IO-Link

Contents

Distributed Modular I/O

Technology 2.2

Applications 2.5

IO-Link Master Blocks 2.6

IO-Link Input/Output Devices 2.8

IP20 Terminal Hubs 2.9
Analog Plugs 2.9
M8 and M12 Hubs 2.10

IO-Link Connection Devices 2.12

Non-Contact Connectors 2.13
USB Master 2.13
Valve Manifold Connectors 2.14

IO-Link RFID 2.16

Read Only Systems 2.17
Read/Write Systems 2.18

IO-Link Intelligent Sensors 2.20

Level 1 Intelligent Sensors 2.23
Level 2 Intelligent Sensors 2.24
Level 3, IO-Link Intelligent Sensors 2.26

n www.balluff.com 2.1
 IO-Link
What is Distributed Modular I/O?

Think of a remote “slice” I/O solution. In a typical application, the communication head and the power supply sit on the left hand side and are
followed along the backplane by the individual I/O devices, such as discrete 24V input cards or 0-10V analog cards. Usually there are a limited
number of slots available in the backplane and individual slices of control components can be inserted.

In a similar fashion, a Distributed Modular I/O system has a

communications head that talks over the desired industrial network
on one side and the right hand side acts as a data collector. In lieu of
a backplane, each device is connected to an industry standard M12
Communication

Discrete I/O

Discrete I/O
port utilizing a basic 3-wire sensor cable for IO-Link communication.

Analog I/O

Specialty
Power

Outputs
With the ability to be installed within a 20 meter radius from the data,
collector devices can be easily distributed across the machine.

Discrete
Power I/O

RFID or
Discrete Analog Valve Manifold Specialty
I/O I/O Control Devices

The backplane of Distributed Modular I/O =

Utilizing a widely accepted and open point to point technology, IO-Link, a Distributed Modular I/O system is fieldbus independent, is easily
configured and is vendor neutral. Process data shows up as simple packets of bytes in the controller for easy integration. The parameterization
data allows the devices to be quickly configured using simple read/write commands, and best of all, there is no “sub-bus” to cause headaches,
nor is there some new protocol to be educated on. The digital signal is carried over pin 4 of a standard cable and 24V power is provided to the
device in a standard configuration. If required, the IO-Link port can be used for a standard I/O point.

3 Wire or 4 Wire Sensor Cable

20 Meters maximum

L+
24V
1 SIO
C/Q 0V
2 4
3 IO-Link
L-

2.2
 IO-Link
Advantages of Distributed Modular I/O

Simplify Controls Quotation Process

Utilize the same components for I/O regardless of the
PLC brand or industrial network selected. Pricing for
control equipment can be standardized from machine
to machine and calculations are easily expandable.
or

Reduce Total Cost per Point

Simplify the labor involved in parallel wiring a valve
manifold or terminating a set of discrete sensors.
Analog devices can get costly with shielded cable
runs and expensive four channel analog input cards, or
especially when there is only a need for one analog
channel. Distributed Modular I/O reduces hardware
setup labor and can be customized to reduce I/O
hardware costs.

Maximize Spares
Discrete RFID

Most initial designs include a set of spare I/O points for I/O Identification

later development or modifications. Whether the

customer wants to add a few discrete sensors to the Analog
I/O
Specialty
Sensor

design or there is a need to add a single channel of

analog to the machine, spares and additions to the design
Unlimited
can add major cost to the control’s bill of materials. Possibilities

With this solution, spare connections can be a flexible

placeholder for any type of I/O until the need arises.

Types of Distributed Modular I/O devices

Discrete I/O Analog I/O Valve Manifold Control Specialty Devices and RFID

M8 ports 1 channel (14 bit)

– Up to 16 inputs – 0-10 V in/out Measurement
– 4-20mA in/out and position
– PT100 in 25 pin D-sub sensors

M12 ports 4 channels (10 bit) RFID

– Up to 16 inputs – 0-10 V – Read/write
– 16 outputs – 4-20mA – Read only
– 16 configurable – plus 8 inputs
IP67 & Terminal

Non-contact
IP20 terminals
connectors
– Up to 16
– 3 bytes to 11 bytes
configurable

n www.balluff.com 2.3
 IO-Link
Ease of integration

While hardware selection is important to the success of a project, if the hardware is not easily integrated into the engineering software,
any benefits gained could be lost. However, Distributed Modular I/O is easily integrated into typical engineering software with an easy
three step process. Below are examples of how to integrate industrial ethernet solutions. These steps can also be easily implemented on
industrial bus networks.

Step 1 Step 2 Step 3

Select hardware Import add on instructions (AOI) Create user defined tags (UDTs)

Device 1
Device 2
Device 3
Device 4

www.balluff.com/AOI

Step 1 Step 2 Step 3

Select hardware Configure Profinet expander and Assign I/O to user defined
expansion devices from one screen address scheme
using GSD and GSDML files

Device 1
Device 2
Device 3
Device 4

Device parameterization and configuration

There are multiple advantages to device parameterization. The two major advantages are the ability to quickly swap out a failed device and the
ability to reconfigure a device for a recipe or production change on the fly. The controller stores the necessary data for each setup and, when
needed, it sends the parameters via the network over the backplane to the slave device. This can shorten setup times and increase efficiency.

Color Sensor Example

While running project A, the color sensor is configured to detect the After the required parts are run off, a new project is begun with a different color
difference between five different colors as parts are loaded into a fixture. set. In the past, a second color sensor would be required, or the operator
would have to reprogram the current sensor for each new color. By using device
parameterization, the controller tells the sensor its configuration for project B
and quickly, without hassle, the sensor has its new colors.

Green Orange Violet Gray Teal

Red Blue White Black Yellow

2.4
 IO-Link
Distributed Modular I/O applications

Discrete I/O Savings Analog I/O Savings

Machine builders looking One channel of analog
to lower the cost per I/O can add significant
point for discrete I/O cost to a typical
gain many advantages machine design in
with Distributed Modular components, cables,
I/O. Reduced cable and and labor. By putting
device costs can save the analog I/O right
an OEM 15-60% over at the signal’s source,
traditional I/O systems. the complications
and costs can be
significantly reduced.
Analog Output:
Enclosure
– measuring signal
IP20 – set points
I/O

Standard
Block I/O PS
Shielded Nine
Cable Conductors
50-60% 50-60% 40-60% 50-60% 50-60% Average
decrease decrease increase decrease decrease Overall Cost
Decrease
30-40% Master
Device Analog to
Digital
Conversion
Distributed
Modular I/O
Solution
Non-shielded
Three
Cable
Conductors

Valve Manifold Control Quick Tool Change

Every pneumatic action With the increasing
requires valve control. demand for multiple
The typical parallel wiring recipe manufacturing,
of valve manifolds can be the need to quickly
labor intensive and add change tooling on a
dramatically to cabinet robot or in a fixture
space and setup time. is growing. Utilizing
multiple technologies,
the connection can be
made quickly without
failure; tool verification
can be included
with RFID. This
speed has improved
our customers’
Parallel wiring solution throughput by 15%.
– up to 25 individual
terminations
RFID

Non-
contact
Low cost connector
high flex
cables I/O

Distributed Modular I/O solution

– single connector

n www.balluff.com 2.5
 IO-Link
Master blocks

Flexible IO-Link Master Blocks

Each port of the Balluff IO-Link master block can be configured to fit any IO-Link and/or discrete application. The top
4 ports can be configured as NO/NC inputs, outputs, or diagnostic points depending on the block type. The bottom
4 ports can be configured as IO-Link or as any of the discrete settings, depending on the block type.

Pin 2 Pin 4
Input Input
Output* Output* L+
24V
Diagnostic Diagnostic 1 SIO
C/Q 0V
2 4
3 IO-Link
Pin 2 Pin 4
Input Input L-
Output* Output*
Diagnostic Diagnostic
IO-Link

*Only available in configurable versions

Network Protocol EtherNet/IP DeviceNet ProfiNet Profibus

Addressing Display Display Display Rotary Dials
1 IO-Link / 4
RFID BIS VM or VL

4 IO-Link / 4
Configurable

4 IO-Link / 12 BNI004A BNI005A* BNI004U BNI003K

Configurable BNI EIP-502-105-Z015 BNI DNT-502-100-Z001* BNI PNT-502-105-Z015 BNI PBS-502-001-Z001
8 IO-Link / 8 BNI006A* BNI005H*
Configurable BNI EIP-508-105-Z015 BNI PNT-508-105-Z015

*Consult factory for availability

2.6
 IO-Link
Master blocks

Reduce Costs Reduce Engineering and Commissioning

n Connect devices with standard sensor/actuator cordset n Commissioning performed by the controller, not at each individual
IO-Link device
n Simplify cordset stocking with universal M12 standard
connectors on IO-Link devices n Scalability of each IO-Link port

n Secure investment with open standard, valid from all n Same architecture for different network protocols
manufacturers n Fewer network nodes and IP addresses to commission
n Future-proof, with greatest flexibility in project planning

Reduce Maintenance Increase Uptime

n Capability of plug, play, and walk away n Recipe driven parameterization of IO-Link devices
n Automatic read adjustment of parameters n Health diagnostics down to the IO-Link device level
n Reliable error detection n Network cable can be removed from harsh areas, replaced by
standard sensor/actuator cordsets
n Troubleshoot a point-to-point connection,
rather than a network n Continuous monitoring of process parameters

Profibus Profibus Profibus Profibus CC-Link

Display Rotary Dials Rotary Dials Display Display
BIS00T3
BIS V-6102-019-C001
BNI003P BNI0030
BNI PBS-507-001-Z011 BNI PBS-504-001-K008
BNI005R BNI0040
BNI PBS-502-101-Z001 BNI CCL-502-100-Z001

n www.balluff.com 2.7
 IO-Link
Input/output devices

IO-Link Input/Output Devices

One of the major values of IO-Link over standard network I/O is the ability to run many sensors and actuators back
through one node or IP address. This is accomplished using the many varieties of I/O hubs offered by Balluff.

n Multiple analog sensors can be run into an input hub with discrete inputs as well
n Balluff’s full line of mini sensors can be run in small spaces using M8 hubs
n Metal Inputs and Outputs allows for I/O in the most hostile environments

I/O Devices
One analog I/O channel
14 bit resolution

PF

4 analog inputs
10 bit resolution plus
8 discrete inputs

Magneto-inductive
position sensor

Analog I/O devices

Standard sensors
in small places Prox mini.s

Inputs and outputs in

hostile environments

Valve
connectors

2.8
 IO-Link
IP20 terminal I/O hubs
M12 analog I/O plugs

IP20 terminal I/O hubs are designed for use

in custom projects like small push button or
indicator stations.

Connection Type Spring Terminal Spring Terminal

8 Configurable BNI004K
BNI IOL-309-000-K024
16 Configurable BNI004L
BNI IOL-310-000-K025
Max Output Current/Channel 400 mA 400 mA
Max Current <1.4 A <1.4 A
Mounting DIN Rail DIN Rail
Data 1 Byte IN, 1 Byte OUT 2 Bytes IN, 2 Bytes OUT

M12 analog I/O plugs are designed for

applications where you need analog I/O
without the cost or hassle of an analog
input card.

Type Inputs Outputs Order Code/Part Number

0-10 V Analog (14 bit), 3-wire input 1 BNI0042
BNI IOL-714-000-K023
4-20 mA Analog (14 bit), 3-wire input 1 BNI0041
BNI IOL-712-000-K023
PT100 Analog (14 bit), 3-wire input 1 BNI004T
BNI IOL-716-000-K023
0-10 V Analog (14 bit), 3-wire output 1 BNI004E
BNI IOL-724-000-K023
4-20 mA Analog (14 bit), 3-wire output 1 BNI004C
BNI IOL-722-000-K023

n www.balluff.com 2.9
 IO-Link
M8 discrete I/O hubs
M12 discrete I/O hubs
M12 analog I/O hubs

I/O hubs come in multiple form

factors and configurations and
can be used for almost any
basic I/O applications, including
analog inputs.

Type Inputs Outputs M8 Plastic M8 Plastic M12 Plastic

Variation
Number of Ports 4 8 8
Max Output per port/per block –
3-wire input 4 or 8 – BNI000P (4 input) BNI000R (8 input)
PNP BNI IOL-101-000-K018 BNI IOL-102-000-K019
3-wire input, w/diagnostics 4 or 8 – BNI001W (4 input) BNI001Y (8 input)
PNP BNI IOL-101-S01-K018 BNI IOL-102-S01-K019
4-wire input 8 or 16 – BNI0021 (16 input) BNI0005 (8 input)
PNP BNI IOL-104-000-K021 BNI IOL-102-000-K006
4-wire input w/diagnostics 16 – BNI0022 (16 input)
PNP BNI IOL-104-S01-K021
4-wire output – 8

4-wire output, – 8
w/diagnostics

5-wire input 16x PNP – BNI0006

(or NPN) BNI IOL-104-000-K006
5-wire input, w/diagnostics 16x PNP –
(or NPN)

5-wire input, w/diagnostics, 16x PNP –

w/2 bytes ID data (or NPN)

5-wire input, w/diagnostics, 16x PNP –

w/4 bytes ID data

5-wire output – 16

5-wire output w/diagnostics – 16

5-wire configurable max 16 max 16 BNI005L

PNP BNI IOL-302-000-K006
5-wire configurable, max 16 max 16
w/diagnostics PNP

5-wire configurable , max 16 max 16

w/diagnostics, w/2 bytes ID data PNP

0-10 V analog (10 bit) 4x VDC – BNI0008

5-wire input 8x PNP BNI IOL-710-000-K006
4-20 mA analog (10 bit) 4x mA – BNI0007
5-wire input 8x PNP BNI IOL-709-000-K006

*Consult factory for availability

2.10
 IO-Link
M12 discrete I/O hubs

M12 Metal M12 Metal M12 Metal M12 Metal

with Integrated Power with 4-pole Auxilliary Power with 5-pole Auxilliary Power with Galvanic Isolation
8 8 8 8
0.5A / 1.4A 2A / 9A 2A / 9A 2A / 9A

BNI0031 (8 input)
BNI IOL-102-000-Z012

BNI0033
BNI IOL-252-000-Z013
BNI003W
BNI IOL-252-S01-Z013
BNI0032 BNI0063*
16x PNP 16x NPN
BNI0039 BNI0062*
16x PNP 16x NPN
BNI003T BNI0061*
16x PNP 16x NPN
BNI005P
BNI IOL-104-S01-Z012-C02
BNI0043 BNI0034
BNI IOL-205-000-Z012 BNI IOL-256-000-Z013
BNI003Y
BNI IOL-256-S01-Z013
BNI003U BNI0050 BNI0035
BNI IOL-302-000-Z012 BNI IOL-302-000-Z026 BNI IOL-302-000-Z013
BNI003C BNI0051 BNI003A
BNI IOL-302-S01-Z012 BNI IOL-302-S01-Z026 BNI IOL-302-S01-Z013
BNI0048
BNI IOL-302-S01-Z013-C01

n www.balluff.com 2.11
 IO-Link
IO-Link connection devices

Connectivity Products with IO-Link

IO-Link’s versatility can be seen in the deep product offering covered in these pages. There are times when a standard
sensor cable is just not enough. Maybe you need to have I/O on constantly changing end effectors or a rotating fixture.
Valve banks with built in network control can add additional costs to a project. Then there are the times you wish you
could just hook the device to your computer, just to get that extra bit of interaction with the device. All of these things
are capable with IO-Link by Balluff.

n Non-contact connectors allow for quick change out and free rotation without loss of power or signal
n Remove costly valve bank network controllers and go to an intelligent 25-pin D-sub connector
n Connect directly to any IO-Link device with your computer for easy setup or parameterization

Other Devices
Non-contact connectors

Standard 16 input I/O hub

25-pin D-sub valve

manifold connector

USB IO-Link Master for Mechanical switches

parameterization or
reviewing components

USB to PC

2.12
 IO-Link
Non-contact connectors
USB master

Non-Contact Connectors
Base BIC005A BIC000C BIC0053
BIC 1I0-I2A50-Q40KFU-SM4A4A BIC 1I0-I2A50-M30MI3-SM4A4A BIC 1I0-IAA50-M30MI3-SM4A4A
Remote BIC005C BIC000E BIC0054
BIC 2I0-I2A50-Q40KFU-SM4A5A BIC 2I0-I2A50-M30MI3-SM4A5A BIC 2I0-IAA50-M30MI3-SM4A5A
Housing Type 40x40 M30 M30
Remote Side, Max Current 500 mA 500 mA 500 mA
Transmission Range 0...5 mm 0…5 mm 0...5 mm
Max Data Transmitted 3 bytes 3 bytes 10 bytes
Process Data 4 bytes 4 bytes 11 bytes

For more information on applications for these products, visit section 4

Optional – M12-M12 cable

for power control of IO-Link BIC

Ordering code BCC0CT6, 0.3 m

USB Master Features:

- Standard parameterization
- Troubleshooting by device
- PC backup of parameter data

USB Master
USB Master BNI002U
BNI USB-901-000-A501
Number of IO-Link Ports 1
USB, Max Current 50 mA
External Power, Max Current 1.6 A
Software Included Yes

n www.balluff.com 2.13
 IO-Link
Valve manifold control utilizing Distributed Modular I/O

When controls engineers get involved in specifying valve manifolds Valve Mainifold Control over EtherNet/IP
a slippery slope can develop. Where does the mechanical design In this conveyor application, a few cylinders are being used for gate
end and the electrical design begin? Being able to order simple valve control to help sort packages as they come through the process.
manifolds with 25-pin D-sub connectors removes this situation and The valve manifold has a simple 25pin D-sub connector controlling
provides multiple advantages: these valves are low cost, they are 7 positions on the conveyor. Controlling the valve manifold is a 25pin
simple to wire and they are typically standard off the shelf components D-sub valve manifold controller with IP40 protection. This connector
so they are easy to repair. But terminating the 25 wires and trying to is then plugged into an EtherNet/IP master device and the controller
troubleshoot these multiple connections can be time consuming and sees the valve manifold over the network as a simple 2 bytes of output
costly. By utilizing an industrial network and a Distributed Modular I/O data. An auxiliary power output, from the master, controls the device
valve manifold connector, cost and time of installation and repair can power and can turn on or off control to the outputs when necessary.
be dramatically reduced. Four manifolds can be controlled on one EtherNet/IP master and the
manifolds can be up to 20 meters from the master device.
n Max 0.7A per output and up to 1.1A total can be active at once
n Connector provides a 0V common on pin 25 and 24V signals
n Up to 16 output positions can be controlled per manifold
n Up to 4 manifolds can be controlled per master device
n Communication speeds between the master and valve control
of 2ms

Parallel wiring solution

– up to 25 individual terminations

Distributed Modular I/O solution

– single connector

Valve Mainifold Control via Distributed Modular I/O

Pneumatic Systems Improvement – BMF V-Twin & Valve Manifold Control

Network Manifold with Reed Switches BMV V-Twin & Valve Manifold Control
– Centralized Air and I/O – Distributed I/O and Air
– Congested with pipes – Small manifolds
and cables mounted near actuators
– Reed switches prone – BMF V-Twin:
to failure Less cables,
Before After Lifetime warranty

2.14
 IO-Link
Valve manifold control

Part Overview
Part Number BNI IOL-751-V_ _-K007 BNI IOL-770-V06-A027 BNI IOL-77_-000-_027*
Connection Type D-Sub 25-pin M26 26-pin IP54 flying leads
Max Active Current 1.1A 1.1A 1.1A
Output Type 24VDC outputs, OVDC commons 24VDC outputs, OVDC commons 24VDC supply, 24VDC outputs,
OVDC commons
Diagnostics basic device fault events and basic device fault events, point basic device fault events and
information level open coil detection information
Inputs/Outputs 16 or 24 outputs 24 outputs 1=16 or 2=8* configurable
Housing Material plastic metal K=plastic, A=metal*
*Consult factory for availability

Control Connector Max Balluff Ordering Code Accessory

by Manufacturer Type Positions Balluff Part Number Accessory Description

MAC Valve Manifolds

MAConnect D-sub 25pin 16 BNI001L
BNI IOL-751-V02-K007
Bosch Rexroth Valve Manifolds
LS04, HFO2-LG, HFO3-LG, HFO4 D-sub 25pin 24 BNI001K
BNI IOL-751-V01-K007
Festo Valve Manifolds
MPA, VUVB D-sub 25pin 24 BNI001K BAM01RC For some
models, cover
BNI IOL-751-V01-K007 BAM PC-NI-009-4 plate
CPV D-sub 25pin 8 BNI001L BAM01RC For some
models, cover
BNI IOL-751-V02-K007 BAM PC-NI-009-4 plate
SMC Valve Manifolds
FD0 connector kit D-sub 25pin 24 BNI001M
BNI IOL-751-V03-K007
MD0 connector kit M26 26pin 24 BNI004W
BNI IOL-770-V06-A027
Numatics Valve Manifolds
AKJ connector D-sub 25pin 22 BNI001M BCC0CKE Adapter required
for all models
BNI IOL-751-V03-K007 BCC D43T-D43T-30-RA051-000
AKF terminals screw terminals 16 BNI005M *
BNI IOL-771-000-K027
AKR connector kit M26 26pin 22 Contact Factory *

Parker Valve Manifolds

L2 End Plate Kit D-sub 25pin 24 BNI001M
D-sub 25pin versions
BNI IOL-751-V03-K007
Terminal Housing versions screw terminals 16 BNI005M *
BNI IOL-771-000-K027
Norgren Valve Manifolds
VS45 D-sub 25pin 24 BNI001M
BNI IOL-751-V03-K007
VS45 screw terminals 16 BNI005M *
BNI IOL-771-000-K027

*Consult factory for availability

n www.balluff.com 2.15
 IO-Link
Radio frequency identification

Data Tracking with Industrial RFID using IO-Link

In today’s manufacturing environment, it is becoming more and more important to track every step of the production process.
Many manufacturers have installed barcode systems or hand written paper work filed by operators or maintenance crews.
This can be time consuming and prone to failure. Industrial RFID systems can be used to track production data and record
plant floor information in every step of the process. There are two main ways to track part data.

n Centralized Data Tracking: All of the information is stored in a central computer and the RFID system is
used only for identification of the part in the work cell. This is a very similar concept to barcoding, but it is more
rugged and 100% reliable. (Read Only Systems)

n Decentralized Data Tracking: Data per part is stored on the RFID tag and is written to the tag at each
workstation. This concept allows for the data to always stay with the part throughout the production process.

RFID
Read only systems (BIS L)
For centralized data tracking

BIS L-203-03/L

0...7 mm

BIS L-201-03/L

0...35 mm
Modular base
with different heads

Read/Write systems (BIS M)

For decentralized data tracking

BIS M-112-02/L

0...38 mm

BIS M-151-02/A

0...65 mm
Longest range
Metal mounted tags

2.16
 IO-Link
RFID read-only systems

Select your RFID system in 4 easy steps:

1. Decide whether you need to write data to a data carrier.
Yes  see page 2.18
No  see page 2.17
2. Choose the appropriate data carrier form factor.
3. Determine the head based on distance.
4. Determine your required memory capacity.

Size M12 M18 25x50 40x40

IO-Link Processors BIS00E1 BIS00E0 BIS00E2 BIS00CZ
Read only BIS L-409-045-003-07-S4 BIS L-409-045-002-07-S4 BIS L-409-045-004-07-S4 BIS L-409-045-001-07-S4

BIS0035 --- 0...15 mm 0...15 mm 0...25 mm

BIS L-100-05/L-RO
BIS0038 --- 0...18 mm 0...18 mm 0...35 mm
BIS L-101-05/L-RO
BIS003C --- --- --- 0...48 mm
BIS L-102-05/L-RO
BIS003F 0...7 mm 0...10 mm 0...10 mm 0...16 mm
Data Carriers

BIS L-103-05/L-RO
BIS003R --- 0…15 mm 0…15 mm 0…25 mm
BIS L-200-03/L
BIS003T --- 0…18 mm 0…18 mm 0…35 mm
BIS L-201-03/L
BIS003U --- --- --- 0…48 mm
BIS L-202-03/L
BIS003W 0…7 mm 0…10 mm 0… 10 mm 0…16 mm
BISL-203-03/L

Note:
The BIS L-1_ _-05/L-RO uses a single write data carrier with 192 bytes.
The BIS L-2_ _-03/L uses read only data carriers with a fixed “unique number” of five bytes (40 bits).
No repetition of the unique number or delivery of sequential numbers is possible.
All IO-Link RFID processors require a shielded cable. See page 2.19 for suggested part numbers.

n www.balluff.com 2.17
 IO-Link
RFID read/write systems
Standard and metal mount data carriers

Size M15.5 M18

IO-Link BIS00LJ BIS00LW
Processors
BIS M-400-045-002-07-S4 BIS M-402-045-002-07-S4
Read/Write Heads
752 bytes 2000 bytes
BIS0048 BIS004A 0…5(6) mm 0…5 mm
BIS M-122-01/A BIS M-122-02/A
BIS0040 BIS0042 0…6(9) mm 0…5 mm
BIS M-105-01/A BIS M-105-02/A
BIS0044 0…15 mm 0…8 mm
BIS M-110-02/L
Standard Data Carriers

BIS003Y 0…15 mm
BIS M-101-01/L
BIS003Z 0…18 mm
BIS M-102-01/L
BIS0043 0…20 m
BIS M-108-02/L
BIS0045 0…20 mm
BIS M-111-02/L
BIS0046 0…28 mm
BIS M-112-02/L
BIS0047
BIS M-120-01/L

For reliable traceability: All data carriers have a 4-byte unique ID contained in the read/write memory. This number is read-only.
All IO-Link RFID processors require a shielded cable. See page 2.19 for suggested part numbers.

Metal Mount Series: These

tags provide highly reliable RFID
performance mounted on any metal
surface.
Size 80x84
Features:
IO-Link Processors BIS00LM - No reduction in range, regardless
Read/Write Heads BIS M-451-045-001-07-S4 of metal alloy
- Large read/write range
BIS004F 0…65 mm - Compatible with all M processors
DataCarriers
Metal Mount

BIS M-150-02/A (vertical mount) Metal mounting plate 40x22mm
BIS004H 0…65 mm BIS Z-MP-001 please order
separately (10 to a package).
BIS M-151-02/A (horizontal mount) Required if no metal substrate is
used.

2.18
 IO-Link
RFID read/write systems
Shielded cable options

M30 25x50 80x84

BIS00LH BIS00M1 BIS00LK
BIS M-400-045-001-07-S4 BIS M-402-045-004-07-S4 BIS M-401-045-001-07-S4

0...5 (8) mm

0…7(11) mm 0...6 (8) mm

0…20 mm 0...15 mm 0…30 mm

0…20 mm 0…28 mm

0…28 mm 0…45 mm

0…28 mm 0…40 mm

0…28 mm 0…40 mm

0…38 mm 0…60 mm

0…50 mm

Shielded Cable Options

Size M12 - M12 M12
Configuration Female - Male Female with Male Field Attachable
Jacket Shielded PUR Black Shielded PUR Black
Conductors 4x 0.34 mm² 4x 0.34 mm²
Available Lengths 1 m, 2 m, 2.5 m, 5 m 2 m, 5 m, 10 m, 20 m
Double-Ended Straight-Straight BCC M415-M414-3A-305-PS0434-_ _ _*
Single-Ended Straight Female BCC M415-0000-1A-014-PS0434-_ _ _
Single-Ended Right Angle Female BCC M425-0000-1A-014-PS0434-_ _ _
Field Attachable Straight Male BCC M474-0000-2A-000-01X475-000

* 010 = 1 m, 020 = 2 m, 025 = 2.5 m, 050 = 5 m, 100 = 10 m

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 IO-Link
Advantages of intelligent sensors

As manufacturing becomes Intelligent sensors are part of this solution. By providing Constant Condition Monitoring, Preventative
even more competitive and the Diagnostics and Automatic Configuration over common industrial networks, intelligent sensors
demand for flexibility rises, we provide the flexibility and detailed data required in a modern manufacturing facility.
begin to ask tough questions to
ourselves, our machine builders
and our component suppliers:
Detailed sensor information Over the industrial network
n How do I increase my produc- Exact failure location Constant Sensor health indication
Standard indication (ON/OFF, measurement,etc.)
tion throughput and maintain “I’m working!” Condition
quality?
n How can I predict sensor or
Monitoring
machine failure?
n What can I do to decrease my
unplanned downtime?
n Where and how often are Decreasing unplanned downtime Unstable application diagnostics
most failures occurring? Predicting failures – Dirty lens
n How do I get more detailed – Target too close
information out of the system?
“Something changed!” Preventative – Target outside ideal range
Diagnostics
The ideal solution to these
questions is a system that can
easily provide status information
from the health of a PLC and Increasing equipment throughput Parameter configuration
industrial network down to the Increasing process reliability – Remote program from the PLC
individual sensor location at one Maintaining high quality – Multiple Configurations stored on the PLC
work station. The system could Automatic – Control over features and functions
predict impending issues and “Tell me what to do!” Configuration
automatically direct action to
solve the issue before it causes
production to stop. In addition
the system should be able to
be flexible and adjust to multiple
configurations, sizes, colors, etc.

Applications of intelligent sensors

Printing and Paper Example Color Sensor Example
Reliable diagnostics are extremely important for highly dynamic While running project A, the color sensor is configured to detect the dif-
machines. You can identify quality issues linked to the manufacturing ference between five different colors as parts are loaded into a fixture.
process in real-time and take appropriate measures immediately. In the
After the required parts are run off, a new project is begun with
printing and paper machine industry, for example, the machine must
a different color set. In the past, a second color sensor would be
react to faults within milliseconds.
required, or the operator would have to reprogram the current sensor
for each new color. By using device parameterization, the controller
tells the sensor its configuration for project B and quickly, without
hassle, the sensor has its new colors.

Project A

Green Orange

Project B

Red Blue

2.20
 IO-Link
Types of intelligent sensors

Using Distributed Modular I/O technology and talking over the same backplane from slave to master device, multiple intelligent sensors can be
connected to one IP address on an industrial network. Depending on the complexity of the information the sensor provides or requires, any combi-
nation of 1 to 32 intelligent sensors can be connected. Utilizing the open standard IO-Link, it is also possible to mix and match with any Distributed
Modular I/O products available such as: discrete I/O, analog I/O, valve manifold control, RFID and third party intelligent sensors and devices.

Standard
Power I/O

Standard
I/O
Hub Intelligent Intelligent
Sensor Sensor
Hub Hub

Individual
Intelligent Sensor

Standard Intelligent Intelligent

Sensors Sensors Sensors

Standard Level 1 Level 2 Level 3 IO-Link

Sensors Intelligent sensors Intelligent sensors Intelligent sensors
Maximum sensors 16 per hub 8 per hub 8 per hub
per IP address 12 per master 0 per master 0 per master 4 per master
76 per IP address 32 per IP address 32 per IP address 4 per IP address
Available Measure
functions Constant Constant Constant
ON ON Condition ON Condition Condition
OFF OFF Monitoring OFF Monitoring Monitoring

Preventative ON Preventative Automatic

Diagnostics OFF Diagnostics Configuration

Balluff Standard
brands sensors D
Sensors S Sensors Sensors
C

Intelligent Sensor Hub

Ordering Code BNI002Z
Part number BNI IOL-530-000-K006
Type M12 plastic
Number of Intelligent Sensors 8 (Level 1 or Level 2)
Number of Ports 8

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 IO-Link
Intelligent sensors

Level 3 Intelligent Sensors with IO-Link

As manufacturing needs to get more flexible, sensors and other devices installed in the process need to be flexible
as well. Right now, most production lines require the operator to reprogram a sensor, or the engineer needs to
design multiple sensors into the process. Intelligent sensors with IO-Link built into them can reduce this downtime
and the errors that come with reprogramming. IO-Link sensors can have their parameters changed via the PLC to
accommodate multiple recipes or configurations. Some examples of sensors with this capability are:

n Color sensors for detecting product colors for error proofing or JIT (just in time) production
n Measurement sensors for detecting the position of targets or measuring their size
n Precision Mechanical Switches have been in the Balluff product portfolio from the very beginning,
use their upgraded functionality by connecting them via IO-Link
n Edge detection sensors allow for positioning on machines or in production
Sensors
Five color sensing

Red Blue Yellow Green Gray

EdgeMaster™
Edge detection

Measurement
– Inductive
– Laser

Mechanical switches
for position sensing
and triggering

2.22
 IO-Link
Level 1 intelligent sensors

Capacitive Ø 20 mm
Ordering Code BCS0001
Part number BCS 20MG10-XPA1Y-8B-03*
Switching Type PNP complementary
Rated Switching Distance sn 10 mm
Size, Mounting Ø 20 mm, flush
Operating Voltage UB 10...30 V DC
Function Indicator Yes
Degree of Protection per IEC 60529 IP 63
Approvals CE
Housing Material V2A, EP
Connection 3 m cable PUR, 3×0.25 mm²

Constant
ON Condition
OFF Monitoring

Inductive M12 Sensors

Ordering Code BES02MC BES02M5 BES02M8
Part number BES 113-356-SA6-S4* BES 113-3019-SA1-S4* BES 113-356-SA31-S4*
Switching Type PNP normally open PNP normally closed PNP normally open
Rated Switching Distance sn 3.7 mm 3.7 mm 4 mm
Size, Mounting M12×1, non-flush M12×1, non-flush M12×1, non-flush
Operating Voltage UB 20...30 V DC 20...30 V DC 20...30 V DC
Function Indicator No No No
Degree of Protection per IEC 60529 IP 67 IP 67 IP 67
Approvals CE CE CE
Housing Material Stainless steel Stainless steel Stainless steel
Connection M12 connector M12 connector M12 connector

Constant
ON Condition
OFF Monitoring

* Can be used with the constant

condition monitor which provides
a status output.

Ordering code BAE006W

Part number BES 113-FD-1

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 IO-Link
Level 2 intelligent sensors

Inductive M8 Sensors
Ordering Code BES03EN BES03EP BES03EL
Part number BES M08EI-PSY15B-S49G-D01 BES M08EH-PSY25F-S49G-D01 BES M08EI-PSY15B-S04G-D01
Switching Type PNP normally open PNP normally open PNP normally open
Rated Switching Distance sn 1.5 mm 2.5 mm 1.5 mm
Mounting Type Flush Non-flush Flush
Operating Voltage UB 18...30 V DC 18...30 V DC 18...30 V DC
Function Indicator Yes Yes Yes
Degree of Protection per IEC 60529 IP 67 IP 67 IP 67
Approvals CE, cULus CE, cULus CE, cULus
Housing Material Stainless steel Stainless steel Stainless steel
Connection M8, 3-pin M8, 3-pin M12, 3-pin
Inductive
M12, M18, M30 Sensors M12 M12 M18
Ordering Code BES03ER BES03ET BES03EU
Part number BES M12MI-PSY20B-S04G-D01 BES M12MH-PSY40F-S04G-D01 BES M18MI-PSY50B-S04G-D01
Switching Type PNP normally open PNP normally open PNP normally open
Rated Switching Distance sn 2 mm 4 mm 5 mm
Mounting Type Flush Non-flush Flush
Operating Voltage UB 18...30 V DC 18...30 V DC 18...30 V DC
Function Indicator Yes Yes Yes
Degree of Protection per IEC 60529 IP 67 IP 67 IP 67
Approvals CE, cULus CE, cULus CE, cULus
Housing Material CuZn coated CuZn coated CuZn coated
Connection M12, 3-pin M12, 3-pin M12, 3-pin

Constant
ON Condition Preventative
OFF Monitoring Diagnostics

BGL Fork Sensors with Dynamic Sensor Control

Ordering Code BGL003N BGL003P BGL003R
Part number BGL 30A-013-S49 BGL 50A-013-S49 BGL 80A-013-S49
Fork Sensor 1xPNP 1xPNP 1xPNP
Fork Opening 30 mm 50 mm 80 mm
Light Type Infrared Infrared Infrared
Function Indicator Yes Yes Yes
Repeat Accuracy ≤ 0.15 mm ≤ 0.15 mm ≤ 0.15 mm
Connection, Connectors M8, 3-pin M8, 3-pin M8, 3-pin

Constant
ON Condition Preventative
OFF Monitoring Diagnostics

2.24
 IO-Link
Level 2 intelligent sensors

BES03EM
BES M08EH1-PSY25F-S04G-D01
PNP normally open
2.5 mm
Non-flush
18...30 V DC
Yes
IP 67
CE, cULus
Stainless steel
M12, 3-pin

M18 M30 M30

BES03EW BES03EY BES03EZ M8, 3-pin

BES M18MG-PSY80F-S04G-D01 BES M30MI-PSY10B-S04G-D01 BES M30MF1-PSY15F-S04G-D01

PNP normally open PNP normally open PNP normally open
8 mm 10 mm 15 mm
Non-flush Flush Non-flush M12, 3-pin
18...30 V DC 18...30 V DC 18...30 V DC
Yes Yes Yes
IP 67 IP 67 IP 67
CE, cULus CE, cULus CE, cULus
CuZn coated CuZn coated CuZn coated
M12, 3-pin M12, 3-pin M12, 3-pin

Photoelectric Sensor BOS 18 M Teach-In with Dynamic Sensor Control

Ordering Code BOS01CU BOS01CT BOS01CW BOS01CY
Part number BOS 18M-PUD-RD30-S4 BOS 18M-PUD-PR30-S4 BOS 18M-PUD-RE30-S4 BOS 18M-X-RS30-S4
Sensing Technology Retro Reflective Diffuse Thrubeam Receiver Thrubeam Emitter
Switching Type PNP NC/NO selectable PNP NC/NO selectable PNP NC/NO selectable PNP NC/NO selectable
Rated Switching Distance Sn 500 mm 5 mm 20 mm 20 mm
Size, Mounting M18 M18 M18 M18
Operating Voltage UB 10...30 V DC 10...30 V DC 10...30 V DC 10...30 V DC
Function Indicator Yes Yes Yes Yes
Degree of Protection per IEC 60529 IP 67 IP 67 IP 67 IP 67
Housing Material Nickel-plated brass Nickel-plated brass Nickel-plated brass Nickel-plated brass
Connection M12 connector M12 connector M12 connector M12 connector

Constant
ON Condition Preventative
OFF Monitoring Diagnostics

n www.balluff.com 2.25
 IO-Link
Level 3 IO-Link intelligent sensors

Inductive Measurement Sensors

Ordering Code BAW002F BAW003A
Part Number BAW M18MI-BLC50B-S04G BAW Z01AC-BLD50B-DP03
Range 1...5 mm 1...5 m
Switch Points 0 3
Resolution ± 8 μm ± 10 μm
Analog Value Range 0000...03FF 0000...03FF
Process Data 3 bytes 2 bytes

Measure Measure
Constant Constant
Condition ON Condition Preventative Automatic
Monitoring OFF Monitoring Diagnostics Configuration

Inductive Positioning Sensors Laser Measurement Sensors

Ordering Code BIP0004 Ordering Code BOD0012
Part Number BIP LD2-T040-02-S4 Part Number BOD 63M-LI06-S4
Range 0...40 mm Range 200...6000 mm
Target Width 14 mm Resolution ≤ 1 mm
Resolution 40 µm Repeatability ≤ ± 4 mm
Process Data 2 bytes Analog Value Range 00C8...1770
Process Data 3 bytes/1 byte
Measure
Constant
Condition Preventative Measure
Monitoring Diagnostics Constant
ON Condition Preventative Automatic
OFF Monitoring Diagnostics Configuration

2.26
 IO-Link
Level 3 IO-Link intelligent sensors

Edge Detection Color Sensing

30 mm Ordering Code BGL0035 Ordering Code BFS000F
Part Number BGL 30C-007-S4 Part Number BFS 26K-GI-L04-S92
50 mm Ordering Code BGL003F Diffuse Range 12…32 mm
Part Number BGL 50C-007-S4 Reflector Range 50…200 mm
Resolution 0.08 mm Working Colors 5
Light Spot 28 mm x 3 mm Process Data 1 byte
Air Blowoff Built-in Light Spot Ø4 mm at 22 mm
Analog Value Range 0...1024
Constant
Measure ON Condition Automatic
Constant
ON Condition Preventative Automatic OFF Monitoring Configuration
OFF Monitoring Diagnostics Configuration

Linear Position Transducer Mechanical Switches

Ordering Code Part Number BNS 819-...

Part Number BTL6-U100-M_ _ _ _-PF-S4* Housing Series Available 40, 46, 61, 62, 100

Stroke Length 50 mm...4572 mm (2" to 180")

Resolution 5 µm Constant
ON Condition
Analog Value Range 32 bit signed integer OFF Monitoring

Measure
Constant
Condition Preventative Automatic
Monitoring Diagnostics Configuration
*Consult factory for availability
Ordering Instructions:
M_ _ _ _ = desired stroke length in mm (0051 to 4572)

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