Aoi Bni006a 50-31-040 User Guide

AOI_BNI006A_50_31_040
Add-On Instruction
User Guide
December 2, 2013
Balluff Inc.
8125 Holton Drive
Florence, KY 41042
1-800-543-8390
www.balluff.com
Table of Contents
1.0 Scope ..................................................................................................................................................... 3
2.0 Products ................................................................................................................................................ 3
3.0 Instructions ........................................................................................................................................... 4
4.0 User-Defined Data Type (UDT) ........................................................................................................... 11
5.0 Software Validation ............................................................................................................................. 17
6.0 Troubleshooting Tips ......................................................................................................................... 22
7.0 Definitions ........................................................................................................................................... 24
8.0 Related Documents ............................................................................................................................ 26
9.0 References .......................................................................................................................................... 26
(800) 543-8390 FAX (859) 727-8506 www.balluff.com

AOI_BNI006A_50_31_040 User Guide Page 2 of 26
1.0 Scope
1.1 This User Guide describes the installation, use and maintenance of the Add On Instruction (AOI)
software module for the BNI EIP-502-105-Z015. This software module is designed for use with
RSLogix5000.
2.0 Products
2.1 This guide was developed for use with the software module AOI_BNI004A_40_27_041.L5X. This
software module is available for download at the web site www.Balluff.com/AOI.
2.2 This software module was developed for use with the Balluff EtherNet/IP Connectivity block BNI EIP-
508-105-Z015 (hardware version 5.0, firmware version 3.1).
2.3 For the development of this software module and hardware configuration, the following system
components were used and validated:
2.3.1 RSLogix5000, version 18.01 (or later)
2.3.2 Rockwell 1756-L63 controller

3.0 Instructions
3.1 This section describes the process for installing and using the AOI module. This is a three step
process that must be followed sequentially: hardware configuration; import AOI module along with all
associated UDTs; and create new ladder logic with AOI modules.
3.2 Hardware Configuration
3.2.1 Balluff EtherNet/IP IO-Link Master Features
Embedded
Ethernet
Switch
New
Display
Menu
Dual Aux
Power
Ports
8 IO-Link Ports
Pin 2 – Free
Configurable
Pin 4 –Manually
Configured
• IO-Link
• Input/Output

3.2.2 Configuring the BNI EIP-508-105-Z015 in RSLogix5000
3.2.2.1 Establish 1756-ENxx communication module in I/O Configuration
3.2.2.2 Right click 1756-ENxx and choose New Module:
3.2.2.3 Choose ETHERNET MODULE – Generic Ethernet Module:

3.2.2.4 Establish properties of BNI EIP-508-105-Z015:
Comm. Format: Data – SINT

Input Size: 392 bytes Assembly Instance: 100
Output Size: 262 bytes Assembly Instance: 101
Configuration Size: 194 bytes Assembly Instance: 102
5.2.2.5 Depending on the application and network design, verify whether a Unicast connection is
required:
When checked the PLC will establish a Unicast

connection rather than a Multicast connection

3.3 Import AOI
3.3.1 Right click on the Add-On Instructions element of the Controller Organizer to view a menu that
includes “Import Add-On Instruction…” as shown below:
Locate your folder containing the downloaded Balluff AOI modules, highlight
AOI_BNI006A_50_31_040.L5X and click Import…

3.3.2 If the operation is successful, all UDTs associated with the AOI module will be imported into the
project along with the AOI. This can be verified by checking the User-Defined element under
Data Types in the Controller Organizer.
Add-On Instruction
User-Defined Data Types
3.4 Create logic using RSLogix5000

3.4.1 Once an AOI has been imported, it can be used in the same manner as other ladder
instructions. A new Element Group tab will be displayed in RSLogix5000’s Language Element
toolbar. This is shown here with the hover window information displayed:

3.4.2 The AOI module can now be added to a rung of ladder:
3.4.3 All parameters must be defined with tags of valid data type as defined by the AOI module. The
user should create each Tag Name relevant to the user’s project.
Tag Name
Parameter Name Description Data Type
(User specific)
Unique Control Tag for

AOI_BNI006A_50_31_040 AOI_BNI006A_50_31_040 Master_Control_Tag
AOI Module
392 byte array of raw

BNI_EIP_508_Raw_Input Data data from Hardware SINT[392] Module_Name.I.Data
Module Defined Tags

BNI_EIP_508_Raw_Output Data data from Hardware SINT[262] Module_Name.I.Data
Module Defined Tags

BNI_EIP_508_Raw_Config_Data datafrom Hardware SINT[194] Module_Name.I.Data
Module Defined Tags
All I/O Data Associated

BNI_EIP_508_Port_1_Data IO_Link_Port_Data Port1_Data
with IO-Link Port 1

with IO-Link Port 2

with IO-Link Port 3

with IO-Link Port 4

with IO-Link Port 5

with IO-Link Port 6

with IO-Link Port 7

with IO-Link Port 8
All Unique data

Mapped_BNI_EIP_508_Data associated with BNI UDT_BNI006A_50_31_040 Mapped_Master_Data
EIP-508 module
Note that in this example, Module_Name has been defined in the I/O Configuration Tree as
Balluff_IO_Link_Master.

4.0 User-Defined Data Type (UDT)
4.1 The User-Defined Data Type for the Add On Instruction defines the interface for the AOI and the user’s
project. For AOI_BNI006A_50_31_040, the highest level UDT. UDT_BNI006A_50_31_040, is
comprised of three sub-UDT components: Input (I), Output (O) and Configuration (C). One additional
UDT is defined, IO_Link_Port_Data, for integrating data through configured IO-Link ports.
4.2 The highest level UDT (UDT_BNI006A_50_31_040) consists of the three sub-UDT components
described in Sections 4.3 through 4.5 below.

4.3 The Input UDT (UDT_BNI006A_Inputs_50_31_040) consists of all inputs associated with the BNI004A
block. A description of this UDT and its function is included here:
4.3.1 Data – this is a single 16-bit INT register that contains all discrete input data bits. If a port is
configured in IO-Link mode, the indicated result is 0.
4.3.2 Short_Circuit – this is a single 16-bit register that contains all discrete short circuit bits. These
bits indicate a short circuit between pins 1 and 3 on stated port.
4.3.3 Overload – this is a single 16-bit register that contains all discrete overload bits. These bits
indicate an overload has occurred on the indicated port and pin number. Note that these bits
will only function if the port is configured as an output.
4.3.4 UA_Fault – this Boolean value indicates whether auxiliary power is currently applied to the
BNI004A device’s output points. This bit is typically used to indicate an Emergency Stop has
occurred.
4.3.5 US_Fault – this Boolean value indicates whether sensor power is currently applied to the
BNI004A device.
4.3.6 Port_x_IO_Link_Status – (x = 1, 2, 3, or 4) this Boolean value indicates whether the indicated
Port (1-4) has been placed in IO-Link mode.
4.3.7 Port_x_Device_Connected – (x = 1, 2, 3, or 4) this Boolean value indicates whether the
indicated Port (1-4) has an operational IO-Link device connected to the port.
4.3.8 Port_x_Validation_Failed – (x = 1, 2, 3, or 4) this Boolean value indicates whether the indicated
Port (1-4) has passed the validation type as defined in the Configuration UDT (see Section 4.5).

4.4 The Output UDT (UDT_BNI004A_Outputs_40_27_041) consists of all outputs associated with the
BNI004A block. A description of this UDT and its function is included here:
4.4.1 Data – this is a single 16-bit INT register that contains all discrete output data bits.
4.4.2 Restart – this is a single 16-bit INT register that contains all discrete Restart bits. A Restart bit
must be toggled following a detected short-circuit event.
4.4.3 Display_RED – this Boolean value transitions the Red LED display on the BNI004A block.
4.4.4 Display_GREEN – this Boolean value transitions the Green LED display on the BNI004 block.
4.4.5 Display_LOCK – this Boolean value locks the display and prevents the user or PLC from
changing the display. While this bit is “high” or ON, a key icon will be indicated on the display.

4.5 The Configuration UDT (UDT_BNI004A_Configuration_40_27_041) consists of all IO-Link data
associated with each port for the BNI004A block. A description of this UDT and its function is included
here:
4.5.1 Port_x_Function – (x = 1, 2, 3, or 4) this SINT value determines whether the indicated Port (1-4)
will function in Standard Input/Output (=0) mode or IO-Link (=1) mode. It is important to note
that after changing the value for any Port_x_Function registers, power must be cycled to the
BNI004A block for the change to take effect. (Note: values of 2 or higher will adjust port into
Fallback mode, which ceases all process data flow)
4.5.2 Port_x_Cycle_Time –(x = 1, 2, 3, or 4) this SINT value holds the cycle time for the indicated
Port (1-4). Bits 0-6 hold the cycle time value while bits 7-8 represent the time base.
4.5.3 Port_x_Validation_Type –(x = 1, 2, 3, or 4) this SINT value determines the type of validation
used for each Port (1-4). If this value is 0, then no validation is used – this is the default setting.
If this value is 1, then a compatible device (matching Vendor ID and Device ID) must be
connected to the port. If this value is 2, then the exact device (matching Vendor ID, Device ID
and Serial Number). (Note: The connected IO-Link device must support this feature)
4.5.4 Port_x_Vendor_ID – (x = 1, 2, 3, or 4) this SINT value indicates the Vendor ID of the device
connected to the Port. For any Balluff device, this value will be 0378hex.
4.5.5 Port_x_Device_ID – (x = 1, 2, 3, or 4) this SINT value indicates the Device ID of the device

connected to the Port. Each device will have a unique Device ID that can be found in its
corresponding manual.
4.5.6 Port_x_Serial_Number –(x = 1, 2, 3, or 4) this 16-byte SINT array indicates the Serial Number
of the device connected to the Port.
4.5.7 Port_x_Parameter_Upload_Enable – (x = 1, 2, 3, or 4) this Boolean value must be set “high” or
ON to perform an upload of the current parameter set. ). (Note: The connected IO-Link device
must support this feature)
4.5.8 Port_x_Parameter_Download_Enable – (x = 1, 2, 3, or 4) this Boolean value must be set “high”
or ON to perform a download of the current parameter set. ). (Note: The connected IO-Link
device must support this feature)
4.5.9 Port_x_Parameter_Server_Enable – (x = 1, 2, 3, or 4) this Boolean value must be set “high” or
ON to allow either an upload or a download of the current parameter set. ). (Note: The
connected IO-Link device must support this feature)

4.6 The IO_Link_Port_Data UDT consists of the 48 input bytes (SINTs) and 48 output bytes (SINTs) that
the IO-Link master allocates to each port. Under normal operating conditions, the user will not be
aware of any data being passed through this UDT. The AOI automates the parsing of the data for each
port and allows the user to access the data directly without mapping each of the four port’s data into the
master’s single data buffer. This UDT is used for both the IO-Link master AOI as well as each IO-Link
slave AOI. The master and slave must share the same tag name for the corresponding port.
4.6.1 Inputs – this 48-byte SINT array contains all raw input data values being passed from the IO-
Link slave device input array to the master device input array.
4.6.2 Outputs – this 48-byte SINT array contain all raw output data values being passed from the IO-
Link slave device output array to the master device output array.

5.0 Software Validation
5.1 If the preceding instructions (5.0 Instructions) have been successfully completed, the software module
will be integrated into the RSLogix5000 project and it will be ready to use. The user will be able to
verify proper operation of the AOI by monitoring the transition of a controller-scoped tag and its
corresponding real world device. This section describes a sampling technique that will verify the proper
operation of one input bit, one output bit, and a configuration parameter.
5.2 This example describes how to validate the transition of a controller-scoped input tag.
5.2.1 This example uses Port 6, Pin 4 (Input buffer byte 0, bit 6) although any input bit will suffice.
Note that all I/O points are freely configurable as either inputs or outputs and will respond to
logic accordingly. The key point of this example is to ensure that the AOI bit corresponding to
the selected input bit follows it. Place a device (discrete sensor or jumper wire) between pins 1
and 4 on Port 6 to cause this Input bit to transition to ON or “high”. This bit can be viewed in the
Controller scope tags as shown below:
Note that when the AOI module was used in the logic, the parameter Mapped_BNI_EIP_502_Data was
assigned to a tag named “Mapped_Master_Data”.
5.2.2 While this bit (Mapped_Master_Data.I.Data.12) is ON or “high”, the corresponding LED on the
I/O block should be lit. If this is not the case, please refer to Section 7.0 Troubleshooting.

5.3 This example describes how to validate the transition of a controller-scoped output tag.
5.3.1 This example uses Port 4, Pin 4 (Input buffer byte 0, bit 4) although any output bit will suffice.
Note that all I/O points are freely configurable as either inputs or outputs and will respond to
logic accordingly. The key point of this example is to ensure that the AOI bit corresponding
follows the selected output bit. Place a device (pilot light, voltage meter or other discrete output
device) between pins 1 and 4 on Port 4, then transition the output bit to ON or “high”. This bit
can be viewed in the Controller scope tags as shown below:
5.3.2 While this bit is ON or “high”, the discrete output device should transition to its ON state,
indicating that power is being passed to the device.
5.3.3 While this bit is ON or “high”, the corresponding LED on the I/O block should be lit. If this is not
the case, please refer to Section 7.0 Troubleshooting.
5.3.4 After confirming the operation of this output bit, return the bit to “low” or OFF to ensure that the
operation of logic is not affected.

5.4 This example describes how to validate the transition of a controller-scoped configuration tag.
5.4.1 This example uses Port 1 Vendor ID although any configuration tag will suffice. The key point of
this example is to ensure that the AOI value corresponding to the selected configuration value
displays properly. this example will include a two-step process:
1. Configure Port 1 to IO-Link mode
2. Observe Balluff’s Vendor ID
5.4.1.1 To configure Port 1 to IO-Link mode, set the value of the Port_1_Function tag equal to 1. After
this tag has changed value, cycle the power to the BNI004A device in order for the port function
change to take effect. After power is restored to the BNI004A, the Port 1 IO-Link LED will be lit
steady green while an IO-Link device is connected (this LED will blink green if it is in IO-Link
mode without an operational device connected). Your controller scope tags should look similar to
this:

5.4.1.2 While any Balluff device is connected to Port 1 while this port is in IO-Link mode, the displayed
Vendor ID should be 0378h or in decimal of 3(120). These values bit can be viewed in the
Controller scope tags as shown below (the two screen shots are identical except for the “Style”
column):
Note that this screen shot and the following screen shot display the same information except that two tags
have been changed to Hex format.

5.4.2 While any Balluff IO-Link device is connected to Port 1 in IO-Link mode, these values will be
displayed. When the IO-Link slave is disconnected from Port 1, these values will return to 0. If
this is not the case, please refer to Section 6.0 Troubleshooting.
5.5 All released Balluff AOI modules have been validated according to Balluff QF 4.4.12. A copy of this
validation report can be obtained by contacting Balluff Technical Support at
technicalsupport@balluff.com.

6.0 Troubleshooting Tips
6.1 If the user does not obtain the results described in Section 5.0 above, please ensure that the following
match those described in this User Guide:
6.1.1 Hardware System layout – system must consist of the following:
6.1.1.1 Rockwell Automation Logix processor
6.1.1.2 Rockwell Logix EtherNet/IP network bridge
6.1.1.3 ODVA-compliant EtherNet/IP physical media
6.1.2 Software configurations – RSLogix5000 version 18.01 or higher must be used with this Add-On
Instruction
6.1.3 Revision levels
6.2 After confirming the revision levels of all system components, the next step should be to observe the
raw data from the EtherNet/IP master in RSLogix5000. This can be accomplished by observing each
step through the process of an input bit through the raw data into the AOI data buffers.
6.2.1 The initial step is to confirm that the IO_Link_Port_Data tag for the input is received. For the
controller-scoped input tag described in Section 5.2 (Port 6, Pin 4), you must observe Input
buffer byte 0, bit 6 while the input has transitioned to “high” or ON as shown here:

6.2.2 To confirm the raw data for this same input bit, you must observe the Input buffer of the IO-Link
master. Since this BNI0039 hub is connected to Port 1 of the master, the subject bit should be
byte 8, bit 6 as shown here:
Note that byte 8 corresponds only to Port 1 on the BNI004A master. This input bit will be indicated in
byte 56 (Port 2), byte 104 (Port 3), or byte 152 (Port 4).
6.3 If all system components are consistent with those described in Section 6.1 above and the raw data is
being received properly in RSLogix5000 but the user does not view AOI data as described in Section
5.1 above, additional steps can be taken to verify the proper operation of both the software
configuration and the hardware system and components.
6.3.1 To validate the software configuration:
6.3.1.1 Ensure that the Balluff hardware is communicating properly with the Logix processor. A
communication error is easily identified when RSLogix5000 is online with the processor
as the network hardware will be identified with a yellow warning triangle when the
communication fails.
6.3.1.2 Start a new RSLogix5000 project using only the Balluff hardware and AOI module. This
should eliminate any potential software conflicts.
6.3.2 To validate the hardware system and components:

6.3.2.1 Remove all other hardware nodes from the Ethernet network so that only the Balluff
module and the Logix processor are connected.
6.3.2.2 Verify that any switches used in the network layout are operating properly and have solid
connections.
6.3.2.3 Identify and remove any potential sources of electrical noise or interference that might
impede network communication.
6.4 If the system still does not respond properly, please contact the Balluff Technical Support Group at
technicalsupport@balluff.com.

7.0 Definitions
7.1 The following terms are used in this guide with these definitions:
7.1.1 Controller Organizer – the area of RSLogix5000 where all project components can be accessed.
If this toolbar is not visible, it can be opened by pressing Alt+0.
7.1.2 AOI – Add On Instruction – reusable software module created with RSLogix5000. Balluff’s AOI
modules are composed of UDTs and associated logic to implement control algorithms. This
module is hardware specific. All AOI modules contained in a project will be located in the
Controller Organizer as shown below:
7.1.3 Controller scoped tag – a tag of any valid data type that is available to all programs within a
project and must be used uniformly throughout the entire project.
7.1.4 AOI Parameter – a tag of any valid data type that is created during the definition of the AOI
module and is isolated to that AOI. Its scope is limited to the each discrete use of AOI function.

7.1.5 UDT – User Defined Data Type – reusable software module created with RSLogix5000.
Balluff’s UDTs define the input and output tag names to be used when implementing our AOI
modules. A UDT can be composed of any combination of standard Data Types defined by
RSLogix5000 or other UDTs. All UDTs contained in a project will be located in the Controller
Organizer as shown below:
7.1.6 I/O Configuration Tree – the area of RSLogix5000 where all physical, or “real world”, Inputs and
Outputs associated with the controller are defined. One example of an I/O Configuration Tree is
shown below:
7.1.7 EDS – Electronic Data Sheet – software configuration file that defines how a hardware product
will communicate with the network master using EtherNet/IP. The format and content of an
EDS is defined by ODVA, the controlling organization for EtherNet/IP specficiations.

8.0 Related Documents
8.1 The following Balluff documents support the release of this User Guide and its related software module.
Each of these documents can be obtained by contacting Balluff Technical Support at
technicalsupport@balluff.com:
8.1.1 BNI EIP 508-105-Z015 User’s Guide
8.2 Other documents – Each Balluff IO-Link device that may be connected to this IO-Link Master device will
have its own User Guides, both for hardware and for the AOI module software. These AOI modules
and User Guides can be downloaded from Balluff’s AOI website: www.Balluff.com/AOI.
9.0 References
9.1 None


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(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

3.2.2.2 Right click 1756-ENxx and choose New Module:

3.2.2.3 Choose ETHERNET MODULE – Generic Ethernet Module:

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

Comm. Format: Data – SINT

When checked the PLC will establish a Unicast

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

User-Defined Data Types

3.4 Create logic using RSLogix5000

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

Unique Control Tag for

392 byte array of raw

262 byte array of raw

194 byte array of raw

All I/O Data Associated

All I/O Data Associated

All I/O Data Associated

All I/O Data Associated

All I/O Data Associated

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

All I/O Data Associated

All I/O Data Associated

All Unique data

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

6.3.2 To validate the hardware system and components:

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(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

(800) 543-8390 FAX (859) 727-8506 www.balluff.com

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