FMS BKS309.EIP User manual

Operating Manual BKS309.EIP
Digital Web Guide Controller with EtherNet/IP Interface
Version 2.60 07/2019 NS
Firmware Version: V2.43
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Table of Contents
1 Safety Instructions ...................................................................................... 4
1.1 Description Conditions 4
1.2 List of Safety Instructions 4
2 System Description ..................................................................................... 5
2.1 Functional Description 5
2.2 Steering Frame or Actuator 5
2.3 Electronic Control Unit 5
2.4 Sensors 6
2.5 System Integration in an Ethernet Network 6
3 Quick Installation Guide ............................................................................. 6
3.1 Preparations for Set-up 7
3.2 Installation Procedure 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 Electrical connection BKS309.EIP.R / .S or .W 10
5.2 Relays Outputs 12
5.3 Digital Inputs 12
5.4 Opening the Housing 14
6 Configuring the System ............................................................................ 15
6.1 Power up the BKS 309 15
6.2 Adjustment of the Sensors 15
7 Network Connection over EtherNet/IP ................................................... 16
7.1 EtherNet/IP Specification: 16
7.2 Controller Functionality over EtherNet/IP 16
7.3 Integration of BKS309.EIP in an Ethernet Network 16
7.4 Configuration of the Web Guide Controller over EtherNet/IP 17
8 Integration in an Allen-Bradley PLC ......................................................... 18
8.1 Hardware Environment 18
8.2 IP Configuration 18
8.3 Integration in a Project 18
8.4 Access to the Status Information 22
9 Operation .................................................................................................. 23
9.1 Operation Panel 23
9.2 Operating the Web Guiding System via the Front Panel 23
9.3 Automatic Operation 24
9.4 Manual Operation 25
9.5 Saving the Travel Limits 25

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10 Parameter Setting over the Front Panel .................................................. 26
10.1 Basic Instructions for Parameter Setting 26
10.2 Setting of Operation Parameters 26
10.3 Setting of System Parameters 26
10.4 List of Operation Parameters 27
10.5 Description of Operation Parameter 28
10.6 Description of System Parameters 39
10.7 Reset to Default Parameter Set 41
11 Parameter Setting via a PC ....................................................................... 42
11.1 Parameterization in a Network via Web Browser 43
11.2 Parameterization via a PC (peer-to-peer connection) 46
12 Mechanical Dimensions ........................................................................... 49
13 Trouble Shooting ...................................................................................... 51
14 Technical Specification ............................................................................. 52

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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
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 electronic control unit. In our case a BKS309.EIP web guide
controller. The control compares the position feedback signal with the reference. If the
difference of these two values is higher than the stored dead band value, the steering
frame will be adjusted.
Fig. 1: Basic system arrangement with BKS309.EIP web guide controller K309003e
2.2 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.
2.3 Electronic Control Unit
The micro-processor based electronic control unit handles all calculations and
communications. Parameter setting can be performed via the front panel, through a

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Web Browser or via the EtherNet/IP. All parameters are stored in a none-volatile
EEPROM memory. The BKS309.EIP controllers work in combination with FMS steering
frames of the type webMASTER, with steering rollers of the type webDIRECTOR, and
actuators of the type winderGLIDE.
2.4 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.
Note
If you retrofit a DLS2 sensor to an existing controller you have to restart the
controller after the installation of the sensor. This will allow the controller to detect
the DLS2 sensor correctly.
2.5 System Integration in an Ethernet Network
The web guide controller BKS309.EIP offers in addition to his standard features the
possibility to be used as an EtherNet/IP device in a corresponding network. EtherNet/IP
bases on the Ethernet TCP/IP and the UDP technology as well as on the CIP (Common
Industrial Protocol). The web guide controller can be embedded in a standard Ethernet
infrastructure. Its fast data rate with cycle times down to 2ms makes the device ideal for
applications in automated assembly and production lines. Configuration of the web
guide controller takes place either over the EtherNet/IP, a web browser or over the
operating panel.
Fig. 2: BKS309.EIP in an Ethernet Network K309EIP001e
3 Quick Installation Guide
In a Plug & Play configuration the set-up of the BKS309.EIP controller and corresponding
guiding unit is limited to only mounting the devices on the machine frame, wiring and
powering up system.

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3.1 Preparations for Set-up
1. Read the Operation Manual of your web guide or actuator system.
2. Check your system requirements such as:
– Desired guiding form (edge, centre or line guiding)
– Unit system (metric, imperial)
– Relay or digital input requirements of your set-up
3. Draw the wiring diagram for your configuration (ref. to chapter 5.1 to 5.6)
4. If required, determine special parameters (ref. to 10 “Parameter Setting over the Front
Panel”)
3.2 Installation Procedure
1. Mount and ajust your material sensor(s) to the steering frame (ref. to chapter 4.3)
2. Mount the steering frame or actator to the machine
3. Wire the sensor(s) to the electronic unit (ref. to chapter 5)
4. Wire the steering frame to the electronic unit (ref. to chapter 5.1 to 5.6)
5. Mount the electronic unit 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. Integrate web guide controller in an Ethernet network and PLC (see chapters 7.3 and
8)
8. If required, make additional settings (ref. to 10.2 “Setting of Operation Parameters”)

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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
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 Mounting the Sensors
The sensors will be mounted with brackets to the rail of the steering frame or to the
sensor arrangement of the unwind/rewind stand (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. 2).

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Definition of Left and Right:
Left and right are always seen in direction of the running web (see Fig. 3).
Fig. 3: Position of the sensors according to the web K400005e
Note
Make sure that the sensor(s) are connected properly to the electronic unit by means of
the delivered cables. For left / right orientation please refer to Fig. 3. 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.EIP 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 (stand alone and build-in in steering frame)
The mechanical dimensions can be seen in chapter 12 “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.EIP 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. 4)
5.1 Electrical connection BKS309.EIP.R / .S or .W
Fig. 4: Electrical connections BKS309.EIP BKS_309.ai

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5.1.1 Connecting the material sensors
Fig 5: BKS_309.ai
5.1.2 Connecting steering frames FMS webMASTER BKS020, BKS015
Fig 6: BKS_309.ai
5.1.3 Connecting FMS winderGLIDEs BKS.D.3, BKS.D.4 or a steering frame
FMS webMASTER BKS030
Fig 7: 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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5.1.4 Connecting an actuator BKS.D.6
Fig 8: BKS_309.ai
5.2 Relays Outputs
The BKS309.EIP 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
• Indicated if web is loaded (material is present)
• Indicate if web is loaded and Automatic Mode on
• Indicate if no web is loaded 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 10.5 “Description Operation
Parameter”.
Hardware access via screw terminals (see Fig. 9)
Signal Name Terminal #
Relay 1/1 9
Relay 1/2 10
Relay 2/1 11
Relay 2/2 12
5.3 Digital Inputs
The BKS309.EIP 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

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• Decrease reference value in 0.1mm steps (automatic mode) or
move actuator in 0.1mm steps to the left
• Increase reference value in 0.1mm steps or
move actuator in 0.1mm steps to the right
• Lock steering device (steering frame or actuator)
• Reset reference value
For more details about the functions refer to chapter 10.5 “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
.
Caution
Bad earth connections may cause electric shocks to persons, malfunction of the total
system or damage of the control unit! It is vital to ensure that the earth connection is
properly done.
5.4 Opening the Housing
The housing of the control unit BKS309.W.ACV.EIP can be opened by unscrewing the 4
Philips screws. This has to be handled with special care since some of the contacts in the
power supply board are under a tension of 85 to 264V.
Danger
Some of the wire terminals in the power supply board of the BKS309.W.ACV.EIP
controller are under a tension (85-264 VAC). Mortal danger! Only specially instructed
and qualified personnel should handle this controller unit. In any case the power
supply must be disconnected from the main supply before opening the housing.

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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
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 or actuator starts-up in Manual Operating Mode.
6.2 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. 10).
Fig 10: Alignment of the sensor axis to
the web edge K100004e

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7 Network Connection over EtherNet/IP
The web guide controller BKS309.EIP is able to communicate with other devices over an
Ethernet network. CIP (Common Industrial Protocol) is used as the protocol for the data
link. The controller acts as a so called “Producer” and the machine control (or PLC) as
the “Consumer”.
7.1 EtherNet/IP Specification:
Physical layer: Ethernet IEEE 802.3.
Transport protocol: TCP/IP und UDP
Standard: CIP IEC 61158
Conformity: CPF 2 (Communication Profile Family 2) IEC 61784-1
7.2 Controller Functionality over EtherNet/IP
Basically, all functions for configuration and calibration can be performed over
EtherNet/IP. Furthermore, status information of the controller can be cyclically
propagated over the network and made available to the Consumer (PLC).
7.3 Integration of BKS309.EIP in an Ethernet Network
In order to integrate the web guide controller in an Ethernet network and enable data
transfer over it following conditions must be fulfilled:
✔ An BKS309 controller with the option EtherNet/IP (EIP) must be used.
✔ The IP-Address must be assigned in the fix address block and must be
unambiguously. It may only exist once in the network.
✔ The network mask must correspond with the used device configuration.
If these prerequisites are given, the controller will recognise the amplifier as an
EtherNet/IP device in the network and be able to communicate with it. The interface
information for BKS309.EIP is defined in an EDS-file. The EDS file is only used as
documentation and cannot be imported into RSLogix 5000.
EDS-files for BKS309._. EIP can be downloaded from the FMS webpage.
Note
The device does not support the import of the EDS files. The import with development
software e.g. RSLogix5000 will generate error messages.
Utilize “Messages” to change parameter values of the device. Details are explained in
the sample file which is available for download on the FMS website.

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7.4 Configuration of the Web Guide Controller over EtherNet/IP
BKS309.EIP may, but need not be configured via EtherNet/IP. It can be configured by
means of a machine control unit. This unit is integrated in the same network. The
communication between machine control and web guide controller is carried out with
dedicated software (e.g. RSLogix5000 from Rockwell). Please refer to the operating
manual of the respective machine controller.
There are three possibilities to configure the BKS309.EIP. If the method over EtherNet/IP
is selected, the other two options (operation panel or web interface) are still possible
but not meaningful. The EtherNet/IP method has then always priority and overwrites
any other configurations set by the other two methods.
If the configuration over EtherNet/IP is selected then messages from the PLC to the
BKS309 must be used.
How the messages are used is described in the example project.
The example project BKS309_BKS015_EIP_Example_Project_Vx.xx is available for
download on the FMS website.
Note
The configuration of the web guide controller via EtherNet/IP must be used as
commissioning procedure. Continuously writing parameters on a cyclic base is not
allowed and will lead to communication problems and reduced the lifetime of the
device.

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8 Integration in an Allen-Bradley PLC
Following chapters deal with the integration and operation of the BKS309.EIP controller
with an Allen-Bradley PLC. The project software RSLogix5000 from Allen-Bradley is
required to program the PLC. Furthermore, it is assumed that a development system
with PC and corresponding development software RSLogix from Rockwell Automation is
available and the programmer is familiar with these tools..
8.1 Hardware Environment
The BKS309.EIP must be connected to an Ethernet switch which in turn is in the same
network as the PLC. Only in this way a communication between BKS309.EIP and PLC can
take place. Several BKS309.EIP or other ErtherNet/IP devices can be connected to the
same network.
.
8.2 IP Configuration
In an industrial environment, the IP addresses are normally assigned fix to the EIP
devices. This holds also for the BKS309.EIP controller that needs a fix IP address in the
network. The IP address configuration must take place before the BKS309.EIP is
integrated in a network. This is done over the operation panel or over the web interface.
The procedures are described in the state diagrams chapter 10 (Fig. 22) and chapter 11
(Fig.31)
8.3 Integration in a Project
Before starting the development system RSLogix5000 the PLC and BKS309.EIP need to
be connected to the network and powered-up. Now a new project or an existing project
can be opened in RSLogix5000. Search in the tree structure Controller Organizer for the
listing Ethernet and make a right mouse click (see Fig. 11).

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In this example CompactLogixL23E-QB1B is used. If a different hardware is used, one
may find the listing Ethernet in another place. However, the principal approach is always
the same. After a right mouse click on Ethernet a dialog window will open up. Left
mouse click on New Module...and a new window will open up (see Fig.12).
Fig. 11: Controller Organization K309EIP02

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Open plus-sign [+] in front
of Communications to see
all the other listings.
Select ETHERNET-
MODULE Generic
Ethernet Module and
confirm with OK.
Following window opens
up in which the Name
BKS309_91, the Comm
Format
Input Data - DINT and the
IP Address (eg.
192.168.0.91) need to be
entered. On the
Connection Parameters
side the values Input=100
with Size 2, Output= 101
(leave empty) and
Configura-tion= 102 with
Size 88 must be entered.
Confirm with OK
Fig. 12: Module Selection E309022
Fig. 13: : Module Selection open E309023
Fig. 14: New Module K309EIP03