Set up a Balluff BNI IO-Link Master with ctrlX CORE using EtherCAT

PretschC · ‎02-03-2023

Introduction

This HOW-TO describes the integration of a Balluff EtherCAT IO-Link master BNI0077 into ctrlX. It shows possibilities for diagnosis and parameterization of IO-Link Devices. Other Balluff EtherCAT IO-Link masters can also be commissioned in this way.

Requirements

Hardware

ctrlX CORE
Balluff EtherCAT IO-Link Master (e.g. BNI0077)

Software

Rexroth PLC app on ctrlX CORE
Rexroth EtherCAT Master app on ctrlX CORE
ctrlX I/O Engineering and PLC Engineering (ctrlX WORKS)

Step-by-Step guide

New Project

Open ctrlX CORE user interface in browser.
ctrlX CORE User Interface
Add EtherCAT master by clicking [+] in EtherCAT > Configuration.
EtherCAT / Configuration / [+]EtherCAT / Configuration / [+] / [OK]
Open ctrlX I/O Engineering

ctrlX I/O Engineering
Open New project.
New Project

Install device description

Download ESI (device description) on Balluff website:
Download ESI
e.g. for this example: https://www.balluff.com/de-de/products/BNI0077
Open Tools > Device Repository
Open Device Repository
Install device description
Install device description

EtherCAT-Device configuration

Add Device to EtherCAT-Master by right-click in the device tree on ethercatmaster > Add Device:
EtherCAT device configuration
Choose the relevant ESI (device description) for your device from device catalog > Add Device:
Add device
The IO-Link Master is now pre-configured with standard I/O on pin 4 for all ports
Preconfiguration

Port Configuration

Technical data IO-Link port

The ports of the IO-Link Master are freely configurable for your application and individual needs. For connecting IO-Link devices, an IO-Link communication can be set up on pin 4. If only digital IOs are needed, Pin 2 and 4 can also be configured as simple input or output. The configuration of the pin functions is done by plug device. The configuration of pin 4 has to be done for each port seperatly, pin 2 is combined for each port.
To configure the IO-Link port communication on pin 4, a suitable process data module must be selected: right click on IO-Link channel > Plug Device
Plug device selection
Choose module > Plug Device
Plug Device
For the correct process data size, see the manual of the IO-Link device used.
Make sure that enough memory space has been reserved in case one of the modules does not fit exactly.

There are two possible data types for process data, which are indicated by different colors of the IO-Link icon: grey for bits and black for array of bytes. Use plug device to choose one of these representation of process data.
Process data figure
To configure pin 4 as input or output, use the input or output module, not a IO-Link module
IO_Link_CHx > Plug Device
Configure pin 4

As with IO-Link, separate process data are now created for each port.
To configure pin 2 as input or output, plug the device into slots for pin 2.
Input_Pin_2 > Plug Device to configure input process data
Output_Pin_2 > Plug Device to configure output process data
Configure pin 2

It is alwas possible to use pin 2 in both directions. Attention: In contrast to pin 4, a common byte is used for the pin 2 function. The bits from 0 to 7 represent the pin 2 of port 0 to 7.

Diagnosis

There are four slots for direct and fast diagnosis of the powersupply:
Diagnostic bytes

For short circuit modules: each bit of the byte represents one of the eight ports.
Short circuit modules

The module status shows the power supply of the IO-Link Master
Module status
The status of the IO-Link communication is displayed for each channel in a status byte.
Communication status

The Status can also be seen in the CoE online data:
CoE communication status

These are the possible values:
Possible ports
A validation for each Port can be configured: IO-Link_Chx > Startup Parameter
Port validation

The validation mode is stored in parameter index 0x20n2, subindex 0x02 (n = port number 0...7)
No validation (value 0): validation deactivated, every device will be accepted
Compatibility (value 1): manufacturer ID and device ID are compared to the module data. The IO-Link communication is only started if there is a match.
Identity (value 2): manufacturer ID and device ID and serial number are compared to the module data. The IO-Link communication is only started if there is a match.

The values for validation are stored in index x80n0, subindex 0x04 (Device ID), 0x05 (Vendor ID), 0x08 (Serial Number).

EoE-Communication

EtherCAT network configuration

Activate the virtual ethernet port and configure the network adress in the tab EoE of the EtherCAT Master:

EtherCAT Master > EoE > virtual Ethernet port (master)
EoE settings

In the tab EoE of the EtherCAT Master is a overview of all slaves that support EoE functionality. Here, it is possible to activate the virtual port of the slaves and assign the network configuration automatically or manually.

It is also possible to activate expert settings to enable EoE on the IO-Link Master. The EoE tab appears. Now you can activate the virtual port of the IO-Link Master and assign the network configuration here .

EtherCAT Slave > General > enable expert settings
Expert settings

EtherCAT Slave > EoE > virtual ethernet port
Virtual ethernet port
ctrlX CORE network configuration
It's necessary to enable IP forwarding in the connectivity settings of the EoE port (eoe0) and the engineering port (eth0).

Settings > Connectivity
ctrlX CORE connectivity settings

Settings > Connectivity > eoe0 > enable IP forwarding
ctrlX CORE IP forwarding eoe0

Settings > Connectivity > eth0 > enable IP forwardingctrlX CORE IP forwarding eth0
Add Routing
For network access set the according route on your host operating system.

Open command line on your host:
Route

Use your network specific configuration for ip adress, mask and gateway.
For mor details use command "route ?"

To test the route, ping an EoE Slave in the EtherCAT topology.

IO-Link Parametrization

Via Webserver

If you have access to Webserver over EoE, you can configure your IO-Link devices in a web browser.
Open website via IP-Adress > ports
Webserver

To write parameters, you must log in. Password: BNIECT.
It's also possible to upload an IODD file to set parameters with plane text.
Via Parameter Server:
An IO-Link master according to IO-Link Specification 1.1 can act as a parameter assignment server for the IO-Link device.

IO-Link_Chx > Startup Parameter > Set Parameter Server index 0x20n2, subindex 0x03 (n = port number 0...7)
Parameter server

Switched on: data management functions enabled, parameter data and identification data of the IO-Link devices are residually saved.
Switched off: data management functions disabled, saved data are retained.
Deleted: data management functions disabled, saved data is deleted.
Enable upload: Select whether an upload of parameter data to the data management of the IO-Link master port is to be carried out or not. If the upload is enabled, the master starts a parameter data upload as soon as a device requests an upload (upload flag set) or if there is no data saved in the master port (e.g. after data has been deleted or before the first data upload)
Block upload: If the upload is disabled, no data upload will be started. When there is an upload request from the IO-Link device, a download (if enabled) is started because no upload may be carried out if there are different parameter sets.
Enable download: Select whether a download of parameter data to the IO-Link device is to be carried out or not. As soon as the saved parameter data in the parameter server of the port is differentiated from the connected IO-Link device and no upload request from the IO-Link device is present, a download is carried out.
Block download: If the download is blocked, an upload (if enabled) of the parameter data occurs independent of the upload flag of the IO-Link device.
Block upload and download: If upload and download are blocked, no parameter data exchange occurs. The IO-Link device then communicates anyway with the IO-Link port.

The following values are possible for the settings:
0x8X Switch on
0x0X Switch off
0x40 Delete
0xX1 Switch on upload
0xX2 Switch on download

To enable the upload flag of an IO-Link device, the value 0x05 must be entered in the index 0x02, subindex 0
(e.g. see Parametrization via CoE Online)

via CoE online
Via object 0x40n0 (IO-Link Service Data Ch. X), IO-Link ISDU parameters can be read or written from the IO-Link device. To do this, the corresponding index and subindex must be entered. In addition, the corresponding length and the data must still be entered when writing. Via the control object, the read or write task is then started. In the Object status, the result is then displayed.

IO-Link_Chx > Startup Parameter > IO-Link Service Data CH .X index 0x40n2 (n = port number 0...7)

Control Values for the Control:
• 0x00: No action
• 0x02: Write
• 0x03: Read

Status Values for the Status:
• 0x00: No activity
• 0x01: Active / Busy
• 0x02: Access
• 0x04: Error
• 0xFF: Failure

example: reading index 0x10 Vendor Name
1. Set IO-Link index (CoE Subindex 0x03), IO-Link subindex (0x04)
2. Set contol (0x01) to value 0x03 (read)
CoE read
3. The answer is displayes in Data (0x06), Status (0x02) displays answer 0x02 (access).

To write parameter, also set lenght (0x05) and data array (0x06).
Status (0x02) displays answer 0x02 (access).

via Startup Parameter
For startup parameter you have to follow the same steps as for parameters via CoE.
Make sure that the control command is always the last command for this parameter set. For more than one parameter, start again by setting index, subindex, lenght and Data and end the parameter with the command control .

Startup parameter selection

Startup parameter overview

The Company

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cristinafurini · ‎10-11-2023

Hi,

how many BNI0077 could I use with one ctrlX?

is there an App from Balluff to check sensors?

thank you

Cristina

PretschC · ‎10-18-2023

Hi Cristina,

thank you for your question.

In principle, there is only the limitation of 65535 EtherCAT slaves for an EtherCAT master and the performance of the controller. There are no special limitations for IO-Link.
In my application I had up to 4 IO-Link masters and two additional EtherCAT slaves without any problems.

What do you mean by an app for testing sensors?

Feel free to write me a private message or contact me at support.de@Balluff.de.

Best regards
Carsten

Set up a Balluff BNI IO-Link Master with ctrlX CORE using EtherCAT