm steps to the desired direction. Holding
the key will increase the speed of the movement.
Selection of the guiding logics. The system guides along the left edge
or line. The LED indicates "edgle left"
Selection of the guiding logics. The system guides along the right edge
or line. The LED indicates "edgle right"
+
By pressing both keys you will enable the center guiding mode. The
system will follow along the theoretical center line of the both sensor
positions.
The guiding logic is dependent on the applied number of sensors. You
can select the center guiding mode only if you have installed 2
sensors. One for each side of the web.
6.3 Changing and storing positions of the actuator
You can adjust the home, middle and maximum position of the actuator. These
values are stored as operating parameters [Home Pos], [CentrPos] and [Max Pos].
You can either changes these parameter directly via the operating parameter menu
or alternatively move the actuator to the desired position in manual mode and store
the approached position.

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Key Function
+ Press both keys. The LED is on. The LCD indicates the actual
position of the actuator.
Approach the desired position.
After pressing briefly the LED stars flashing. The position can now be
stored.
Stores the actual position as [Home Pos]
Stores the actual position as [Max Pos]
Stores the actual position as [CentrPos]
If the operation was successful, the controller will confirm with "Safe
Pos done" in the display.
If the "Safe Pos failed" is shown in the display the position has not
been stored. This message indicates that the different position do not
correspond to each other. This may happen if e.g. the value for the
desired home position exceeds the value for the center position. The
positions always have to be in line. [Home Pos] is the smallest value,
[Max Pos] is the highest value and the value for [CentrPos] has to be
some in between.
6.4 Selection of the guiding logics
You can choose from 3 different guiding logics. The selected logic and the
configuration of the installed traverses influence the functions of the traverses.
Selected
logic
Installed
traverse(s)
Reference run of
traverse
Edge
detect
Retract from
web
left right left right left right
left left X X X
left right X X
left left & right X X X X X
right left X X
right right X X X
right left & right X X X X X
center left X X X
center right X X X
center left & right X X X X X X
Table 2: Guiding logics

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7 Basic functions of the motorized traverse
in manual mode
7.1 Retract the sensors [Retract]
Select this function to move the sensors away from the web.
Key Function
Switch to manual mode. The LED is off
Enter the menu for changing the traverse parameters. The LED is on.
Scroll through the list of parameters to the menu point [Retract]
Confirming the selection will instantly start the function. The sensor
moves away for the web to outer position of the traverse.
Leave the menu for changing the traverse parameters. The LED above
the key is now off.
7.2 Automatically detect the web edge [Detect]
The traverses move in direction of the web. The sensor signal is permanently
monitored. The movement will stop as soon as the web reaches the center of the
sensor area. To start this function please, follow the instructions similar to "Retract
the sensors".
7.3 Approaching the home position as reference [RefRun]
To initialize the drives of the traverses the exact position of the sensors on the rail
hast to be set. The reference run provides this function. The traverses are
completely retracted. If they already are on this position they will travel inwards a
short range and return to the home position. To start this function please, follow the
instructions similar to "Retract the sensors".
7.4 Set an absolute zero point [SetZerPR] [SetZerPL]
With the setup of this zero point you will be able to use the values of the sensor
position as absolute dimension. This will be of advantage if you have installed 2
traverses or during the setup procedure your machine.
You can choose each point along the axis of your traverse as a zero point. Pay
attention to the following restrictions.
• Max. offset ± 2000 mm
• If you have installed 2 traverses both of them have to have the identical zero
point. Therefore you have to make a one-time measurement of the sensor
positions and the traverses.

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Illustration 13: Zero point set outside the
web, e.g. on the machine frame
Illustration 14: Zero point set in the
center of the web, in between the
traverses.
Absolute zero point 6 Web and direction of travel
Home position of each traverse 7 Left traverse, sensor left
2
"Sens R/l" – moving both
sensors at the same time. The
value indicates the position of
the right sensor
8 Right traverse, sensor right
3 Sens L- distance of the
sensors during movement Pos. 1 Save Pos – current position sensor 1
4
Sens L/r – moving both sensors
at the same time. The value
indicates the position of the left
sensor
Pos. 2 Save Pos – current position
sensor 2
How to setup the zero point
• Mark the desired spot for the zero point e.g. on the machine frame, etc.
clearly with tape, scriber, etc.
• Measure the distances from the zero point to the sensors and note these
values. Use the marks on the sensor indicating the center of the sensor area
to get distinct values or mark the sensor yourself.
• Enter the values in the menu for changing the traverse parameters.
• As soon as you entered the values, the sensor positions will be refereeing to
the zero point.
Key Function