EtherCAT integration

With the EtherCAT integration, the system is made up of the following components:

• Bus master

• Bus modules/slaves (here the bus module BNI)

Device data

In order to properly parameterize the bus master, device data in the form of three ESI files is enclosed with the bus module BNI.

Input/output buffer

The data exchange with the controlling system takes place in the input and output buffer. The size of this buffer must be configured by the master.

Configuration

During the project planning the BNI bus module is displayed as a modular device. The device data required for the project planning is stored in the ESI files. The data modules of the inputs/outputs, the IO-Link Port and any additional modules are shown in the project planning software in relation to the slot.

The ESI files make available the possible data modules (inputs/outputs, IO-Link Ports of varying data width and other additional modules).

The appropriate data modules are assigned to a certain slot for the configuration of the BNI. Unused slots can be released.

Integration in project planning software

As an example, the connection of the BNI to a Beckhoff TwinCAT control is shown with the TwinCAT System Manager. The exact procedure depends on the project planning software used.

Installing ESI files

The device description has the following name: Balluff BNI XG5-538-1B5-Z067 ECS V.x.x.x.xml

• Copy the file to the corresponding TwinCAT directory (in the standard: C:\TwinCAT\3.1\Config\Io\EtherCAT).

  ⇒ Installed devices are available when the TwinCAT System Manager starts again.

Automatic scanning

Prerequisite

Before connecting devices to the EtherCAT network, the EtherCAT system must be in a secure, de-energized state.

1. Switch on the operating voltage and start the TwinCAT System Manager in Config mode.

2. Scan BNI as a box.

   

Manually adding a device

Prerequisite

Before connecting devices to the EtherCAT network, the EtherCAT system must be in a secure, de-energized state.

1. Switch on the operating voltage and start the TwinCAT System Manager in Config mode.

2. Attach a box.

   

3. Select a box.

   

Necessary configuration of device

After automatic scanning or manual adding of the device, the device appears in the tree structure of TwinCAT.

The BNI supports EoE (Ethernet over Ethercat). In order to configure TwinCAT, in the EtherCAT tab select Advanced settings.

A valid DNS name and then a valid IP address must be entered.

Configuring Station Alias

The Station Alias can be selected under the EtherCAT tabAdvanced settings.

1. Open ESC Access.

2. Open E²PROM.

3. Select Configured Station.

   

Configuring the network module

The BNI is a modular EtherCAT device. The device has the following slot structure:

In order to configure the IO-Link Ports, a defined number of process data (buffer size) must be assigned to the EtherCAT slots. In the TwinCAT System Manager this works as follows:

1. Delete assignment of IO-Link channel (or port) with x.

2. Place the channel selected on the left side with with < the module configuration selected on the right.

3. Transfer configuration to the EtherCAT slave with restart of TwinCAT in Config mode.

Bitmapping and function

Signals from configured inputs or outputs are displayed in the modulesSTD_IN_1bit(inputs Pin 4), Input Pin 2 (inputs Pin 2), as well asSTD_OUT_1bit(outputs Pin 4) and Output Pin 2 (outputs Pin 2).

Network modules

The IO-Link modules are always established according to the same schema:

IOLI/Ox/xBytes

• Quantity of process data used (should be greater than or equal to the process data length of the O-Link device)

• I = Input data

• O = Output data

• I/O = Input and output data

Short circuits and restart bits

The BNI restarts automatically if a short circuit occurs at one of the IO-Link Ports. No restart bits are required.

IO-Link state

In the IO-Link state the current status of each port is displayed.

Start-up

In the start-up the IO-Link Ports and outputs can be preconfigured. For more information, see Configuration without ESI.

The entries are transferred during the transfer of the configuration.

Configuration of modules

Validation

No validation: Validation deactivated, every device is accepted.

Compatibility: Manufacturer ID and device ID are compared with the module data. IO-Link communication is only started if they match.

The following values are possible for the validation setting:

The validation can be activated via the CoE object additional IO-Link Configuration Data for each port with subindex 1 (validation and backup). The values used for the validation must be configured in the CoE object IO-Link Configuration Data for each port.

Parameter server

Switched on : Data retention functions active, parameter data and identification data of the IO-Link device are saved in a remanent memory.

Disabled : Data storage function disabled, stored data remains stored.

Deleted : Data storage function disabled, stored data is deleted.

Upload enabled : Can be used to select whether an upload of the parameter data to the data storage of the network module port should be performed or not. If the upload is enabled, as soon as a device has requested an upload (Upload flag set) or if no data is saved in the master port (e.g. after deletion of the data or before the first data upload), the master starts uploading the parameter data.

Block upload : No data upload is started if the upload is blocked. For an upload request from the IO-Link device, a download (if activated) is started in the case of different parameter sets as no upload may be carried out.

Enable download : Can be used to select whether a download of the parameter data to the IO-Link device should be performed or not. As soon as the stored parameter data in the port’s parameter server differs from the connected IO-Link device and there are no upload requests from the IO-Link device, a download is performed.

Block download : If the download is blocked, an upload (if activated) of the parameter data takes place, irrespective of the upload flag of the IO-Link device.

Block upload and download : There is no exchange of parameter data if both upload and download are blocked. The IO-Link device communicates then with the IO-Link Port.

The following values are possible for the settings:

The data memory can be activated via the CoE object additional IO-Link Configuration Datafor each port with subindex 1 (validation and backup). There is no read or write access to the content of the data memory via EtherCat.

Upload flag at IO-Link device

The upload flag is required in order to overwrite data already saved in the parameter server with new parameter data of the same IO-Link device.

In order to activate the upload flag of an IO-Link device, the value 0x05 must be entered in the parameterIndex 0x02, Subindex 0.

Failsafe values

If the EtherCAT connection fails or if the EtherCAT status is notOperate, the IO-Link Ports use these values:

• If a port is in the IO-Link stateOperate, the process data displayed is switched to invalid.

• If Pin 2 or Pin 4 are in the digital output mode, zero (low level) is displayed.

IO-Link parameterization

Via the object 0x4000 (IO-Link Service Data Ch. X), IO-Link ISDU parameters can be read or written from the IO-Link device. For this purpose, the corresponding index and subindex must be entered and for writing the corresponding length and data must be entered. The read or write operation is started via the control object. The result is displayed in the status object.

Values for the control

Values for the status

Example of CoE setting

This example shows how the index 0x40 of Smartlight (mode) is changed by reading and writing.

1. Select module.

2. Open CoE - Online.

3. Activate the setting Auto Update.

4. Under Advanced select the setting Online - via SDO Information.

   

5. In port, select 4030:0(here channel 4).

6. Read index by double clicking 4030:0 and specifying the respective index (here 0x0040 64).

7. In control write the command 0x03.

   

   ⇒ Content of the index is read and displayed in data.

8. Change data, specify length and use the command 0x02.

   

   ⇒ The data is written and the parameter is changed in the device.Acyclic access via AoE

Acyclic access via AoE

The ETG5001.6220 describes AoE instead of CoE for the ISDU read/write access to IO-Link device parameters. Details on ADS can be found in the Beckhoff TwinCAT documentation and in ETG.1020. In contrast to CoE, AoE permits non-blocking processing.

AoE ISDU access uses these definitions (all are 32 bit):

• AoE IndexGroup = 0x0000F302

• AoE PortNumber = 0x00001000 + IO-Link port number, starting with 0.

• AoE IndexOffset

  • 16 Bit IO-Link Index

  • 8 Bit always zero

  • 8 Bit IO-Link Subindex

• Return error code

  • 16 Bit additional information about the error code, which is 0x0700 (ADS device error).

  • 16 Bit error code via IO-Link

Function blocks ADSREAD and ADSWRITE

Function block ADSREAD in TwinCat

ADSREAD commands

Function block ADSWRITE in TwinCat

ADSWRITE commands

Preparation for the web server

EoE set-up

In order to be able to access the web server of the BNI module, access via EoE (Ethernet over EtherCAT) must be configured first.

1. Select the Advanced Settings… button.

   

2. Enter valid DNS name and valid IP address.

   

Preparing network

Before the web server can be reached via EoE, the network of the Beckhoff control must be configured.

Configuring Beckhoff control

A static IP address must be assigned to both network cards.

1. On the Beckhoff control select Start > Control panel Network and dial-up connections > PCI…Settings.

2. Assign IP address.

   

3. Under Start > Control Panel > Beckhoff CX Configuration Tool > Miscellaneous activate the setting IP Routing.

   

EoE and PC networks

For the EoE settings in the Twincat, the IP address of the second network card of the Beckhoff control must be entered as a default gateway.

As a default gateway for the network configuration of the PC, the IP address of the first network card of the Beckhoff control must be entered.

Object directory

Map TxPDO input pin 2 (0x1A90)

Input Pin 2, one bit for each port.

Map TxPDO pin 4 (0x1A0n)

The following index range applies in a modular EtherCAT device:

• 0x6xxx is a module-specific input range for TxPDO data.

• 0x7xxx is a module-specific output range for RxPDO data.

IO-Link data is up to 32 bytes for input and output.

If a connection is configured as aDigital InputorDigital Output, the value of pin 4 is mapped to data byte 0, bit 0.

Map TxPDO input pin 2 (0x1A90)

Input Pin 2, one bit for each port.

Map TxPDO PowerStatus (0x1A91)

Index	Subindex	Name	DataType
0xF601	0x01	Global status: Bit 0: Sensor supply low (1 = low, 0 = OK) Bit 1: Actuator supply low (1 = low, 0 = OK)	UINT8
	0x02	Short circuit in the sensor supply; one bit for each port	UINT8
	0x03	Short circuit at pin 4 of the actuator supply, one bit for each port	UINT8
	0x04	Short circuit at pin 2 of the actuator supply, one bit for each port	UINT8

IO-Link Service Data Ch. x (0x4000 – 0x4FFF)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Sub-index	Name	DataType	Access	Value
0x40n0	0x01	Control	UINT8	RW	0: no control action 3: read 2: write
	0x02	Status	UINT8	RO	0: no activity 1: busy 2: success 4: error 0xFF: failure
	0x03	Index	UINT16	RW	–
	0x04	Subindex	UINT8	RW	–
	0x05	Length	UINT8	RW	–
	0x06	Data	UINT32	RW	–
n = 0…7	0x07	Error code	UINT16	RO	–

IO-Link Configuration Data Ch. x (0x8000 – 0x8FFF)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Sub-index	Name	Value	DataType
0x8nn0 n = 0…7	0x04	Device ID	24-Bit-ID	UINT32
	0x05	Vendor ID	16-Bit-ID	UINT32
	0x32	IO-Link revision	0x10 or 0x11	UINT8
	0x33	Frame Capability	not in use	UINT8
	0x34	Desired Cycle Time	Cycle Time	UINT8
	0x35	Offset Time	not in use	UINT8
	0x36	Max. PD In Length	Max. length	UINT8
	0x37	Max. PD Out Length	Max. length	UINT8
	0x38	Compatible ID	not in use	UINT16
	0x40	Master Control	see Configuration without ESI.	UINT16

IO-Link Information Data Ch. x (0x9000 – 0x9FFF)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Subindex	Name	DataType	Access
0x90n0	0x04	Device ID	UINT32	RO
n = 0…7	0x05	Vendor ID	UINT32	RO
	0x20	IO-Link revision	UINT8	RO
	0x22	Min Cycle Time	UINT8	RO
	0x24	Process Data In Length	UINT8	RO
	0x25	Process Data Out Length	UINT8	RO

IO-Link Diagnosis Data Ch. x (0xA000 – 0xAFFF)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Subindex	Name	DataType	Access
0xa0n0 n = 0…7	0x01	IO-Link state	UINT8	RO
	0x02	Lost Frames	UINT8	RO

Values for IO-Link state (Subindex 0x01)

Value	Name	Status of IO-Link Port
0	INACTIVE	Deactivated
1	DIGINPUT	Digital Input
2	DIGOUTPUT	Digital Output
3	ESTABLISHCOMM	not in use
4	INITMASTER	not in use
5	INITDEVICE	not in use
6, 7	Unused	not in use
8	OPERATE	IO-Link, in status Operate
9	STOP	IO-Link, not in status Operate state (error or no device)

Values for Lost Frames (Subindex 0x02)

This parameter counts lost IO-Link Frames (M sequence repeats).

Two repeat attempts are generally added when changing the device. This value is only reset to zero during the start. The value is updated regularly, e.g. once a second.

IO-Link Status Data Ch. x (0xF100)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Subindex	Name	DataType	Access
0xF100	0x01	Status of IO-Link Port 1	UINT8	RO
	0x02	Status of IO-Link Port 2	UINT8	RO
	0x03	Status of IO-Link Port 3	UINT8	RO
	0x04	Status of IO-Link Port 4	UINT8	RO
	0x05	Status of IO-Link Port 5	UINT8	RO
	0x06	Status of IO-Link Port 6	UINT8	RO
	0x07	Status of IO-Link Port 7	UINT8	RO
	0x08	Status of IO-Link Port 8	UINT8	RO

The CoE objectDevice Status(0xF100) is mapped asTxPDO-Mapping of Status Datato the Process Data.

IO-Link Port Qualifier Ch. x (0xF101)

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

Index	Subindex	Name	DataType	Access
0xF101	0x01	Port Qualifier Port 1	UINT8	RO
	0x02	Port Qualifier Port 2	UINT8	RO
	0x03	Port Qualifier Port 3	UINT8	RO
	0x04	Port Qualifier Port 4	UINT8	RO
	0x05	Port Qualifier Port 5	UINT8	RO
	0x06	Port Qualifier Port 6	UINT8	RO
	0x07	Port Qualifier Port 7	UINT8	RO
	0x08	Port Qualifier Port 8	UINT8	RO

The CoE objectPort Qualifier(0xF101) is mapped asTxPDO-Mapping of Port Qualifierto the Process Data.

Port Qualifier Bits

Bit	Description
4	PortActive / Port activated 1 = Port can be used. 2 = Port deactivated.
5	DevCom / device is ready for operation 1 = Device detected and in status Operate 0 = everything else
6	DevErr / device error 1 = Error occurred (validation error, short circuit, etc.) 0 = OK
7	PQ / validity of input data of IO-Link device 1 = valid 0 = invalid

Configuration without ESI

Note

Please check whether IO-Link is supported by your module before using this function. For more information on product variants that support IO-Link, see Supported product variants

The ports can also be configured without integration of an ESI. For this, the master control and the respective length of the process data must be set in the object 0x8000.

Values for the master control (80X0:28)

Value	Function
0x0000	Deactivated
0x0001	Port in Standard Input
0x0002	Port in Standard Output
0x0003	Port in IO-Link mode
0x0005	Power

Process data length

IO-Link Ports

Byte	Length of data
1 Byte	0x08
2 Byte	0x16
4 Byte	0x83
6 Byte	0x85
8 Byte	0x87
10 Byte	0x89
16 Byte	0x8F
24 Byte	0x97
32 Byte	0x9F

Standard input/output ports

0x01

Example

MasterControl = 3 --> IO-Link
IO-Link size	Process Data In Length		Process Data Out Length
	Hex	Dec	Hex	Dec
IOL_l_1byte	0x08	8	0x00	0
IOL_l_2byte	0x16	22	0x00	0
IOL_l_4byte	0x83	131	0x00	0
IOL_l_6byte	0x85	133	0x00	0
IOL_l_8byte	0x87	135	0x00	0
IOL_l_10byte	0x89	137	0x00	0
IOL_l_16byte	0x8F	143	0x00	0
IOL_l_24byte	0x97	151	0x00	0
IOL_l_32byte	0x9F	159	0x00	0
IOL_l_1byte/0_1bytes	0x08	8	0x08	8
IOL_l_2byte/0_2bytes	0x16	22	0x16	22
IOL_l_2byte/0_4bytes	0x16	22	0x83	131
IOL_l_4byte/0_4bytes	0x83	131	0x83	131
IOL_l_4byte/0_2bytes	0x83	131	0x16	22
IOL_l_2byte/0_8bytes	0x16	22	0x87	135

In the start-up the configuration for Port 6 in IO-Link mode with 32 Byte process data length for input and output looks as follows: