FMS BKS309.MS Operating 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.

Operating Manual BKS309.MS

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”).
If necessary, continue with the configuration of your system (ref. to chapter 6)

9.

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 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.

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.

The LED indicates the left edge guiding mode.

The LED indicates the right edge guiding 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.

Fig. 12:
100005e

Position at automatic start K

Note

If the web leaves the sensor detection band, control is no longer effective. Hold
the web edge strictly inside the sensor detection band.

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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

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.

for 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

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Fig. 14: State Diagram Operation Parameters (2) K309010e

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Fig. 15: State Diagram Operation Parameters (3) K309011e_MS

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Fig. 16: State Diagram Operation Parameters (4) K309014e_MS

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8.3 Setting of System Parameters

To enter the Parameter Setting Mode the web guide controller must be in the Manual

Mode. Press the and key together for longer than 3 sec to enter the System
Parameter List. The LED will light and the first parameter will appear on the LCD
display. Proceed like in chapter 8.2 for changing parameters.

Fig. 17: State Diagram System Parameters K309018e

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8.4 List of Operation Parameters

Parameter LCD Unit Min Max Selection Default

Adjust Reference
Position

Set Reference
Mode

Save the
Reference Position

Ref Pos

mm -5.00 +5.00 - 0.00

Ref Mode - - -

SaveRef - - -

Manual

Auto

No

Yes

Manual

No

Dead band DeadBand mm 0.0 2.0 - 0.1

Relay 1 or Relay 2
setting

Relay 1

Relay 2

- - -

MidSenso
MatFound
Auto&Mat

R1=

MidSenso

Aut&Miss

Auto

Centre

R2=

MatFound

Disabled

Digital Input 1, 2,
3 or 4 Modes

Input 1
Input 2
Input 3
Input 4

- - -

Edge→Aut

Lv→Auto

Centre

- Ref/←
+Ref/→

Centre

Lock

ResetRef

I1=

Edge→Aut

I2=Center

I3=

-Ref/←
I4=

+Ref/→

Disabled

DLS Sensor DLS - - - none

none

left

right

Language Language - - -

English

German

Password Password - - -

No

English

No

Yes

LCD-Contrast Contrast % 1 100

Unit System Unit Sys - - -

- 65

Metric

Metric

Imperial

Gain Setting Gain - 0.02 2.00 - 0.2

Adjust Correction

AdjSpeed % 1 100 - 100

Speed

Power Modes Power ON - - -

Manual

Manual

Auto

Last Set

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Behaviour when

Auto→Man - - ­leaving Automatic
Mode

8.5 List of System Parameters

Parameter LCD Unit Min Max Selection Default

Manual

Centre

Manual

Device Mode DevicMod - - -

Chas&Fol

Chas&Fol

Standard

Master Input MastrInp - - - right

right

left

Home Position 3)

Middle Position3)

Maximal Position3)

Actuator Actuator - - -

Home Pos mm 0.0 300.0 -

Mid Pos mm 0.0 300.0 -

Max Pos mm 0.0 300.0 -

Left

0.0 3)

62.5 5)

125.0 5)

Left

Right

IP Address IP Addr - 0 125 -

192.168.0
.090

Subnet Subnet 0 255 -

255.255.2

55.0

LAN Speed LANSpeed MBPS - -

10

100

Factory Settings 4)

Default - - -

Not set

Not Set

Yes

3)

Parameter only used in winderGLIDE (actuator) applications

4)

This parameter change requires a restart of the web guide controller.

5)

The default value is dependent on the actuator used.

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8.6 Description Operation Parameter

Adjust Reference Position [Ref Pos]

Purpose: The reference position can be adjusted using this parameter.

Range: -5.00 to +5.00 Default: 0.00

Increment: 0.01 Unit: [mm]

Set Reference Mode [Ref Mode]

Purpose: This parameter determinates how the reference position is defined.

This can either be the position that is defined with parameter [Ref
Pos] or the actual material position within the sensor when the
controller is switched to automatic operation.

Two settings are possible:

Setting: [Manual]

Purpose: If [Manual] is chosen, the Reference Position is taken from the

parameter [RefPos].

Setting: Automatic [Auto]

Purpose: If [Auto] behaviour is chosen, the Reference Position is determinate

by taking the actual material position within the sensor when the
controller is switched to automatic operation.

Save the Reference Position [SaveRef]

Purpose: The parameter saves the last Reference Position change. It sets after

re-booting the Reference Position to the last used value or to 0 (zero).

Two settings are possible:

Setting: [No]

Purpose: If [No] behaviour is chosen, the Reference Position is set to 0 after

rebooting (default setting).

Setting: [Yes]

Purpose: If [Yes] behaviour is chosen, after rebooting the Reference Position is

set to the last used value.

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Dead band [DeadBand]

Purpose: This parameter defines the dead band tolerance. Dead band is a free

programmable range, in which the web may move freely without the
steering readjusting the frame. Keep in mind that: A [DeadBand] of
e.g. 0.3mm“ results in a tolerance band of ±0.3mm.

If the deviation is higher than the tolerance, the web will be readjusted into

the range of the dead band.

Range: 0.0 to 2.0 Default: 0.1
Increment: 0.1 Unit: [mm]

Relay 1 or Relay 2 setting [Relay 1 or 2] (two Parameters one for each relay)

Purpose: This parameter determines the relay behaviour.

The user can choose between seven settings.

Setting: Middle Position [MidSenso]

Purpose: If [MidSenso] is chosen then the relay goes on when the material

edge is at the sensor’s middle position.

(Default setting for Relay 1)

Setting: Material Found [MatFound]

Purpose: If [MatFound] is chosen then the relay goes on when material edge

is detected. (Default setting for Relay 2)

Setting: Automatic Mode and Material Found [Auto&Mat]

Purpose: If [Auto&Mat] is chosen then the relay goes on when material edge

is detected and the controller is in Automatic Operation.

Setting: Automatic Mode and Material Missing [Aut&Miss]

Purpose: If [Aut&Miss] is chosen then the relay goes on when no material

edge is detected and the controller is in Automatic Operation.

Setting: Automatic Operation [Auto]

Purpose: If [Auto] is chosen then the relay goes on when the controller is in

Automatic Operation.

Setting: [Centre]

Purpose: If [Centre] is chosen then the relay goes on as soon as the motor

drive stands still after a centre run.

Setting: [Disabled]

Purpose: If [Disabled] is chosen then the relay function is disabled. The relay

will never go on.

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Digital Input 1, 2, 3 or 4 Modes [Input 1…4]
These are actually fore parameters one for each digital input

Purpose: This parameter determines the functions of the digital inputs.

The user can choose between seven settings.

Setting: Edge Triggered Automatic Mode [Edge→Aut]

Purpose: The controller switches either to automatic or manual operation

depending in which mode the controller currently is. The switching is
taking place when a rising edge is detected on the digital input.
(Default setting for dig. input 1)

Setting: Level Controlled Automatic Mode [Lv→Auto]

Purpose: The controller switches either to automatic or manual operation

depending on the voltage level at the digital input. If the voltage is
high then the controller switches to Automatic otherwise to Manual
Operation.

Setting: Drive to Center Position [Centre]

Purpose: If [Centre] is chosen then the motor drive moves to the centre

position. The event is edge triggered. (Default setting for dig. input 2)

Setting: Move Frame to the Left [-Ref/←]

Purpose: In manual operation the motor drive moves to the left respectively to

the retracted position (default setting for dig. input 3).

Setting: Move Frame to the Right [+Ref/→]

Purpose: In manual operation the motor drive moves to the right respectively to

the extended position (default setting for dig. input 4).

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Setting: Lock Guide [Lock]

Purpose: The motor drive is immediately locked when this parameter is chosen

and the digital input voltage is high.

Dig. Input Lock, Operation State Automatic and Parameter

[Auto→Man] work in a combinative manner. Their interdependency is
described in the following table:

Dig. In.

Lock

Op. State

Automatic

Parameter

Auto→Man

Function

0 inactive Centre Move to middle position
0 active irrelevant Automatic operation
1 inactive Manual Stop at actual position
1 inactive Centre Move to middle position
1 active irrelevant Stop at actual position

Setting: Reset of Reference Value [ResetRef]

Purpose: This function resets the reference value to 0, if a positive signal edge

is applied to the digital input.

Setting: Disabled

Purpose: With [Disabled] parameter the digital input is disabled.

DLS

Purpose: If you use a DLS2 sensor, you have to set the correct installation

direction. You can only connect one DLS2 sensor.

The user can choose between three settings.

Setting: [none]

Purpose: There is no DLS2 sensor connected

Setting: [left]

Purpose: The DLS2 sensor is installed on the left-hand side (in direction of the

moving web)

Setting: [right]

Purpose: The DLS2 sensor is installed on the right-hand side (in direction of

the moving web)

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Password

Purpose: The web guide controller can be protected from unauthorised access

by means of password. If Password Yes is chosen, the system will
request the password to change parameters and other setting. The
password itself can’t be changed. It is always 3231

The user can choose between two settings

Language: [No]

Purpose: The Password protection is deactivated (default setting)

Language: [Yes]

Purpose: The Password protection is activated

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Language

Purpose: This parameter determines the displayed language.

The user can choose between two languages.

Language: [English]

Purpose: If [English] is chosen, the display shows all texts in English. The web browser

is always in English.

Language: [German]

Purpose: If [German] is chosen, the display shows all texts in German.

LCD-Contrast [Contrast]

Purpose: The parameter [Contrast] changes the contrast of the LCD to achieve

optimal readability.

Range: 1 to 100 Default: 65

Increment: 1 Unit: [%]

Unit System [Unit Sys]

Purpose: This parameter determines the unit system used.

The user can choose between two settings.

Setting: [Metric]

Purpose: If [Metric] is chosen, the controller displays all data in metric units.

Setting: [Imperial]

Purpose: If [Imperial] is chosen, the controller shows all data in imperial

units.

Gain Setting [Gain]

Purpose: This parameter defines the gain of the feed back value.

Range: 0.02 to 2.00 Default: 0.20

Increment: 0.01 Unit: [ - ]

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Adjust Correction Speed [AdjSpeed]

Purpose: This parameter determines the maximum used speed.

Range: 1 to 100 Default: 100

Increment: 1 Unit: [%]

Power Modes [Power ON]

Purpose: This parameter determines the operation mode after power on.
The user can choose between three behaviours.

Setting: [Manual]

Purpose: The controller goes to Manual Operation Mode after power on.

Setting: Automatic [Auto]

Purpose: The controller goes to Automatic Operation Mode after power on.

Setting: Last Setting Used [Last Set]

Purpose: The controller restores the operation mode that was previously

chosen before power off.

Behaviour when leaving Automatic Mode [Auto→Man]

Purpose: This parameter determines the behaviour of the controller leaving

the automatic mode.

The user can choose between two behaviours.

Setting: [Manual]

Purpose: The controller stops guiding. The motor drive is locked at the

current position (Manual Mode).

Setting: [Centre]

Purpose: The controller stops guiding. Afterwards the motor drive moves to

the centre.

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Device Mode [DevicMod]

Purpose: This parameter determines whether the web controller controls a

standard steering frame or a Chase & Follow application.

The user can choose between the two settings.

Setting: [Chas&Fol]

Purpose: Control of a Chase & Follow application (default setting)

Setting: [Standard]

Purpose: Control of a standard FMS steering frame

.

Master Sensor Input [Mastrinp]

Purpose: This parameter determines in a Chase & Follow application the

sensor input connector for the master web.

The user can choose between two settings.

Setting: [right]

Purpose: The right sensor input is used for the master web (default setting).

Setting: [left]

Purpose: The left sensor input is used for the master web.

Home Position [Home Pos]

Purpose: This parameter determines the position of the actuator spindle in

its retracted position. In Automatic Mode the actuator stops at this
position and moves no further backwards. In Manual Operation
this parameter has no meaning.

Range: 0.0 to 300.0 Default: 0.0

Increment: 0.1 Unit: [mm]

Condition: This parameter appears on the display only if an actuator /

winderGLIDE is connected to the controller.

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Middle Position [Mid Pos]

Purpose: The [Mid Pos] parameter determines the centre position of the

actuator spindle. An actuator stops at this position, if you press the

centre key . In Automatic Operation this parameter has no
meaning.

Range: 0.0 to 300.0 Default: 62.5

5)

Increment: 0.1 Unit: [mm]

5)

The default value is dependent on the used actuator

Condition: This parameter appears on the display only if an actuator /

winderGLIDE is connected to the controller.

Maximal Position [Max Pos]

Purpose: This parameter determines the limit for the extended position. In

Automatic Mode the actuator stops at this position and moves no
further forward. In Manual Operation this parameter has no
meaning.

Range: 0.0 to 300.0 Default: 125.0

Increment: 0.1 Unit: [mm]

5)

The default value is dependent on the used actuator

5)

Condition: This parameter appears on the display only if an actuator /

winderGLIDE is connected to the controller.

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Actuator [Actuator]

Purpose: The parameter [Actuator] determines the control logic of the web

guide controller BKS309.

Condition: This parameter appears on the display only if an actuator /

winderGLIDE is connected to the controller.

The user can choose between two control directions.

Action: [Left]

Purpose: [Left] is the control direction when the actuator is mounted on the

left side of the unwind/rewind station seen in direction of the
running web (see Fig. 2)

Action: [Right]

Purpose: [Right] is the control direction when the actuator is mounted on the

right side of the unwind/rewind station seen in direction of the
running web (see Fig. 2)

[IP Addr]

Purpose: The parameter assigns an IP address to the controller. This

enables the user to communicate via a web browser with the
controller that is imbedded in a network. The IP address must be
entered in 4 separate blocks (IP Bl. 1; IP Bl. 2; IP Bl. 3; and IP Bl. 4)

Range: 0 to 255 Default: 192.168.0.090

Increment: 1 Unit: [ - ]

[Subnet]

Purpose: The parameter assigns the Subnet Mask of the controller in the

Ethernet network. This enables the user to communicate via a web
browser with the controller. The Subnet Mask must be entered in 4
separate blocks (Sub. Bl 1; Sub. Bl 2; Sub. Bl 3; and Sub. Bl 4).

Range: 0 to 255 Default: 255.255.255.0

Increment: 1 Unit: [-]

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[LANSpeed]

Purpose: [LANSpeed] determines the data speed of the web guide controller

to communicate the receiver (Switch, Hub or PC).

The user can choose between two data speeds.

Action: [100 MBPS]

Purpose: [100 MBPS].means 100 M bit per second

Action: [10 MBPS]

Purpose: [10 MBPS].means 10 M bit per second

Factory Settings [Default]

Purpose: This menu point is a command. It resets the parameters to the

factory settings.

The user can choose between two actions.

Action: [Not Set]

Purpose: If [Not Set] is chosen, all parameters stay as set by the user.

Action: [Yes]

Purpose: If [Yes] is chosen, the default parameters are loaded.

Note

The operation parameters [Home Pos], [Mid Pos], [Max Pos], as
well as all system parameters are not reset with the factory
setting command [Default].

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8.7 Setting of System Parameters

Caution

System parameters are factory settings and should not be changed without contacting the
service department of FMS. An unauthorised change can cause malfunctions in the
system or damage in the machine.

To enter the System Parameter Setting Mode hold the two + keys for longer then
3 sec. The LED will light and the first parameter will appear on the LCD display

Offset Centre [Offset><]

Purpose: This parameter adjusts the position of a steering frame exactly to

the centre.

Position Detection [PosDetec]

Purpose: This parameter determines what devices that are used to detect the limit

positions.

The user can choose between three types.

Type: [Potentio]

Purpose: A potentiometer is used to detect the Home position, Middle

Position and Maximum Position. It is automatically set, if an
actuator / winderGLIDE of the type BKS.D.3 is used.

Type: [One Hall]

Purpose: One hall sensor is used to detect the Home position, Middle

Position and Maximum Position.

Type: [Two Hall]

Purpose: Two hall sensors are used to detect the Home position, Middle

Position and Maximum Position.

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Centre Position [CentrPos]

Purpose: The [CentrPos] parameter is only used with the position detection

system based on hall sensors. For all other position detection
system this parameter is not used and hence not displayed. The
parameter determines the centre position of the actuator spindle
in motor steps (measured from the left reference position). The

actuator stops at this position, if you press the centre key .
In Automatic Operation this parameter has no meaning.

Right Limit [RightLim]

Purpose: The [RightLim] parameter is only used with the position detection

system based on hall sensors. For all other position detection
system this parameter is not used and hence not displayed. The
parameter limits the maximum travel to the right side of the
actuator spindle in motor steps (measured from the left reference
position). In the operation or in manual mode this limit will never
be exceeded

Drive Direction [DriveDir]

Purpose: This parameter determines the guiding orientation of the

controller.

This parameter should not be changed without contacting the

service department of FMS.

Setting: [Standard]

Purpose: [Standard] For standard motors and standard frames of FMS

(default setting).

Setting: [Invers]

Purpose: [Invers] The controller sets the drive direction automatically, if

FMS products are use.

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Actuator Type [winderGL]

Purpose: This parameter determines the used actuator type. The product

name of FMS actuators is winderGLIDE.

The user can choose between three types.

Type: [D.3.125] or [D.6.125]

Purpose: If type [D.3.125] or [D.6.125] is chosen, the maximum travel of the

spindle will be 125mm (4.92in). It is the maximum travel position.

Type: [D.3.200] or [D.6.200]

Purpose: If type [D.3.200] or [D.6.200] is chosen, the maximum travel of the

spindle will be 200mm (7.87in). It is the maximum travel position.

Type: [D.3.300] or [D.6.300]

Purpose: If type [D.3.300] or [D.6.300] is chosen, the maximum travel of the

spindle will be 300mm (11.81in). It is the maximum travel position.

8.8 Reset to Default Parameter Set

Factory settings of your BKS309 web guide controller can be re-established either
over the parameter setting menu (see 7.2 “Setting of Operation Parameters”,
parameter [Default]) or by:

Holding the two keys

+ while powering –up the controller.

Note

The operation parameters [Home Pos], [Mid Pos], [Max Pos], as well as all system
parameters are not reset with the factory setting command [Default].

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9 Parameter Setting via a PC

The BKSZ309 web guide controller can be embedded in an Ethernet network and the
parameter setting can be done over this network by means of a web browser
(Internet Explorer 7). The devices have a static IP-address that can be set over the
user interface. The IP-address is not automatically received over DHCP.
The parameter setting can also be carried out with a desktop- or laptop computer via
a peer-to-peer connection (see paragraph 9.2)
Fig. 18 shows the BKS309 configuration in a LAN (Local Area Network).

Fig. 18: BKS309 embedded in a LAN EMGZ309001e

Note

Fig. 19 and 20 show the peer-to-peer connection between PC und BKS309. Please
be aware that for this configuration a cross-over-cable needs to be used.

Fig. 19: Correct connection with cross­over-cable. E309002e

Fig 20: Connection with wrong cable
E309003e

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9.1 Parameterization in a Network via Web Browser

Before the parameterization of the BKS309 it must be certain that the BKS309 uses
an IP address in a static block. For the integration of a BKS309 web guide controller
in your Ethernet network please contact your IT system administrator.
Once the BKS309 was integrated in the network you can address the device e.g. with

http://192.168.000.090 . After establishing the link, the screen Fig. 21 will open up.

Fig. 21: Serial number and device information Home.jpg

With the menu on the left side of the screen you can navigate through the web page.

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Fig. 22: Parameter setting and Remote Control Remote Control

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Fig. 23: Parameter list webMASTER Steering Frames wMASTER.jpg

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Fig. 24: Parameter list winderGLIDE Actuators wGLIDE.jpg

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Fig. 25: Ethernet settings and device addresses Ethernet Settings

Fig. 26: Firmware update Firware Updates

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9.2 Parameterization via a PC (peer-to-peer connection)

This paragraph describes the procedure for setting up a desktop or laptop computer
to communicate with FMS BKS309 web guide controller.
Before connecting the FMS BKS309 controller with a “cross-over-cable” directly to a
PC, the computer must be configured with a “static” IP address. If the BKS309
controller is connected to a network by using e.g. a switch, the following procedure is
not necessary. To establish the connection between your PC and the BKS309 follow
the steps below

Setup in Microsoft Windows XP:

1. Click on the Start button (lower left-hand corner of the screen)

2. Click on Control Panel

3. Double click on Local Area Network

4. Right click on the network adapter that is used for the connection.

5. Click on Properties on the pop up menu, the following dialog box “Local Area
Connection Properties” will appear.

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In the list box “This connection uses the following items:”, scroll down to “Internet
Protocol (TCP/IP). Select the “Internet Protocol (TCP/IP) and click “Properties” button.

The following dialog box will appear. Make sure the “General” tab is selected.

Select the radio button “Use the following IP address:”

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In the IP address box enter the IP address for the computer that could be

192.168.0.1.
In the Subnet mask, enter 255 255 255 000, as shown below.
Notice that the “000” in both boxes will change automatically to “0”.

The dialog box will change to look like the following:

Click the “OK” button. The following dialog box will appear again:

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Click on the “Close” button.
Close the “Network Connection” window
Close “Control Panel”

The computer is now ready to communicate with the BKS309 controller:

1. Connect the “cross over cable” to both the BKS309 and to the appropriate
port on the desktop or laptop computer.

2. Open Microsoft Internet Explorer or Mizilla Firefox.

3. The default IP address for the BKS309 is 192.168.000.090 as long as it was
not changed over the operating penal. Enter the IP address in the address bar
and hit the Enter key. If a different IP address and subnet mask is configured
at the BKS309 make sure that the computer is setup appropriate.

4. The screen Fig. 21 will open up. Continue then with the procedure described
in 9.1 “Parametrization in a Network via a Web Browser”.

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10 Mechanical Dimensions

The BKS309 series is available in three different housing options. The mechanical
dimensions can be seen in the following pages.

Fig. 27: Outline Drawing BKS309.R rail mount housing K309006e

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Fig. 28: Outline Drawing BKS309.W wall mount housing K309008e

Fig. 29: Outline Drawing BKS309.S panel mount housing K309007e

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Fig. 30: Outline Drawing BKS309.R.C for DIN real mounting with connectorsK309016e

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11 Trouble Shooting

Error Cause Corrective action

Edge outside
detection band

BKS guides web
edge immediately
out of the sensor

Sensor is connected

Steering frame
does not move

No signal; cable

No signal; sensor

No response of
the interface

Edge has moved
outside the sensor
detection band

Sensor is mounted on
the wrong side

to the wrong socket

No signal; sensor not
correctly connected

interruption

defect

Wiring not correct Check wiring

Adjust sensor more accurately to the
web edge;
Adjust reference position less during
automatic operation

Mount sensor to the correct side (right
sensor for „Edge right“, etc.)

Connect sensor plug to the correct
socket (left plug to left socket, etc.)

Connect sensor correctly according to
screw terminal arrangement and
installation guide

Replace cable or send sensor to FMS

Send sensor to FMS; use other sensor

Display shows
nothing, frame
doesn’t react

Power supply defect Check or correct power supply

Electronic control unit

Frame moves
abrupt to one of
the end positions

Fuse blown Replace Fuse on power supply board

installation

Contact FMS customer service

defect

Stepper motor driver
defective

Exchange actuator of the frame.
Contact FMS service department for
spare parts and installation guide.

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12 Technical Specification

Cycle time processor 1ms
Drive of steering
frame
Dead band 0…2mm, adjustable in 0.1mm steps
Position reference ±5mm, adjustable in 0.1mm steps
Control modes edge left / edge right / center guiding / line guiding
Interface Web browser Ethernet Explorer 7 or higher
Operation 3 keys and 5–key wind rose pad
Analogue inputs 2 inputs 0...10V (for sensors)
Digital inputs 4 dig. inputs 24VDC galvanic insulated
Relay outputs 2 relay outputs. DC: 220V/2A/60W; AC:250V/2/62.3VA
Supply voltage 18…30 VDC (Vnom.= 24 VDC),

Temperature range -10 ... 60°C (14…140°F)
Protection class IP 30 (Standard) / IP65 (.W), IP00 (.S)

Stepper motor. Power amplifier 24V integrated in
housing

version .ACV 85…264 VACV / 80W

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FMS Force Measuring
Systems AG
Aspstrasse 6
8154 Oberglatt (Switzerland)
Tel. [phone]
Fax [phone]
[email protected]
www.fms-technology.com

FMS USA, Inc.
2155 Stonington Avenue
Suite 119
Hoffman Estates,, IL 60169
(USA)
Tel. [phone]
Fax [phone]
fmsusa@fms­technology.com

FMS (UK)
Aspstrasse 6
8154 Oberglatt
(Switzerland)
Tel. [phone]
[email protected]

FMS (Italy)
Aspstrasse 6
8154 Oberglatt (Switzerland)
Tel. [phone]
[email protected]

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