FMS BKS600A User manual

Operating Manual BKS600A
Digital microprocessor controlled web guide
for DC drive
Version 1.11 08/02 pw
Firmware Version: ab 2.00
Hardware Rev. D
This operation manual is also available in German.
Please contact your local representative.
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie die Vertretung im zuständigen Land.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

Operating Manual BKS600A
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1Safety Instructions
1.1 Description Conditions
High danger of health
injury or loss of life Risk of damage
to machines Note for
proper function
Danger
This symbol refers to high risk
for persons to get health injury
or loss life. It has to be
followed strictly.
Caution
This symbol refers to risk of
heavy mecanical damage.
This warning has to be
followed absolutely.
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
Proper function of the electronic unit is only guaranteed with the recommended
application of the components. In case of other arrangement, heavy malfunction can be
the result. Therefore, the installation instructions on the following pages must be followed
strictly.
Local installation regulations are to preserve safety of electrical equipment. They are not
taken into consideration in 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 electronic unit! It is vital to ensure that proper earth connection is done.
The processor board is mounted to the housing cover. Improper handling may damage the
fragile electronic equipment! Don’t use rough tools such as screwdrivers or pliers! Touch
processor board as little as possible! Touch earthed metal part to discharge static
electricity before opening the housing!
If external parts are in the travel range of the linear units, the sensors can be damaged
while moving! It is to ensure that large enough distances are kept allover.
With the line-up of the limit of travel positions, the software limit switches of the steering
frame or the unwinding roller are set. Bad setting may cause damage of the steering frame
or the unwinding roller! Therefore, the setting should only be made during the first initial
operation and by authorized and specially trained personnel only!
Wrong setting of the jumpers and solder bridges may cause malfunction of the electronic
unit or the total system! Setting of the solder bridges and jumpers must be checked
carefully prior to power on! Setting of the solder bridges should be carried out by trained
personnel only!

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Table of Contents
1 Safety Instructions............................................................................................2
1.1 Description Conditions 2
1.2 List of Safety Instructions 2
2 Definitions .........................................................................................................4
3 System Components.........................................................................................4
4 System Description...........................................................................................5
4.1 Functional Description 5
4.2 Steering device 5
4.3 Electronic Control Unit 6
4.4 Edge Sensors 7
4.5 Manual Sensor Adjustment 7
4.6 Linear Units 7
4.7 Remote Control Box 7
5 Quick Installation Guide .................................................................................8
6 Dimensions........................................................................................................9
7 Installation and Wiring..................................................................................10
7.1 Mounting the Electronic Unit 10
7.2 Wiring Diagrams 12
7.3 Mounting the Steering Device 15
7.4 Mounting of Manual Sensor Adjustment 15
7.5 Mounting of the Linear Units 16
7.6 Mounting of the Edge Sensors 17
8 Operating ........................................................................................................18
8.1 View of the Operating Panel 18
8.2 Configuring the Electronic Unit 19
8.3 Main Operating Menu and Special Functions 20
8.4 Manual Operation 21
8.5 Operation without Linear Units 22
8.6 Operation with Linear Units 23
8.7 Measuring from a Reference Point on the Machine Frame 25
9 Parametrization..............................................................................................26
9.1 Schematic Diagram of Parametrization 26
9.2 List of the System Parameters 27
9.3 List of the Parameters BKS600A 27
9.4 Description of the system parameters 28
9.5 Description of the Parameters BKS600A 29
9.6 Service Mode 33
9.7 Line-up of the limit positions and Offset Compensation 37
10 Serial Interface (RS232)...............................................................................39
11 Interface PROFIBUS...................................................................................39
12 Interface CAN-Bus.......................................................................................39
13 Interface DeviceNet......................................................................................39
14 Technical Reference.....................................................................................40
14.1 Additional Setting Elements 40
14.2 Setting Elements on the Extension Board 41
14.3 Jumper for the Analog Inputs / Outputs 42
14.4 Technical Data 44
15 Trouble Shooting..........................................................................................46

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2Definitions
Left and Right: Left and right are always seen in direction of the running web.
Linear unit: Motorized Sensor adjustment (option). The sensor is adjusted automatically by a
linear guide with stepper motor to the edge or line to be detected.
Steering device: Hydraulic cylinder, steering frame or similar actuator.
Dead band: A free programmable range of tolerance in which the web may move freely
without readjusting the steering device. Keep in mind that „0.3mm“ means ±0.3mm.
If the deviation is higher than the tolerance, the web will be readjusted into the range of the
dead band.
Subprint: Electronic extension module which can be plugged to the main board of the
electronic unit if required. That way, the possibilities of the electronic unit can be extended
easily.
3System Components
A BKS600A web guiding system consists of the following components (refer also to fig. 1):
Steering device
•Electrically or hydraulically driven
Electronic unit BKS600A
•For all control functions
•With operation panel for parametrization
•Steering frame with DC motor or analog control output
±10V / 0...10V / 0...20mA / 4...20mA
•Power amplifiers for the stepper motors of the linear units
•Interface RS232, PROFIBUS, CAN-Bus, DeviceNet
•Digital inputs and outputs
•Remote control box
•With robust aluminium housing
Sensors
•For detection of web edge
•1 or 2 analog sensors
Linear units
•linear units with two phase stepper motor and limit switch for reference
(components and variants in italic letters are options)

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4System Description
fig. 1: Basic structure of the BKS600A web guide K600023e
4.1 Functional Description
The sensors measure the position of the web edge and send this information as an analog
signal to the electronic control unit. The control unit compares the position feedback signal
with the reference. If the difference is higher than a parametrized value (dead band), the
steering device is adjusted to bring the web into the right position.
If the sensors are equipped with linear units, the control unit automatically lets them follow the
edge. The actual position of the sensors on the linear unit is taken into calculation for the
actual web position.
4.2 Steering device
The steering device adjusts the web position laterally. Its width is depending on the web
width. Any steering device can be used if it can handle the signal for an FMS steering frame
with DC motor drive:
−FMS steering frame with DC drive
−any actuator with analog input ±10V / 0...10V / 0...20mA / 4...20mA
−Optionally: ±300mA / ±10V for a moving coil controller (hydraulic actuator)

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4.3 Electronic Control Unit
Common
The electronic unit is mounted to a robust aluminium housing. It contains the power amplifier
to drive the actuator and the power amplifiers to drive the linear units. The electronic unit has
no trimmers and only few jumpers to keep most accurate long-time and temperature stability.
Operation
The large backlit display with 2x16 characters, 4 LED’s and large keys guarantee simple
operation. All information is in plain text with the following languages selectable: English,
German, French and Italian. Most of the functions may be paramterized. The parametrization
can be done via the keys or the interfaces. All inputs are fail-safe stored in an EEPROM.
Additional settings can be made with jumpers or solder bridges.
Interface
As an option, there are RS232, PROFIBUS, CAN-Bus or DeviceNet interfaces available. All
inputs and settings can be made by the integrated operation panel or by the interfaces.
fig. 2: Block diagram BKS600A K600024e

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4.4 Edge Sensors
An optical sensor (AZS01) and an ultrasonic sensor (US01) is available from FMS.
Adjustment is done automatically.
4.5 Manual Sensor Adjustment
The manual sensor adjustment allows an easy positionning of the sensor across the whole
material width. Focussing of the sensor is kept.
4.6 Linear Units
The linear units are also used for sensor positioning but give much more comfort than the
manual one. The control unit automatically lets the sensors find the edge or the line across the
whole material width.
This kit contains 1 or 2 linear units with travel range according to customer specification, the
sensor mounting bracket and the necessary cables. The control unit detects automatically if 1
or 2 linear units are installed.
It is possible to define a fixed reference point (machine frame for example). Then, all position
values will refer to this reference point.
4.7 Remote Control Box
The remote control box simplifies resetting the machine for a new job. The position reference
can be adjusted with two keys on the box in 0.1mm steps. It enables the operator to stand
beside the machine and get a direct feedback when adjusting the lateral position.

Operating Manual BKS600A
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5Quick Installation Guide
•Check all your requirements such as:
– Control mode (edge left, edge right, center guiding)?
– Number and setup of the edge sensors?
– Steering device type (FMS steering frame, hydraulic drive or other device)?
(if a linear DC drive for unwind or rewind stands is used it must be setup; refer to
„9.7 Line-up of the limit positions and Offset Compensation“)
– configuration of the digital inputs and outputs?
– linking by interface etc.?
•Draw your final wiring diagram according to the wiring diagram (refer to „7.2 Wiring
diagrams“)
•Install and wire all your components (refer to „7. Installation and wiring“)
•Turn power on and do the setup according to „8. Operating“
•Proceed a test run with low speed

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6Dimensions
fig. 3: Dimensions K600019e

Operating Manual BKS600A
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7Installation and Wiring
Caution
Proper function of the electronic unit is only guaranteed with the recommended application of
the components. In case of other arrangement, heavy malfunction can be the result. Therefore,
the installation instructions on the following pages must be followed strictly.
Caution
Local installation regulations are to preserve safety of electrical equipment. They are not taken
into consideration in this operating manual. However, they have to be followed strictly.
Caution
Bad earth connection may cause electric shock to persons, malfunction of the total system or
damage of the electronic unit! It is vital to ensure that proper earth connection is done.
7.1 Mounting the Electronic Unit
The housing can be mounted in a control cabinet or directly beside the machine. All
connections are led into the housing through glands and are connected to the plug-in screw
terminals according to the wiring diagrams (fig. 7...12).
fig. 4: Wiring path inside the housing E600011e

Operating Manual BKS600A
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Caution
The processor board is mounted to the housing cover. Improper handling may damage the
fragile electronic equipment! Don’t use rough tools such as screwdrivers or pliers! Touch
processor board as little as possible! Touch earthed metal part to discharge static electricity
before open the housing!
fig. 5: Screw terminal arrangement on the processor board K600028e
fig. 6: Screw terminal arrangement on the extension board and the power amplifier for
the DC drive K600007e

Operating Manual BKS600A
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7.2 Wiring Diagrams
fig. 7: Wiring of the power supply to the electronic unit K600027e
fig. 8: Wiring of steering frame or other steering device K600025e

Operating Manual BKS600A
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fig. 9: Wiring of the edge sensors K600009e
fig. 10: Wiring of the linear units K600026e

Operating Manual BKS600A
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fig. 11: Wiring of the digital inputs and outputs K600011e
red
green
red
green
Siemens color code
fig. 12: Wiring of the interfaces K600030e

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7.3 Mounting the Steering Device
Mounting and wiring is done according to manufacturer’s specifications. Take care that the
steering device is mounted in the right position regarding the running direction of the material
web. If a steering frame is used, the pivot point mus be located at the entry side and the edge
sensors must be located at the exit side (fig. 13).
Wiring to the screw terminals of the electronic unit is done according to wiring diagram (fig.
8).
fig. 13: Notice the running direction of the web when mounting the steering device.
K600005e
7.4 Mounting of Manual Sensor Adjustment
The manual sensor adjustment must be installed after the steering device regarding running
direction (fig. 13). It will be mounted directly to the machine frame.
The sensors can be moved on the location rail. Use the fixing nut to lock the sensor.
Note
For optimum control results, the sensors adjustment has to be placed in a way that the sensors
are placed next to the exit roller of the steering frame. If the sensors are placed far from the
steering frame, control dynamics will be reduced drastically.

Operating Manual BKS600A
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7.5 Mounting of the Linear Units
The linear units must be installed after the steering frame regarding running direction (fig. 13).
They will be mounted directly to the machine frame using the supplied brackets.
Wiring of the linear units is done according to wiring diagram (fig. 10). The electronic control
unit detects automatically if 1 or 2 linear units are connected.
Note
For optimum control results, the linear units have to be placed in a way that the sensors are
placed next to the exit roller of the steering frame. If the sensors are placed far from the
steering frame, control dynamics will be reduced drastically.
Caution
If external parts are in the travel range of the linear units, the sensors can be damaged while
moving! It is to ensure that large enough distances are kept allover.

Operating Manual BKS600A
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7.6 Mounting of the Edge Sensors
The edge sensors will be mounted by brackets to the sensor adjustment (refer to operating
manual AZS01 and US01). The sensors may be mounted to the left or right web edge.
fig. 14: Position of the edge sensors referring to the web. They may be mounted to the
left-hand or right-hand side. K400005e
Wiring of the edge sensors to the terminals is done according to wiring diagram (fig. 9).
The FMS sensors provide a signal of 0...10V. If sensors with different signal range are used,
this must be parametrized (refer to „8.2 Configuring the Electronic Unit“).
Note
The inputs for the analog signals have different Gnd terminals. Therefore the terminals Gnd
and Signal Gnd have to be bridged. If not, malfunction may appear.

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8Operating
8.1 View of the Operating Panel
fig. 15: Operating panel BKS600A K600020e

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8.2 Configuring the Electronic Unit
Prior to the first calibration, the following settings must be done (ref. to „9. Parametrization“
and „14. Technical reference“):
System parameters
Language Required display language
Service parameters
Motor config. 1) Standard
Stroke motor 1) depending on steering device used
Start pos. motor 1) (will be set with Line-up of the limit positions;
Center pos. motor 1) ref. to „9.7 Line-up of the limit positions and Offset
End pos. motor 1) compensation“)
Offset motor 1) determine with Offset compensation; ref. to „9.7 Line-up of
the limit positions and Offset compensation“
Length of rail left (only if left rail is used)
Length of rail right (only if right rail is used)
Sensor covered depending on sensor used
Sensor uncovered depending on sensor used
Sensor range depending on sensor used
1) only if no steering frame is used
Parameters BKS600A
Control mode According to requirements
Dead band For the time being set to 0mm
Analog output 2) Controller output2) or Feedback sensor
Scale feedback 2) According to requirements
Output manual 2) According to requirements
Offset output 2) For the time being set to 0
Limit output 2) For the time being set to 100%
Output config. 2) According to requirements
Output direction 2) Standard
Base distance left For the time being set to 0mm
Base distande right For the time being set to 0mm
2) only if analog controller output is used
Note
Wrong setting of the parameters may cause malfunction of the electronic unit! Setting of the
parameters must be done carefully prior to setting into operation!

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8.3 Main Operating Menu and Special Functions
fig. 16: Main operating menu BKS600A K600018e
Special function Operation
Automatic ↑↓= automatic on / off
←= commit settings
Reference ↑↓= enlarge / reduce reference value 1) 2)
←= quit input mode
Center ↵= drive to center position
←= (abort)
Manual ↑↓= move steering frame manually left / right 1) 2)
←= quit input mode
Init. Motor (ref. to „9.7 Line-up of the Limit Positions and Offset
compensation“)
Detection 3) ↵= proceed for edge detection
←= (abort)
Freerun 3) ↵= proceed for sensor freerun
←= (abort)
Sensor l. 3) ↑↓= move left sensor 1) 2)
←= quit input mode
Sensor r. 3) ↑↓= move right sensor 1) 2)
←= quit input mode
1) Typing adjusts the value for 0.1mm. If the key is hold for more than 1s the value is modified
continuously.
2) The value is taken immediately to the control loop
3) Only with linear units