In every
field

WE SPEAK IO-LINK.
ON A GLOBAL SCALEWe Speak IO-Link | 3

CONTENTS

For fast, flexible
and efficient production

4
IO-LINK – THE IDEAL SOLUTION
Modular control concepts

6
IO-LINK IN THE PASSING LANE

88
IO-Link saves time and		 money10		 Migrate Fieldbuses11		 Automate Robots
12
Consolidate and Gather		 I/O Signals

14		 Track Data
15		 Measure, Control and		Regulate
16		Signaling
17		 Handling and Assembly

18		 We Speak IO-Link
20		 Communicate consistently 				interference-free
22		 Fast Tool Changing
24		 Position Workpieces in		Assembly
26		 Monitor Process Media
28		 Easily Visualize Operating 				States
30		 Constant Temperatures		 in Induction Hardening
32		 Monitoring Clamping
		 in the Machine System
34		 Automatically Acquire Data
36		 Automate Format Changes

38		 Measure Position and		 End-of-Travel with
		 Absolute Accuracy
40		 Quality Control to your		 Individual Specifications
42		 Automated Tool
		 Management44		 Safety over IO-Link
46		 Safe Personal Protection
48		 Safety for People
		 and Systems
50		 Safety for Clamping
		Equipment
52		 Reliably transmit signals
		 in Electrical Noise Fields
54		 The Optimal Power		 Supply for Noise-Free
		Operation

MORE EFFICIENCY, LOWER COSTS

18
IO-LINK IN THE ENTIRE PRODUCTION PROCESSSERVICES 56
REFERENCES 58

www.balluff.com

4 | IO-Link – the ideal solution

For fast, flexible and efficient production

IO-LINK – THE IDEAL
SOLUTION

Just one interface for improved process quality
Intelligent combining of industrial network with the IO-Link communication
standard is the ideal solution for ever faster, more flexible, more efficient andmore adaptable production. This provides you with a powerful infrastructure
for reliably managing the growing volume of data. It transports your data throughthe entire manufacturing process and enables seamless communication fromthe sensor into the Internet, making IO-Link the ideal enabler for Industry 4.0.

Why IO-Link increases the performance of your network
IO-Link is the first globally standardized IO technology (IEC 61131-9) that
communicates from the controller down to the lowest automation level. This
universally applicable interface is a fieldbus-neutral point-to-point connection
which uses standard unshielded cables. IO-Link sends all the sensor andactuator signals to the controller and in turn carries controller data to thesensor/actuator level with revolutionary consequences.
This open standard opens all sensors to the fieldbus level and even transports
analog signals noise-free by digitizing them. IO-Link enables fully continuous
diagnostics as well as automated configuration of the IO-Link devices via thecontroller. This means IO-Link is simple to install. In addition to the IO-Link master,
all you need is a standard unshielded 3- or 4-conductor cable to connect sensors
and actuators.

www.balluff.com

IO-Link in the passing lane | 7

Modular Control Concepts

From parallel wiring to the fieldbus protocol

Universal, simple and flexible: IO-Link!

WHY IO-LINK
IS IN THE PASSING LANE

Replacing parallel wiring with the use of fieldbuses was anenormous step because fieldbus protocol has successfully
eliminated the immense installation effort associated withcopper cables and substantially reduced the costs. It is notjust that the fieldbus reduces the working time because a bus
cable replaces numerous parallel strands of wire. Since fewer
strands are needed, also material and space are conserved.
Simultaneously, the bus cable connects the components ofdifferent levels. Now a system without a control cabinet ispossible.

The weaknesses of the fieldbus protocol are now a thing of
the past thanks to IO-Link because the unshielded, 3- or
4-conductor standard industrial cables are highly flexible andsuitable for many bending cycles. They are easy to connect,
highly economical, and can use M5, M8 or M12 connectors.
Therefore, with IO-Link you can rely on an establishedstandard for connecting the widest possible variety of devices.
IO-Link ensures extremely flexible control concepts. Thisversatility, simplicity and performance capability mean IO-Link
can be considered a universal interface – like USB – inautomation.

Pitfalls of the fieldbus protocol
But even fieldbus cables are not without problems, even if
their protocol is no longer electrical and the cabling effort
goes down by orders of magnitude. Fieldbus cables have a
low signal level, are noise-susceptible, don’t like to be bent
and because of the shield are expensive.

But with IO-Link the flexibility is even much greater becausewith Safety over IO-Link Balluff offers the first safety solution
to be integrated with IO-Link for combining safety andautomation technology in one system. Safety over IO-Link
provides both sensor/actuator details as well as safety
information, so that you can benefit from the best of bothworlds with our safety concept.

FLEXIBILITY WITH IO-LINK

SAFETY OVER IO-LINK

PARALLEL WIRING

PS

CPU

IN

FIELDBUS/NETWORK

OUT

1
2

12
10

4
2

5

4

6
7

9

11
13

3
8

2
14

1
2
3
4
5
6

Terminal block
Sensors
Junction blocks
Valve interfaces
Fieldbus module
IO-Link SmartLight

7 IO-Link pressure sensor
8 Industrial RFID system
9 IO-Link master10 IO-Link analog converter
11 IO-Link valve interfaces
12 IO-Link sensor hubs

15

13 IO-Link safety hubs
14 Opto-electronic
protective devices
15 Emergency stop device

www.balluff.com

More Efficiency, Lower Costs | 9

More Efficiency, Lower Costs

IO-LINK SAVES TIME
AND MONEY

Easy installation

More efficient operation

For IO-Link all you need is an industrystandard 3- or 4-conductor cable. The
uniform standard interface can bequickly and easily integrated into thefieldbus world to simply link evencomplex devices. One special feature:
the digital communication ensuresnoise immunity even without the useof expensive shielded cabling. Analog
signals are digitized with no conversion
losses.

With IO-Link you can position sensors
in the machine just as the process
requires, since accessibility of thesensors is no longer a factor. Processmonitoring, configuration and error
analysis of the IO-Link devices now
takes place in the controller. Machinesequences are now time-optimized.
Signal delays and distortions are reliably
eliminated because digital transmissionof data also ensures high signal quality.

Highest machine availability
IO-Link enables quick, error-free sensor
replacement and prompt commissioning.
You can significantly reduce downtimes
since the parameters of a replaced
IO-Link sensor are automatically writtenfrom the IO-Link master to the newsensor. Commissioning processes,
format changes or recipe changes arehandled centrally via the controller’sfunction modules. This saves time andreduces the potential for mistakes toa minimum. Another advantage to you:
IO-Link devices cannot be mixed up,
since they are automatically identifiable
via IO-Link.

STANDARD PLC

SAFETY PLC

FIELDBUS MASTER
WITH IO-LINK INTERFACE

A wide range of application requirements
can be easily met with IO-Link because
you can use both binary and analog
standard devices at the same time alongwith IO-Link sensors/actuators.

SAFETY-OVERIO-LINK DEVICE*

IO-LINKDEVICES

High-performance, consistent network
Controller concepts using IO-Link
provide you with simple and universal
solutions for a high-performance,
consistent network, so that with thisuniversal interface you profit from lower
costs and are more flexible than ever.
Use the typical applications presented
on the next pages to learn about thepossibilities IO-Link opens up for you.

Requirements-based maintenanceContinuous diagnostic data for the entire
process extends your service intervals,
since automatic readjustment via IO-Linkmeans you need to maintain equipment
and machines much less often. And
now predictive error detection is evenpossible because the complete processparameters are consistently displayed in
the controller.

STANDARDSENSORS/ACTUATORSSAFETYSENSORS/ACTUATORS*for use only with Profinet

10 | More Efficiency, Lower Costs

More Efficiency, Lower Costs | 11

IO-Link provides a high standardization factor

A simple M12 connection is all you need

Migrate Fieldbuses

Automate Robots

Plug-and-Play in all networks

Profit from minimal downtimes

As a systems and machine builder you market and sell yourproducts around the globe. This means your products have toadapt to the conditions of very different countries. And are
tuned to very different networks.
No matter what countries you are active in, with IO-Link there
is one concept for field installation for various markets: for
Profibus, Profinet, Devicenet, Ethernet/IP, EtherCAT, CC-Link
or CC-Link IE/Field.

To adapt the bus system, simply change out the master andyou can continue working seamlessly with virtually the identicalschematics – without any added effort.

Modern robot systems need many sensors – primarily in the
robot arm. However, they should have less mass in order toensure the dynamics and minimize the energy consumption.
Furthermore, the expensive wiring of multiple cables makes it
difficult to achieve high efficiency.

Inductive couplers provide you with quick tool changes
because they send both data and power at the same timeover an air gap. Plug-and-play makes for prompt connectionof the new tool and is automatically parameterized by thecontroller via IO-Link. You no longer struggle with cablebreaks, but rather profit from high flexibility and from minimal
downtimes.

Thanks to IO-Link, difficulties like this are a thing of the past.
This is because a standard M12 connection is all you needto ensure the function of the robot – no need for special
connectors. I/O module and valve terminal are easily linked
and complexity is reduced.

7

6
4
5

6

9

7

2

1

3

9

6
8

9

7
9

1
2
3
4
5

IO-Link master
Fieldbus cable
Power cable, 7/8”
Inductive coupler, 40 × 40 mm, Base, IO-Link, bi-directional
Inductive coupler 40 × 40 mm, Remote, IO-Link, bi-directional

6
7
8
9

M12 sensor hub, configurable, I/O with expansion
IO-Link valve interface (Festo, Bosch Rexroth)M12 sensor hub, 16 inputs, PNP
Single-ended cordset, M12 → M12, 4-conductor

www.balluff.com

12 | More Efficiency, Lower Costs

More Efficiency, Lower Costs | 13

Expand decentralization

Consolidate and Gather
I/O Signals

M8 IO-Link hubs (digital)R

Minimize critical installations

Configure up to 496 I/O’s

With IO-Link, you need only a node/IP address to transmit
the data of up to 496 inputs/outputs. With the compression of
the data, you preserve the valuable addresses and minimize
critical installations.

A 16x IO-Link master allows up to 496 I/Os to be
configured. The range is doubled and exponential
cost savings are realized.

IO-Link valve interfaceR

All you need to implement this network structure is astandard unshielded cable. You still have access to theentire IO-Link functionality while reducing your wiring
effort and saving money.

Here the IO-Link actuator/sensor hub with its expansion port
sets the standard. Combined with the IO-Link master you
have completely new options for expanding the decentralized
structure of your network topology because you can use thisport to connect valve interfaces or an additional IO-Link hub:
Simply, using plug-and-play. Additional in- and outputs areprocessed this easily as well – with no additional master.

Plastic

Metal

M12 IO-Link hubs (digital)
R

2

1

3

3

8

Plastic

Metal

IO-Link universal devices
R

Plastic(weld-resistant)

Stainless steel

IO-Link SmartLightR

4

M12 IO-Link hubs (analog)R

IO-Link analog converters
R

4
5

1
2
3
4

7

IO-Link master
Fieldbus cable
Power cable, 7/8”
IO-Link sensor hub, configurable, I/O with expansion

I/O Expansions
5
6
7
8

6

IO-Link valve interface (Festo, Bosch Rexroth)
IO-Link valve interface (SMC, Parker, Norgren)
IO-Link valve interface (Numatics)
single-ended cordset, M12 → M12, 4-conductor

5

Plastic

Metal

Plastic

Stainless steel

www.balluff.com

14 | More Efficiency, Lower Costs

More Efficiency, Lower Costs | 15

Maximum transparency for the optimal process

Correctly feed process media

Track Data

Measure, Control and Regulate

Ensure quality

Example with oil supply for a hydraulic cylinder

The intelligent combination of RFID and sensors with IO-Link
makes it possible to cost-effectively handle your identification
requirements and process signals at the same time.
When is comes to quality assurance, RFID systems record
the entire production sequence and make it traceable in realtime. The data are documented directly on the workpieceor pallet, regardless of ambient conditions, read distancesor technologies (low-frequency – LF, high-frequency – HF,
ultra-high frequency – UHF).

Depending on the data volume and speed, we offer different
devices: BIS V processor units for fast processing of high data
volumes – and if you want to run LF, HF and UHF read/write
heads simultaneously, the BIS V lets you process all these
RFID technologies at the same time.

IO-Link and simple unshielded standard cables ensure correct
feeding of your process media. All you need is an IO-Link
master to receive and pass along the data. So you only use
one bus address for the entire control circuit of the masterassembly.

The sensors measure the flow, temperature and pressureof the oil. These data are continuously passed to the variable
regulator through the master, with the regulator comparing
the data with the nominal value, initiating – if necessary – areadjustment and providing feedback to the controller.

An IO-Link master is appropriate for standard ID tasks toconnect I/O units or IO-Link capable sensors/actuators. Eachindividual production step, for example, can also be displayedusing the SmartLight tower light.

For example, for the oil feed of a hydraulic cylinder you canfully automatically measure, control and regulate all the relevant
components – pressure-, temperature- and flow sensor,
control valve and the hydraulic cylinder itself which ensures
the optimum oil flow.

Correct control of the hydraulic cylinder by the control valve is
now possible. The master also passes this information to thecontroller, which in turn generates the positioning commands
for the hydraulic cylinder. These commands in turn arrive where
they are needed through the master. A great feature: you canwire the entire control circuit with unshielded, 3- or 4-conductor
cables.

1

2

9

9

9

2

3

9
9
9

9

6

6
7

7

6
7

7

6
7

7

7

7

8
6

7

5
11
10

8

5

8

8

11
3

2

8

10

10

10

12

Hydraulic cylinder

4

4

4

10

1

10

Variableregulator

Flow sensor,
temperature sensor
Control valve

1 Profinet, 8 × IO-Link master2 Profinet cable, M12 → RJ45, shielded
3 Profinet cable, M12 → M12, shielded
4 Power cable, 7/8”, 4-conductor
5 Industrial RFID, Profinet processor unit 4x, 1 × IO-Link master6 Industrial RFID, read/write head
7 Industrial RFID, data carrier
8 M12 sensor hub (metal), 16 I/O, configurable
9 IO-Link SmartLight, 3 segments
10 Single-ended cordset, M12 → M12, 4-conductor
11 RFID single-ended cordset, M12 → M14, shielded, 4-conductor

Profinet, 4 × IO-Link master
Profinet cable, M12 → M12, shielded
Power cable, 7/8”, 4-conductor
IO-Link pressure sensor
Profinet transducer BTL7,
Length max. 7620 mm
6 IO-Link- analog converter, input 0...10 V DC
1
2
3
4
5

7 IO-Link analog converter, output 0...10 V DC
8 M12 sensor hub, analog 0...10 V DC, digital
9 Single-ended cordset, M12 → M12, 4-conductor
10 Single-ended cordset, M12 → M12, shielded, 4-conductor
11 Magnet for transducer
12 Power cable, M12, 4-conductor

www.balluff.com

16 | More Efficiency, Lower Costs

More Efficiency, Lower Costs | 17

Continuous diagnostics of the operating states

A network distributor for complex tasks

Signaling

Handling and Assembly

Setup without mechanical reconfiguring

Modules reducible

If you need seamless visualization of the production sequence
on your production line, the SmartLight signal tower lightprovides the perfect solution. The SmartLight displays trends
and tendencies, so that you can continually monitor various
stages. This optimizes cycle times and gives early indicationof any possible bottlenecks or maintenance duties.

The various modes – run light, stack light and level mode –can be set without making any mechanical changes. Use
the controller to choose between Running Light and Color
Gradient or the display of up to five color segments.
Just as important: the SmartLight is simple to retrofit.

Whether you are bundling signals, switching pneumatics,
recording and tracking data or want to display operating
conditions with the SmartLight signal tower light – one
network distributor used as a remote data compressor
handles such complex tasks: all the analog functions, RFID
applications, the valve control, signaling and the use of
remote I/O.

One IO-Link master per production segment is all you need.
In this way you can reduce various modules and select anddeselect equipment options. This affords you great flexibility
and saves you cash. At the same time an IO-Link master isextremely powerful. It scores additional points by virtue ofadditional features like a display, integrated switch and web
server, which make it especially user-friendly.

4
4

4

4

6

6

7

7

6

7
7

7

8

8

4

2

4

3
5
9

5

10

9

2

9

10

9

3
5

5
5

1

PRODUCTION CELL
10

1
2
3
4
5
6
7

PRODUCTION CELL
20

IO-Link Master
Fieldbus cable
Power cable, 7/8”
IO-Link SmartLight, 5 segments and buzzer
Single-ended cordset, M12 → M12, 4-conductor
Stand for SmartLight, 400 mm highStand for SmartLight, 100 mm high

PRODUCTION CELL
30

PRODUCTION CELL
40

5

1

1 IO-Link master2 Fieldbus cable
3 Power cable, 7/8”
4 M8 sensor hub, 16 inputs, PNP
5 IO-Link valve interface (Festo, Bosch Rexroth)
6 IO-Link SmartLight, 3 segments
7 Industrial RFID, read/write head
8 Industrial RFID, data carrier
9 Single-ended cordset, M12 → M12, 4-conductor
10 RFID single-ended cordset, M12 → M14, shielded, 4-conductor

www.balluff.com

18 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 19

FAST TOOLCHANGING 22
INTERCONNECTED NOISEFREE COMMUNICATION 20

MANAGE TOOLS 42

TRANSMIT SIGNALSIN NOISE FIELDS 52

OPTIMIZE QUALITYCONTROL 40

MEASURE POSITION AND
END-OF-TRAVEL 38

MONITOR PROCESSMEDIA 26

VISUALIZE OPERATINGSTATES 28
POSITION
WORKPIECES 24
MONITOR THE
CLAMPING PROCESS 32

In the entire production processWE SPEAK
IO-LINK

Balluff IO-Link ensures transparency for all of automation.
In every area – whether logistics, service, production,assembly, inspection and packaging. And for every single
application – whether fluids, identification, travel measurement or object detection.
At Balluff you get holistic IO-Link solutions with high-performance IO-Link sensors and the best IO-Link networkand connectivity. Balluff speaks IO-Link in every field andwith all principles of operation, so you have access tothese IO-Link advantages throughout the entire system.
n Easy to installn Requirements-based maintenancen Efficient operationn Highest machine availability

AUTOMATE FORMATCHANGES 36

This lets you exploit all the possibilities of this digitalcommunication standard. In the following you will see
specifically all the ways you can use IO-Link performance.
VOLTAGE SUPPLYFOR NOISE-FREE
OPERATION 54

SAFETY FOR CLAMPING
DEVICES 50

MONITORTEMPERATURES 30
DATEN AUTOMATISIERTERFASSEN 34

SAFETY OVER IO-LINK 44-49

www.balluff.com

20 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 21

7
7

1
3
2

4

6

Simplify network topology
5

All devices become IO-Link capable
Modern robotics equipment requires many sensors – especiallyin the robot arm which, because of the dynamics and energy
consumption, still needs to have as little mass as possible.
Another difficulty is the cumbersome wiring of multi-conductor
cables.
Not so with IO-Link because this digital communication
standard requires only a traditional industrial cable which issimple to install. IO-Link also ensures noise immunity withintelligent devices without the need for shielded cables.
Whether Profibus/Profinet over CC-Link/CC-Link IE-Field,
Devicenet or Ethernet/IP and EtherCAT – our IO-Link masters
let you use IO-Link with any controller. After all, IO-Link isfieldbus-neutral. With IO-Link you can bring a wide variety
of devices together in this structure, so that even the mostcomplex tasks including robotics and beyond can be simply
mastered with the greatest possible flexibility.

The universal IO-Link interface integrates intelligent devices into
the controller. Likewise you can also integrate standard analog
sensors into the controller using our IO-Link analog converters.
Or simply connect them to our IO-Link hubs, which can digitize
the analog input signals and pass them on to the IO-Link
master. With the IO-Link master you can also control actuatorsand valve terminals. Simply use the valve interface to connect
the valve terminal to the IO-Link master. Here again all you needis a standard cable to make use of the full functionality.
A Balluff IO-Link sensor hub bundles the signals from up
to 16 sensors or actuators. A special highlight are ourcascadable hubs with expansion port to which you canconnect an additional sensor hub or a valve terminal. If thesehubs are cascaded with an additional hub and connected
to our 16x IO-Link master, a module transmits up to
496 inputs/outputs.

1 Universal IO-Link interfaces
2 Vision sensors
3 IO-Link ultrasonic sensors
4 IO-Link sensor/actuator hubs
5 IO-Link masters
6 IO-Link valve interface
7 Photoelectric IO-Link multifunction sensors

Communicate
consistently
interference-free22 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 23

2

Contactlessly transmit power and data

Fast Tool Changing

1

Maximum flexibility since the robot radius is increased to 360 degrees
Inductive couplers are a windfall for robotics because they
send both data and power at the same time over an air gap.
How do you benefit? Greatly, and in many ways. Now therisk of cable breaks is fully precluded. Mechanical contactingof mechanical connectors is eliminated, and the robot has acontinuous radius of movement of 360 degrees.

1

Our inductive couplers with IO-Link guarantee you fast gripper
changes and increase the up-time of your system. This isbecause the signal is transmitted directly following the gripper
change so that production can continue without interruption.
The speed and flexibility support frequent format changes. The
result is that you can produce even small batches efficiently.
Another attractive feature: no mechanical wear means
inductive couplers are maintenance-free.
The quick-disconnect units provide the greatest flexibility foryour machine design. Even hard to access components are
simple to connect with IO-Link. This is because all IO-Link
capable devices now connect to the IO-Link master and tothe controller flexibly and without contact.
The bi-directional inductive data couplers allow the data to
be sent in both directions, and you can simultaneously control
actuators and valve terminals while collecting signals. Thesevariants support the full IO-Link functionality so that intelligent
sensors and actuators can be configured and diagnosed
without contact.

1 Inductive couplers (style Q40)
2 IO-Link SmartLight

www.balluff.com

24 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 25

7

5
1
6

2

1

4
3

Full transparency all the time

Position Workpieces
in Assembly

Smart diagnostics increase reliability
When it comes to Industry 4.0, generating, transporting andprocessing information are indispensable parts of the process.
This makes local intelligent sensors all the more important. Our
photoelectric multi-function sensors detect actual operatingstates while collecting and processing information. And via
IO-Link they provide far more data than just the switching
signal.
The BOS 21M ADCAP multi-function sensor with red light isideal for optimally positioning your workpieces for assembly.
For the best functionality as required, you can use IO-Link toconveniently select between four different sensor modes.
This allows you to utilize the best and most reliable detection
method depending on your application.
The sensor simultaneously sends diagnostic data as well.
Now you can evaluate the light emissivity value provided anddetect increasing contamination of the sensor. In this way

maintenance and cleaning schedules can be designed sothat the sensor is always cleaned at just the right time before
failures can occur. You also know whether the sensors are still
optimally adjusted after a cleaning.
The BOS 21M ADCAP can do even more: it continuously
monitors light intensity and brightness of the LED emitter beam
so that faulty switching of the sensor is virtually eliminated. The
built-in count function with various counting and reset modes
also allows the quantity to be checked in the controller without
any additional programming effort.
If your detection requirements are even more demanding,we offer our photoelectric High-Precision Laser BOS 21M HPL
with numerous additional functions. Thanks to various
detection and processing modes, this high-performer also
detects complex objects and the smallest details with absolute
precision.

1 Photoelectric IO-Link multifunction sensors
2 Multiple position switches
3 IO-Link masters
4 IO-Link ultrasonic sensors
5 IO-Link color sensor
6 IO-Link fork sensor
7 IO-Link SmartLight

26 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 27

For high production quality

Monitor process
media

1
Plug-and-play sensor replacement: high machine availability
Pressure sensors are indispensable when you need to monitor
process media such as coolants and lubricants, hydraulic fluids
and pneumatics. The system pressure affects things such as
the surface quality when processing workpieces. Continuousand exact regulation of the pressure is provided by our IO-Linkpressure sensors, since they are continuously transmitting theirmeasurement values and data to the controller.
Pressure sensors also ensure the best results on a machining
center. There they provide clamping distance monitoring toguarantee secure holding of the workpiece and tool in thelathe.
IO-Link pressure sensors are configured via the controller,
so that they can be installed where the action is or in hardto-reach places in the best position for measurements andperfectly matched to the machine design. This guarantees you
fast and precise results and reduces your costs, since you can
now reduce cumbersome mechanical installation of hydrauliclines to a minimum.
IO-Link pressure sensors ensure that you enjoy the greatest
possible machine up-time. Replacing a sensor is plug-andplay, since the data for the replaced sensor are automaticallyloaded into the IO-Link master.
Depending on your requirements you can choose between
IO-Link pressure sensors with display and IO-Link pressuretransmitters without display. This ensures you of the best andmost economical solution.

1 IO-Link pressure sensors

www.balluff.com

28 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 29

1

1

2

1

Greater flexibility was never easier

Simple visualizationof operating states

One light. Many functions. Unlimited uses.
It’s not yet possible to foresee all the demands of theSmart Factory. But to visualize your automation you can geta modern IO-Link device today that has virtually unlimited
application and is ideally equipped for the future.

programmable foreground and background color(Run Light mode).

The LED stack light with IO-Link interface offers you apreviously unimagined flexibility because with the Balluff
SmartLight you can represent operating states in detail.
In addition, you can even see trends and progressions.
The SmartLight features three different modes.

The best part: You can change to any mode on-the-fly.
Colors can also be changed while running because you
configure the SmartLight simply from the controller. So forgetthe cumbersome mechanical reconfiguration of traditional
stack lights. And in contrast to those older systems, you
can individually specify the colors and zones for number,size and color definition.

Display a wide range of color signals in freely configurable
segments (Segment mode). Color progression display for
representing variables such as level, position or temperature(Level mode). And an automatic run light with freely

Like all IO-Link devices, the SmartLight is simple to connect
and install. A 3-conductor sensor cable is all you need toquickly connect it to your system and have immediate accessto the full functionality.

1 IO-Link SmartLight
2 Inductive couplers (style Q40)

30 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 31

Reliable condition monitoring: high product quality

Constant temperatures for
induction hardening

1

Sensor right where the action is
Whether you process your parts by annealing or induction
hardening, our infrared temperature sensors will help give you
full control over your quality because monitoring temperaturesduring the hardening process is extremely important for not
damaging the workpiece and ensuring the required productquality. Our sensors in the rugged M30 stainless steel housing
handle this job without contact and reliably. And at atemperature range of from 250 to 1250 °C. They detect hot
objects even while moving. Our temperature sensors makeit possible to significantly reduce the process time.
An important value in non-contact temperature detection is theemissivity. You can teach this with just a key press if you know
the object temperature. This is usually simpler than exactly
determining the emissivity values and adds the advantage thatyou can set the machine up in a much shorter time.
IO-Link lets you install the non-contact sensors just where they
are needed, since you can configure all the functions andparameters remotely from the controller. Nor are any settingchanges necessary at the sensor location when products arechanged. The appropriate configuration sets can be updated
and loaded at any time via IO-Link.
This communication standard enables consistent diagnostics.
You can query the device status at any time through the
IO-Link interface at the same time. In addition, the information
provided by the sensor via IO-Link related to ambientconditions can be logged and documented including thetemperature values for the hot workpieces.

1 IO-Link high-temperature sensors

www.balluff.com

32 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 33

Continual, non-contact linear position measurement

Monitoring the clamping
process in the machine
systemGreatest process security – even in a harsh industrial environment
Compact, precise tool spindles, clamping cylinders and toolchangers on a machining center play a central role in the work
process. This is why reliable and wear-free monitoring of theongoing clamping process in the machine system is so critical.

1
2

Meet this demanding challenge simply with the new IO-Link
positioning system. It features an absolute measuring principle
and transmits an additional Out-of-Range bit. This tells thecontroller that the target has left the measuring range, thereby
increasing reliability. In addition, you can set up to threeswitching signals, and internal temperature detection is also
possible. The high linearity and precise repeat accuracy of themeasuring system give you reliable results.
At the same time, the non-contact measuring system in the
fully potted housing will ensure the highest process reliability
and automation quality even in the harshest industrial
environments. Also advantageous here is the high level ofelectromagnetic compatibility. You can use our inductive
IO-Link positioning system in many different ways thanks to
its configurable measuring range. And the compact size means
it can be installed even where space is at a premium.
Its digital IO-Link signal means the positioning system isguaranteed to be noise-immune even using unshielded cables.
Thanks to IO-Link you can eliminate an analog input card.

1 IO-Link inductive positioning systems
2 IO-Link inductive distance sensors

www.balluff.com

34 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 35

2

ID complete solutions for transfer systems

3

AutomaticallyAcquire Data

1

Increases product quality, optimizes the process
When your automation calls for parts tracking, there is noalternative to RFID because these self-controlling systems
record and document all the data in real time. They makeevery single production step, every material used and each
operating resource traceable, so that corrections are possible
while the process is still running. This comprehensive
transparency provided by RFID represents the prerequisite
for process optimization while ensuring high product quality.

BIS V comes with four ports which can be individuallyconfigured and operated simultaneously with up to four read/
write heads. In addition, you can connect IO-Link capablesensors and actuators or a sensor hub with up to 16 sensors
to the integrated IO-Link master port. Now you can bundle
sensor data in the simplest way possible in any network
technology. Your network structure becomes more efficient,while you save time and money.

Our rugged BIS V processor unit provides fast datatransmission, short cycle times and increased data security inall applications. This lets you use different RFID technologies –LF, HF and UHF – at the same time on a single processor unit.
Just one type of processor unit is all you need to handle any
application. Whatever industry you are in, this high-performer
features perfect electromagnetic compatibility and works withall common bus systems.

Alternately, you can use IO-Link ID systems. As easy toconnect to the IO-Link master as a sensor, they require
no processor unit. The bottom line: IO-Link makes parts
tracking especially economical.
1 BIS V processor unit with IO-Link master
2 BIS L IO-Link read/write heads
3 BIS M-Link IO-Link read/write heads

IO-Link in the Entire Production Process | 37

Fast parameter replacement, minimum scrap

Automate Format
Changes

React quickly and flexibly to changing requirements
Ever smaller lot sizes mean your production has to be able torespond ever faster to changing customer demands. And in a
flexible way, since different sizes and formats are involved in
feeding, processing and packaging the material.
The position and spacing of the adjustment points such astransport belts and guide rails, therefore, need to be reset eachtime the product format is changed. Using position measuringsystems for format changing shortens the change time,increases product quality and reduces scrap to a minimum.
Our magnetostrictive linear position sensors with IO-Linkinterface provide high-precision, fast and absolute position
detection for your individual format settings. The rugged
design with a hermetically sealed housing makes it completely
impervious to contamination, shock and vibration. You willprofit from high machine and system up-time even under
extreme ambient conditions. Simultaneously querying multiple
positions with a single positioning system saves you additional
integration effort and cost.
1

IO-Link gives you multiple benefits: incorporation into thecontrol system and replacing the parameters using the defined
protocols is simple and time-saving. Plug-and-play makes
system interchanging quick and easy. The system is up andready again immediately with no homing move for a maximum
stroke length of 4572 mm.

1 IO-Link magnetostrictive linear position sensors

www.balluff.com

38 | IO-Link in the Entire Production Process

1

1

1

Simple handling, versatile
application – economical!

Measureposition andend-of-strokewith absoluteaccuracy

Continuously monitor position during movement
When other travel measuring systems are too large, too slow,
too imprecise or too inflexible, you can count on the BML-SL1
absolute magnetic encoder. It stands out wherever you needhigh absolute accuracy of positions and end-of-travel.
Specifically developed for measuring and positioning tasks,
it is super-fast, highly precise and can be used in any industry.
The encoder is compact, making it easy to integrate. It issimple to use and at the same time extremely cost-effective.
Special flexibility comes from its built-in IO-Link Interface.
And not least, IO-Link allows you to conveniently connect themeasuring system. Format setup and adjustment are also fastand easy using this communication standard because you caneasily enter all the parameters from a central location. Using
IO-Link you can output position information and easily view iton the controller. With IO-Link you monitor the target positionand continually check positions during the move.
With the BML SL1 you get all the advantages of a magnetic
tape system and the innovative interface of the controller
world.

1 BML SL 1 absolute linear magnetic encoder systemwww.balluff.com

40 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 41

Simplify industrial vision applications

Quality control to yourindividual specifications
1

2

Well-positioned for Industry 4.0
For modern, flexible manufacturing our SmartCamera withfieldbuses and IO-Link offers you a wide range of applications.
It takes care of visual quality controls of the finished parts
including their production steps by, for example, checking
whether size, distance and orientation are correct or whether
the parts are complete and flawless. This means you candiscover and correct process errors early in each individual
production step. The result is less scrap and reduced
follow-on costs.
To ensure an optimal process the IO-Link interface allows
additional sensors to be incorporated into the overall solution,
so that with our camera you are well equipped to meet thechallenges of Industry 4.0.
For example, through the IO-Link master interface you canalso directly – without a PLC – display process control statesusing our IO-Link SmartLight stack light. The SmartCamera
enables intelligent data management and provides for modern
information storage. All the data are formatted as desired andpassed on to the host control system.
1

The user-friendly interface ensures that all the tasks canbe simply and quickly taught according to your individual
specifications. The complete software with online help aswell as graphical interface, tool aids and manual are alreadyintegrated. We think you should be able to take brilliant
images for granted.
You also stabilize your entire production process with our
SmartCamera because it can be configured so that only the
information needed for the controller flows through the process
network. All the other data are directed to a separate Gigabit
Ethernet network. This minimizes data load and secures yourprocess network.

1 SmartCamera BVS SC with IO-Link master2 IO-Link SmartLight

www.balluff.com

42 | IO-Link in the Entire Production Process

IO-Link in der gesamten Produktion | 43

Automated tool management with RFID

Automated
Tool Management

2

All the tools at a glance
When it comes to industrial automation, rugged RFID
systems from Balluff have for over 30 years secured the highquality of the tools used and their optimal utilization. We offer
systems which always provide the correct tool data to the
CNC controller in milling machines and machining centers.

1

1

1

With RFID the right tool can be assigned to the rightmachine for any upcoming process. Each individual tool is
independently directed through production, checked and,if necessary, reworked and returned. RFID guarantees you
unique unambiguous identification of every tool used, since
the unique ID on the data carrier fixed to the tool holder isunmistakable. All tool-relevant data can be displayed via
IO-link in the controller. This gives you high machining quality
and optimal tool utilization. In this way RFID-assisted tool
management contributes to greater value creation.
At Balluff you can choose from low-frequency (LF) andhigh-frequency (HF) systems which, thanks to the great
variety of data carriers and read heads, lets you solve allkinds of applications even under challenging conditions.
Our low-frequency BIS C has, over the years, establisheditself as a standard. With our high-frequency BIS M you
can handle large data volumes. And if you need to workwith both LF and HF, our solutions also provide reliable
mixed operation of both frequencies. With Balluff you canchoose a frequency-independent, cross-technology
processor unit.

1 Easy Tool-ID
2 SmartCamera BVS SC with IO-Link master

www.balluff.com

44 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 45

1

3
3

2

3

2

5

3

2

3

3

4

6

IO-Link supplies both sensor/actuator details and secure information
Robotics is indispensable to modern automation. But
robotics demands safety in order to enable the fast interaction
between man and machine. Safety technology is thus a given
for automation: only with it can, for example, fast applications
with pick-and-place be realized.
With our concept you use solutions which will work precisely
and safely over years. And the best part is that these are alsoquite easy to implement because safety technology from Balluff
offers the advantages of IO-Link.
Safety over IO-Link is simple to integrate and reacts quickly.
It communicates down to the last meter and provides both
sensor/actuator details as well as safety information. This lets
you realize reliable, flexible information exchange and datatransport across all levels.

Integration is as simple as connecting the safe I/O module tothe IO-Link master. You can connect nearly any safety device
to this system, which is open all the way to the sensor level,and bundle the signals from binary standard sensors.
The parameterization is done centrally via the controller. The
safety-relevant information is sent through the master to thecontroller.

1 RFID interlocks
2 Safe IO-Link I/O modules
3 Opto-electronic protective devices
4 IO-Link masters
5 Transponder-coded safety sensors
6 Electromechanical safety switches

Information exchange
and data transport across all levels

Safetyover IO-Link

46 | IO-Link in the Entire Production Process4

For the fast interaction of man and machine

Safe PersonalProtection

Economically securing hazardous locations
An economical solution for securing hazardous locations
are our safety light curtains. These non-contact protective
devices reliably detect fingers, hands or the body and stop
all hazard-inducing movements of machines. In this way they
ensure personal safety and eliminate the expense of guard
fence constructions, so that you can better use the available
space. At the same time, you profit from high anti-tamper
protection. Simply connect the light grid to the safe I/O
module that is connected to the IO-Link master. You have now
produced the safety function while at the same time reducing
costs because the connectivity is the familiar M12 standard.

1

To be able to reliably feed material to the robot, our safety lightcurtains can also be used at material locks so that the muting
applications can be implemented. There the safety function is
temporarily jumpered when the material is transported throughthe protective field. Safety is, however, still maintained in casea person inadvertently attempts to enter the hazardous zone.
In the worst case, you can use our E-Stop to trigger the stop
command to stop the hazardous movement. Our E-Stop is
simple to install and versatile in its use. Its compact housing
makes it ideal for a wide range of machines and systems. Its
high protection rating means it is impervious to dust and water.

1

2
3

1 Opto-electronic protective devices
2 Safe IO-Link I/O modules
3 E-Stop devices
4 IO-Link SmartLight

www.balluff.com

48 | IO-Link in the Entire Production Process

Wear-free and tamper-proof

Safety for people
and systems
54
Direct querying of robot position and end-of-travel with metal
Our inductive safety sensors offer you safety for people andequipment. These detect the approach of metallic objects
without contact and provide you with the needed safe signals
for position or end-of-travel. Now you can safely monitor
robots and workpiece carriers. Unlike traditional safetyswitches, inductive safety sensors require no special mating
part. This is how easy it is to directly query robot position andend-of-travel of metallic workpiece carriers. Simply connect thesensors to the safe I/O module, which bundles all the signals
and passes them to the processor through the IO-Link master.

3
2

An economical solution to access security
Our REED safety switches ensure wear-free access security.
This economical solution is insensitive to door shifting andis highly rugged. Another plus: The spacer even makes it
possible to install in ferromagnetic surroundings.

When there is strong vibration

1

If it’s higher demands you have to meet, transponder codedsafety sensors are indispensable. Our RFID safety sensors
ensure safe monitoring of guard doors which are subjected
to strong vibration. You enjoy the benefits of both high coding
levels and high anti-tamper protection because the passive
RFID transponders are uniquely identifiable.

1

The contamination-resistant sensors, with a generous
detection range, are ideal when doors settle or are imprecisely
guided. Which also means they offer great room to play for
installation. And to save on door fittings, you can choose
versions with integrated magnetic clamps.

6

1 Inductive safety sensors

4 Transponder-coded safety sensors

2 Emergency stop device

5 Electromechanical safety switches

3 Safe IO-Link I/O modules

6 Opto-electronic protective devices

www.balluff.com

50 | IO-Link in the Entire Production Process

For pneumatics and hydraulics

Safety for Clamping
Devices

All-in-one solution for connecting sensors andactuators – galvanically isolated

1

Our galvanically isolated sensor/actuator hub ensures safety
on the workpiece holder. This all-in-one solution allows you toconnect both sensors and actuators to just one module. The
sensor segment provides the position feedback. At the sametime, you can safely turn off the actuator segment using its
separately switchable safety circuit, since the IO-Link I/O hub
is divided into two galvanically isolated segments.
To safely interrupt the supply voltage to the actuator segment
you need an external safety device. Then you can implement
safety functions up to SIL2 in accordance with EN62061. Also
reassuring: the rugged IP67 metal housing is designed even forthe harshest surroundings. Diagnostics is provided by IO-Linkand status LEDs. You can also reliably monitor the signal quality.

2

Up to eight digital in- and outputs can be controlled with themodule. If the IO-Link connection is interrupted, the outputs
assume predefined states which remain until the IO-Link
connection is restored. Because of this clear machine status,
you can continue to produce without a reference move and savevaluable time once the connection is made again.

3

4

1 Magnetic Field sensors
2 IO-Link master3 IO-Link I/O module with galvanic isolation
4 Emergency stop device

www.balluff.com

52 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 53

For the extreme conditions of welding

Safely transmit signals inelectrical interference fields

Decentralized system architecture in the welding booth
For the extreme conditions of welding, Balluff offers rugged
modules for reliable signal transmission even in the presenceof interfering ambient influences. Our weld-immune modules,
made of fiberglass reinforced plastic, can reliably handle weld
splatter, welding currents and electromagnetic fields.
The easy to install modules are available as IO-Link masters
and IO-Link sensor/actuator hubs each with 8 IO-Link ports
for 16 in- and outputs. Each input is short-circuit proof, each
output is protected from overload. In addition, our IO-Link
sensor/actuator hubs offer an expansion port for connecting
an IO-Link valve interface or another IO-Link sensor/actuatorhub, so that you can use up to 30 in- and outputs. This lets
you flexibly integrate innovative fieldbus solutions.
The efficient point-to-point wiring of IO-Link allows
construction of a decentralized system architecture in thewelding booth outside the control cabinet. Network
nodes equipped with an IO-Link master communicate
via Ethernet/IP directly with the main controller or control
device on the machine.
2
You can connect a wide variety of intelligent sensors or
I/O modules with IO-Link interface to the IO-Link ports. Now
you are using simple structures that are highly flexible. The
parameters are also simple to transmit. Continuous diagnostics
ensure reliable monitoring. And the affordable, three-core,unshielded industrial cables reduce wiring time.
1

1 IO-Link masters (weld-immune)
2 IO-Link sensor/actuator hubs (weld-immune)www.balluff.com

54 | IO-Link in the Entire Production Process

IO-Link in the Entire Production Process | 55

Condition based maintenance and condition monitoring

The optimum voltage
supply for noise-free
operation1

For noise-free operation
Our IO-Link Heartbeat power supplies, for reliable andefficient voltage supply, stand out with their quality and longservice life. They are manufactured from the highest quality
components and offer you adjustable output voltage with low
ripple.
Especially notable is their clever diagnostics capability that
supports predictive maintenance and condition monitoring
for Industry 4.0 requirements.
Integrated monitoring provides information for Load Level,
Stress Level and Lifetime via IO-Link. This gives you reliable
information about the current electrical and thermal load,
the degree of wear and the remaining lifetime of the power
supply. You can also read off this information locally on thestatus indicator. The 3-color LEDs work here like a traffic
light.
You use IO-Link to call up further detailed diagnostics
and status information for the unit as well as operating
parameters and history, so that you can see this data in
the higher level control and diagnostics system. Now you
increase system up-time by knowing at all times when
you need to replace a unit.
Specially developed for controller units, Balluff power
supplies can be perfectly integrated into your control
package. The extra narrow IP20 housing makes possiblea resource-optimized control cabinet design. IP67 variants
for supplying power to the modules in decentralized
structures in direct proximity to the consumer are alsoavailable.

2

1 Heartbeat power supplies with IO-Link IP20
2 Heartbeat power supplies with IO-Link IP67

www.balluff.com

56 | DienstleistungenWe assist you expertly and personally

SERVICES

Meeting your specific needs

Your Balluff solutions

Our products are precisely tailored to your needs. Our services are too,for fast commissioning, optimum process flows and the greatest possible
planning security and cost effectiveness. Would you like advice on
products and services? Tailor-made solutions? Or expert know-how on
site? You receive our comprehensive support. Expert, uncomplicatedand totally according to your specifications.

n Technical supportn Trainingn Support and consultationn Development and integrationn Product-accompanying services
n Customer-specific solutions

www.balluff.com

References | 59

REFERENCES
Our complete commitment is to the success of our customers. Future-looking
technologies, market-oriented solutions and the expertise of an experienced
manufacturer are what we draw on to increase your competitiveness. This is whyleading companies worldwide trust in Balluff solutions.
We work together with such companies as

Karlsruher Institut
für Technologie

www.balluff.com

Headquarters
Balluff GmbH
Schurwaldstrasse 973765 Neuhausen a. d. F.
Germany
Phone +49 7158 173-0
Fax +49 7158 5010
balluff@balluff.dewww.balluff.com

Doc.-No. 895192 · Mat.-No. 230395 EN · D18; Subject to changes. Replaces 1304.

CONTACT OUR
WORLDWIDESUBSIDIARIES