FMS BKS015.EIP User manual

Operating Manual BKS015.EIP
Steering Frame with Digital Web Guide Controller with
EtherNet/IP Interface
Version 2.14 11/2018 NS
Firmware Version V2.21
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
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© 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 5
2.3 Web Guide Controller 5
2.4 Sensors 5
2.5 Cables 6
2.6 System Integration in an Ethernet Network 6
3 Quick Installation Guide ............................................................................. 6
3.1 Preparations for Set-up 6
3.2 Installation Procedure 7
4 Installation and Wiring ............................................................................... 8
4.1 Mounting the Steering Frame 8
4.2 Mounting the Sensors 8
4.3 Connecting the BKS015.EIP 9
4.4 Connector and Screw Terminal Arrangement 9
5 Configuring the System ............................................................................ 11
5.1 Powering up the BKS015.EIP 11
5.2 Adjustment of the Sensors 11
6 Network Connection over EtherNet/IP ................................................... 12
6.1 EtherNet/IP Specification: 12
6.2 Controller Functionality over EtherNet/IP 12
6.3 Integration of BKS015.EIP in an Ethernet Network 12
6.4 Configuration of the Web Guide Controller over EtherNet/IP 12
7 Integration in an Allen-Bradley PLC ........................................................ 14
7.1 Hardware Environment 14
7.2 IP Configuration 14
7.3 Integration in a Project 14
7.4 Access to the Status Information 17
8 Operation .................................................................................................. 19
8.1 Operation Panel 19
8.2 Basic Instructions for Operation and Parameter Setting 19
8.3 Operating the Web Guiding System via the Front Panel 19
8.4 Operation in Automatic Mode 21
8.5 Operation in Manual Mode 22
8.6 Entering the Parameter Setting Mode 22
8.7 Description of the LED-row 23
8.8 Sensor Detection Range and Reference Position 24
9 Description Parameters ........................................................................... 25
9.1 Description Operation Parameters 25
9.2 Description of System Parameters 28
9.3 Reset to Default Parameter Set 30

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10 Parameter Setting via a PC...................................................................... 31
10.1 Parameterization in a Network via Web Browser 31
10.2 Parameterization via a PC (peer-to-peer connection) 35
11 Dimensions ............................................................................................... 39
12 Trouble Shooting ...................................................................................... 41
13 Technical Specification ............................................................................ 42

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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
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. Therefore, the installation instructions on the following pages
must be followed strictly.
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.
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. 2. If
the connections are crossed over, malfunction can be the result.
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

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2 System Description
2.1 Functional Description
Figure 1 shows the BKS015 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 built-in web guide controller unit. The control 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 BKS015.EIP system K015006e
2.2 Steering Frame
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 by hall sensors. The material sensors are mounted on the lower
frame by means of a bracket array and are easily adjustable to the web width.
2.3 Web Guide Controller
The micro-processor based electronic control unit handles all calculations and
communications tasks. Three buttons and a five key wind-rose serve as the man-
machine interface. Parameter setting can be performed via the front panel or
through a Web Browser (IE 7.0 or higher) or via the EtherNet/IP.
2.4 Sensors
Optical sensors (AZS04) and ultrasonic sensors (US01B) are available from FMS to
work in conjunction with the BKS015.EIP system. These sensors provide a signal of
0...10V. With them edge and center applications can be covered. A wide range of

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materials including opaque, transparent, open weave textiles and metallic webs can
be detected.
2.5 Cables
The power supply cable enters to the web guide via a PG-gland connection. For each
sensor a dedicated orange cable is delivered.
2.6 System Integration in an Ethernet Network
The web guide controller BKS015.EIP.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: BKS015.EIP in an Ethernet Network K309EIP001e
3 Quick Installation Guide
The set-up of the BKS015.EIP web guide including controller unit is limited to only
mounting the devices on the machine frame, wiring and powering up system.
3.1 Preparations for Set-up
1. Prepare your machine frame to integrate the BKS015.EIP web guide. The web
guide is mounted on the machine by means of the 4 holes on its base plate.

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Refer to Fig. 21 for the mechanical dimensions and mounting holes of the
BKS015.EIP.
2. Check your system requirements such as:
– Desired guiding form (edge or centre guiding)
– Supply conditions
3. Draw the wiring diagram for your configuration (ref. to 4.3 “Connecting the
BKS015.EIP“ and chapter 4.4 “Connector and Screw Terminal Arrangement”)
4. If required, determine special parameters (ref. to 7.1 “Description Operation
Parameters”)
3.2 Installation Procedure
1. Mount and ajust your material sensor(s) to the steering frame (ref. to chapter 4.2)
2. Mount the web guide to the machine frame
3. Connect the sensor(s) to the electronic unit.
4. Make sure the power supply voltage is in the range 18 to 36V DC (Vnom= 24V)
5. Power your system on
6. If required, make additional settings (ref. to chapters 8.6 and 8.7)

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4 Installation and Wiring
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
M5 screws to the machine frame. The machine must be prepared to accept the M5
mounting screws.
The steering frame must be connected to earth ground. Ensure that the base plate
of the steering frame has direct contact with the grounded machine frame. In
addition the ground bolt (see Fig. 1) must be connected to the machine earth.
Caution
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 there is a proper and
secure earth connection.
4.2 Mounting the Sensors
The sensors will be mounted with brackets on a rail to the lower frame of the web
guide
They have to be installed after the outbound roller. Mount them as close as possible
to the steering frame (see Fig. 3). The sensors are connected to the web guide
controller by means of the delivered orange cables. Refer to the operation manual
AZS01, US01B for further information about the sensors.

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Definition of Left and Right:
Left and right are always seen in direction of the running web (see Fig. 2).
Fig. 3: Position of the sensors according to the web K400005e
Sensors of the type AZS must be mounted with its narrow side (thinner leg) on the
side of the steering frame
Caution
Make sure that the sensor(s) are connected properly to the electronic unit by
means of the delivered orange cables. For left / right orientation please refer to Fig.
3. If the connections are crossed over, malfunction can be the result.
4.3 Connecting the BKS015.EIP
The power supply unit musst deliver a voltage from 18 to 36V DC (Vnom= 24V).
Connect the cable coming out of the PG-gland to your power supply unit.
Wire colour Signal
brow 24 VDC
blue GND
4.4 Connector and Screw Terminal Arrangement

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Fig. 4: Terminal arrangement on processor board K015008e
Note
An Ethernet connector RJ-45 is also available on the back side of the housing.

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5 Configuring the System
After having mounted and wired the web guide on the machine, the system can now
be configured to the specific requirements of the application.
5.1 Powering up the BKS015.EIP
1. Make sure the power supply delivers a voltage of 18…36 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 starts-up in Manual Operating Mode.
5.2 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 properly positioned, if the web edge goes through
the sensor axis (center of active window; ref. to Fig. 5).
Fig 5: Alignment of the sensor axis to the web edge K100004e
.

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6 Network Connection over EtherNet/IP
The web guide controller BKS015.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”.
6.1 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
6.2 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).
6.3 Integration of BKS015.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 BKS015 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 BKS015.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 BKS015.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.
6.4 Configuration of the Web Guide Controller over EtherNet/IP
BKS015.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.

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If the configuration over EtherNet/IP is selected then messages from the PLC to the
BKS015.EIP 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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7 Integration in an Allen-Bradley PLC
Following chapters deal with the integration and operation of the BKS015.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..
7.1 Hardware Environment
The BKS015.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 BKS015.EIP
and PLC can take place. Several BKS015.EIP or other ErtherNet/IP devices can be
connected to the same network.
.
7.2 IP Configuration
In an industrial environment the IP addresses are normally assigned fix to the EIP
devices. This holds also for the BKS015.EIP controller that needs a fix IP address in
the network. The IP address configuration must take place before the BKS015.EIP
is integrated in a network. This is done via the web interface (see chapter 10.1, Fig.
19)
7.3 Integration in a Project
Before starting the development system RSLogix5000 the PLC and BKS015.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.
6).

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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.7).
Fig. 6: Controller Organisation 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 Configu-
ration= 102 with Size 88
must be entered. Confirm
with OK
Fig. 7 Module Selection E309022
Fig. 8: Module Selection open E309023
Fig. 9: New Module K309EIP03

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The dialog window (Fig. 15) will open up. Here, one can enter the cycle time. This
determines how often the data will be propagated in the network. The minimal cycle
time is 2 ms. Default setting is 10 ms. Basically the cycle time must be set so that
the maximum speed requirements of the system are fulfilled. A fast cycle time leads
to more data traffic in the network. That can create communication bottlenecks.
Especially when using several BKS309 and other EIP devices in the same network a
well-balanced data speed is important.
Fig. 10: Module Properties
Note
Untick the box „Use Unicast Connection over EtherNet/IP“. The use of this feature is
not allowed as it will cause communication problems.
7.4 Access to the Status Information
After the integration of
the BKS015.EIP in the
network the status
information are available
in the global input tags
and that in the defined
cycle time. In our
example the device was
named BKS309.
Operation Status
information can be found
under the controller tags
BKS309:I >> BKS309:I
Data
Fig. 11: RSLogix K309EIP04

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The data show in what operational state the device currently is.
A PLC can analyse the states and execute further actions.
Bit 0 set: Automatic Operation switched on
Bit 1 set: reserved
Bit 2 set: reserved
Bit 3 set: Web Guide or winderGLIDE actuator locked
Bit 4 set: Web Guide or winderGLIDE actuator was driven to the center
Bit 5 and Bit 6 are not set: Left edge guiding
Bit 5 set and Bit 6 not set: Right edge guiding
Bit 5 and Bit 6 are set: Centre guiding

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8 Operation
8.1 Operation Panel
Fig. 12: View of the Operation Panel K015003e
8.2 Basic Instructions for Operation and Parameter Setting
The web guide controller has three operation modi:
• Operation Mode
• Parameter Setting Mode (e.g. Dead Band)
• Change Mode (change of Reference Position)
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 modi by
pressing the corresponding key or key combination. The Parameters are described
in chapter 9.1 “Description of Operation Parameters”. The keys have the following
functions:
8.3 Operating the Web Guiding System via the Front Panel
Key Key function during operation
The sensor is mounted on the left side of the frame and
controls the material on the left edge or on the line, if a line
sensor is used. One sensor is necessary. The LED indicates
t
he left edge guiding mode.
The sensor is mounted on the right side of the frame and
controls the material on right edge or on the line, if a line
sensor is used. One sensor is necessary. The LED indicates
t
he right edge guiding mode.
Two sensors are mounted on both sides of the frame. The
frame is controlled in a way that the material position is kept
centered with regard to both sensor positions. The LED
indicates the centre guiding mode.
Key to enter the Parameter Setting Mode. Hold the key for
longer then 3 sec. The LED above the PARA key lights. A

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second press for longer then 3 sec. on the PARA key will store
t
he value (ref. to 8.6 “Entering the Parame
t
er Settin
g
”)
Automatic or Manual. With this key you can select between
automatic or manual mode. The LED indicates the automatic
mode.
Drive to center position. The frame moves to the center
Position. This
f
unction is only available in manual mode.
In manual mode
t
he 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 the Reference Position will be adjusted to
the left in 0.1 mm steps by pressing the button once. Pressing
the button longer than 1 sec. it will continuously move the
Reference Position to the left (see chapter 8.4 “Operation in
Automatic Mode).
In parameter setting mode: Pressing the button reduces
continuously the parameter value.
In manual mode
t
he 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 the Reference Position will be adjusted to
the right in 0.1 mm steps by pressing the button once.
Pressing the button longer than 1 sec. it will continuously
move the Reference Position to the right. (see chapter 8.4
“Operation in Automatic Mode).
In parameter setting mode: Pressing the button increases
continuously the parameter value.
Fig. 13: Table of key functions
Note
To make the settings easier for the operator, there is visual help in form of LED row.
The pattern on the LED row indicates the setting range (ref. to chapter 8.7
“Description of the LED row).