BNI PBS-552-001-Z001

BNI PBS-552-001-Z001-C04 Profibus DPI/IP Module

User's Guide

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Contents

1 Notes to the User 3 1.1 Structure of the Manual 3 1.2 Typographical Conventions 3

Enumerations 3 Actions 3 Syntax 3 Cross-references 3

1.3 Symbols 3 1.4 Abbreviations 3

2 Safety 4 2.1 Intended Use 4 2.2 Installation and Startup 4 2.3 General Safety Notes 4 2.4 Resistance to Aggressive Substances 4

Dangerous Voltage 4 3 Connection Overview 5

3.1 Connection Overview BNI PBS-552... 5 4 Basic Knowledge 6

4.1 Product Description 6 4.2 Profibus 6 4.3 DPI/IP 6

5 Technical Data 8 5.1 Dimensions 8 5.2 Mechanical Data 8 5.3 Electrical Data 8 5.4 Operating Conditions 8

6 Assembly 9 6.1 Mechanical Connection 9 6.2 Electrical Connection 9

Function Ground 9 Power Supply 10

6.3 Bus Connection 11 6.4 Ports 11

Input Ports 11 DPI/IP Ports 11

6.5 Replacing BNI PBS Modules 11 7 Startup 12

7.1 Profibus Address 12 Address Assignment 12

7.2 Configuration 12 GSD File 12 Head Module 13 Structure of the Head Module 13 Configuration Coding 13 Length Byte Coding 13 DPI/IP Modules 14 Data Module Coding 14 Process Data Coding 15

7.3 Parameter Configuration 16 Standard-specific Parameters 16 Station Status 16 WD_Fact_1 and WD_Fact_2 16 MinTSDR 17 Ident_Number_High 17

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Ident_Number_Low 17 Group_Ident 17 User Parameters 18 Configuration Example 22

7.4 Functional Principle of a DPI/IP Port 24 7.5 Integration into Project Planning Software 25

Installing the GSD File 25 Requirements 26 Integrating the Module 26 Configuring the Slots 27

7.6 The DPV1 Interface 28 8 Diagnostics 30

8.1 LED Displays 30 Status LEDs 30 LED Display Ports 30

8.2 Diagnostics Telegram 31 8.3 Standard Diagnostic 31

Standard Diagnostics Coding 31 Status 1 31 Status 2 32 Status 3 32 Address 32 Identity 32

8.4 Device-specific Diagnostics 33 Coding of device-specific Diagnostics 33 ID-specific Diagnostics 34 Coding of ID-specific Diagnostics 34

8.5 Channel-specific Diagnostics 34 Coding of channel-specific Diagnostics 35

9 Appendix 36 9.1 Scope of Delivery 36 9.2 Order Code 36 9.3 Ordering Information 36 9.4 ASCII Table 37

Notes 38

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1 Notes to the User

1.1 Structure of the Manual

The manual is organized so that the sections build on one another: Chapter 2: Basic Safety Information. ……...

1.2 Typographical

Conventions The following typographical conventions are used in this guide

Enumerations Enumerations are shown as a list with an en-dash

− Entry 1 − Entry 2

Actions Action instructions are indicated by a preceding triangle. The result of an action is indicated

by an arrow. Action instruction 1, Action result. Action instruction 2.

Syntax Numbers:

Decimal numerals are shown without an additional indicator (e.g. 123), Hexadecimal numerals are shown with the additional indicator hex (e.g. 00hex). Menu commands: Menu commands are separated by a vertical line. "Tools | Install new GSD..." refers to the menu command "Install new GSD..." from the "Tools" menu. Buttons: Buttons are shown in brackets, e.g. [Install].

Cross-references Cross-references indicate where additional information on the topic can be found.

1.3 Symbols Note

This symbol indicates general notes.

Attention! This symbol indicates a security notice which must be observed.

1.4 Abbreviations BCD

BNI DPI/IP EMC I port FE GSD file LSB MSB SELV PLC PELV Profibus DP

Binary coded switch Balluff Network Interface Digital Pulse Interface / Integrated Protocol Electromagnetic compatibility Digital input port Function ground General Station Description Least Significant Bit Most Significant Bit Safety Extra Low Voltage Programmable Logic Controller Protective Extra Low Voltage Profibus Decentralized Periphery

1.5 Deviating Views Product views and illustrations in this guide may differ from the actual product.

They are intended only as illustrative material.

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2 Safety

2.1 Intended Use The BNI PBS-... serves as a decentralized input module for connecting to a Profibus DP network. The integrated DPI/IP ports makes it possible to connect DPI/IP-capable position measurement sensors with ease. The module may be used only for this purpose in an industrial environment corresponding to Class A of the EMC Law.

2.2 Installation and

Startup Attention!

Installation and startup are to be performed by trained technical personnel only. Skilled specialists are people who are familiar with the work such as installation and the operation of the product and have the necessary qualifications for these tasks. Any damage resulting from unauthorized tampering or improper use shall void warranty and liability claims against the manufacturer. The operator is responsible for ensuring that the valid safety and accident prevention regulations are observed in specific individual cases.

2.3 General Safety

Notes Commissioning and inspection

Before commissioning, carefully read the User's Guide. The system must not be used in applications in which the safety of persons depends on the function of the device. Intended use Warranty and liability claims against the manufacturer shall be rendered void by damage from:

− Unauthorized tampering − Improper use − Use, installation or handling contrary to the instructions provided in this User's

Guide. Obligations of the owner/operator! The device is a piece of equipment in accordance with EMC Class A. This device can produce RF noise. The owner/operator must take appropriate precautionary measures against this for its use. The device may be used only with a power supply approved for this. Only approved cables may be connected. Malfunctions In the event of defects and device malfunctions that cannot be rectified, the device must be taken out of operation and protected against unauthorized use. Approved use is ensured only when the housing is fully installed.

2.4 Resistance to

Aggressive Substances

Attention! The BNI modules always have good chemical and oil resistance. When used in aggressive media (such as chemicals, oils, lubricants and coolants, each in a high concentration (i.e. too little water content)), the material must first be checked for resistance in the particular application. No defect claims may be asserted in the event of a failure or damage to the BNI modules caused by such aggressive media.

Dangerous

Voltage Attention!

Before working on the device, switch off its power supply.

Note In the interest of continuous improvement of the product, Balluff GmbH reserves the right to change the technical data of the product and the content of these instructions at any time without notice.

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3 Connection Overview

3.1 Connection Overview BNI PBS-552...

1 Mounting hole

2 Profibus input 3 Power input 4 Port 1 (analog input) 5 Port 3 (analog input) 6 Port 5 (DPI/IP) 7 Port 7 (DPI/IP) 8 Port 6 (DPI/IP) 9 Port 4 (DPI/IP) 10 DPI/IP port marking

11 Port 2 (analog input) 12 Port LEDs 13 Port 0 (analog input) 14 Module LEDs 15 Power output 16 Part label 17 Address switches 18 Profibus output 19 Ground connection

1

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4 Basic Knowledge

4.1 Product Description

Balluff Network Interface BNI PBS-...: Connects analog-capable (current/voltage) and DPI/IP-capable sensors to a Profibus DP network. The analog sensors can be connected via 4 standard input ports, the DPI/IP sensors via 4 DPI/IP ports. Connection to Profibus using 2 × M12×1 round connectors. Electrical power supply 24 V DC using 7/8" round connector. The main area of application is:

• In the industrial sector as an interface between sensors and a Profibus.

4.2 Profibus Open bus system for process and field communication in cell networks with a low number of stations as well as for data communication per IEC 61158/EN 50170. Automation devices such as PLCs, PCs, control and monitoring devices, sensors or actuators can communicate over this bus system. Variants:

• Profibus DP for fast, cyclical data exchange with field devices, • Profibus PA for applications in process automation in the intrinsically safe area, • Profibus FMS for data communication between automation devices and field

devices.

4.3 DPI/IP The DPI/IP interface is a universal pulse interface. The position measurement system is controlled via Init and Start/Stop signals. The reference point for the propagation time measurement is the "start pulse". Reliable signal transmission, even over cable lengths up to 500 m between the processor unit and transducer, is ensured by the noise-immune RS485 differential line drivers and receivers. Interference signals are effectively suppressed. IP is a protocol for direct data exchange between a controller and transducer. The signal lines are used to send additional information such as manufacturer, sensor type, measuring length and waveguide speed. This allows start-up or replacement of a transducer without having to make manual changes to the controller parameters. The interface enables bidirectional communication and contains integrated diagnostic functions. Plug and play and automatic configuration reduce downtimes. The DPI/IP method contains two operating modes, the DPI measuring mode and the mode with the IP data protocol.

• DPI = digital pulse interface • IP = integrated protocol

DPI measuring mode The Init pulse is sent to the BTL at regular intervals through the Init line. The pulse has a rising edge that triggers a measurement (Init pulse with TIP < 5 μs = start/stop measuring principle, see image).

Note Only position measurement sensors that work with rising edges may be used with BNI PBS-55x. For example: BTL5-M…, BTL6-P11x, BTL7-P..

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4 Basic Knowledge

Note The BNI PBS-552-001-Z001-C04 module only functions together with BTL7-P511-xxxxx-xxx-SA352-xxx sensors.

Mode with IP data protocol

If the length of the Init pulse TIP increases to approximately 15 μs, then the transducer switches from DPI measuring mode to the mode with the IP data protocol. In this process, a character string is transmitted to the BTL as a command after the Init pulse. The BTL still sends the start pulse over the start/stop cable as a response. Instead of sending the stop pulses, a character string (response) containing contains the requested, command-dependent response is transmitted to the controller.

The BNI PBS-xxx module reads out the data from the connected sensors, and provides the Profibus master with the resulting data via acyclical services (DPV1). Of course, this data cannot be determined for sensors that do not support IP and access to this data is refused with an error message. The exact address assignment and detailed data are described later in this manual.

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5 Technical Data

5.1 Dimensions

5.2 Mechanical Data Housing material die-cast zinc, matte nickel-plated

Fieldbus Profibus: M12, B-coded (male and female)

Power supply 5-pin, 7/8" (male and female)

I/O ports M12, A-coded (8x female)

Degree of protection IP67 (only when plugged-in and screwed-in)

Weight approx.: 735 g

5.3 Electrical Data Operating voltage 18.2 ... 30 V DC

Ripple < 1%

Current consumption without load ≤ 200 mA

5.4 Operating

Conditions Ambient temperature

Storage temperature -5°C … 70°C -25°C … 70°C

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6 Assembly

6.1 Mechanical Connection

The BNI PBS-... module can be connected directly to a mounting wall or to a machine. Be

sure that the mounting base is flat to prevent any mechanical stress on the device housing. Two M6 screws and two washers are required for mounting. The tightening torque is 9 Nm. Installation:

• Attach the module using two M6 screws and two washers. • Keep a distance of at least 3 mm between two modules.

The BNI PBS-... is attached using two max. M6 screws and two washers.

Note Recommended drill dimension: 210.5 ±0.2 mm (when using M6 screws!). All IP67 Profibus/Profinet splitter boxes can be mounted when this hole diameter is used.

6.2 Electrical

Connection The ground connection for the BNI PBS-... modules is located at upper left next to the

mounting hole. Ground straps are preferred for the ground connection. Alternately a fine-stranded FE wire with a large cross-section may be used.

Function Ground

Note The FE-connection from the housing to the machine must have low impedance and be as short as possible.

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6 Assembly

Power Supply Profibus modules require a DC voltage of 24 V DC (SELF/PELF) for power. The power can be provided by regulated and unregulated power supplies. Regulated power supplies allow the output voltage to be increased above the nominal voltage to compensate for line losses.

Attention!

The use of a Profibus hybrid cable is not permitted. Power IN (7/8", 5-pin, male) Power OUT (7/8", 5-pin, female)

Pin Function 1 Ground 0V 2 Ground 0V 3 Function ground FE 4 Module and DPI/IP port power supply +24V 5 Sensor supply +24V

• 24 V DC. • In order to minimize susceptibility to faults, provide the power supply for the

modules, DPI/IP ports, and sensors from as many different voltage sources as possible.

• Total current < 9A. The total current of all modules must not exceed 9 A, even when daisy chaining the power supply.

Note The module and connected position measurement sensors are provided with the "module and DPI/IP port power supply"; the "sensor power supply" runs all input ports.

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6 Assembly

6.3 Bus Connection The bus connection is established using the M12 Profibus IN and Profibus OUT sockets. The address is set on the address switch.

Profibus OUT (M12, B-coded, female)

Profibus IN (M12, B-coded, male)

PIN Function

1 VP(+5V) 2 RxD/TxD-N, A line (green) 3 GND 4 RxD/TxD-P, B line (red) 5 n.c.

Thread Shield/FE

Connection information Connect protective ground to FE Connect the incoming Profibus line to Profibus IN Connect the secondary Profibus line to Profibus OUT and connect to

downstream device or use terminating resistor.

Note Each Profibus segment must be terminated with a bus terminator. The terminating resistor does not require any external voltage. Unused sockets must be fitted with cover caps to ensure the IP 67 degree of protection

Attention!

The use of a Profibus hybrid cable is not permitted.

6.4 Ports Four input ports are provided for connecting digital sensors. The sensor power supply is fused with a self-resetting PTC.

Input Ports Analog input ports M12, A-coded, female

PIN Function 1 + 24 V, max. 1A 2 Input voltage (0-10V) 3 0 V / GND 4 Input current (0-20mA) 5 FE

DPI/IP Ports DPI/IP port M12, A-coded, female

PIN Function 1 +INIT 2 +START / STOP 3 -INIT 4 n.c. 5 -START / STOP 6 0V / GND 7 +24V / 300mA 8 n.c.

6.5 Replacing BNI

PBS Modules • De-energize the Profibus module,

• remove the mounting screws, • replace the unit.

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7 Startup

7.1 Profibus Address

Assigning and configuring the Profibus address The Profibus address is configured directly on the BNI PBS-... using two BCD switches.

Address

Assignment • Permissible address range 1...99.

• Each Profibus node has to be assigned a unique address. • The address is read once after power is turned on. • If the address is changed, this change becomes effective after a power reset on

the module.

A DP master is generally assigned addresses 0 to 2. We recommend setting addresses using values of 3 and higher for the BNI PBS modules.

7.2 Configuration When project planning Profibus devices, a device is mapped as a modular system which

consists of a head module and multiple data modules. GSD File The device data required for project planning are stored in GSD files (General Station

Description). The GSD files are available in 2 languages for downloading over the Internet (www.balluff.com). The data modules of a DPI/IP module are represented in the project planning software by slot. The GSD file provides the possible data modules (inputs of various data widths). To configure the DPI/IP module, the appropriate data modules are assigned to a particular slot.

Slot Module Function 1 Header module Identification/configuration 2 Port 0 (1st analog port)

Analog input modules, each with 2 bytes of data width

3 Port 1 (2nd analog port) 4 Port 2 (3rd analog port) 5 Port 3 (4th analog port) 6 Port 4 (1st DPI/IP port)

DPI/IP data modules of different data widths

7 Port 5 (2nd DPI/IP port) 8 Port 6 (3rd DPI/IP port) 9 Port 7 (4th DPI/IP port)

10 Slots for the following optional additional modules: Peripheral error, sensor short-circuit, station diagnostics, DPI/IP error

11 12 13

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7 Startup

Head Module First the head module is inserted into the configuration. The head module is used for identification and configuration, and contains no process data.

Structure of the

Head Module Coding of the head module

Head module Description Coding BNI PBS-552-001-Z001 BNI DPI/IP Gateway 01hex, 52hex

Configuration

Coding First byte of the head module (header byte)

Definition of module inputs

Bit layout of header byte 7 6 5 4 3 2 1 0

0 0 Number of manufacturer-specific bytes: 0: None, 1..14: Number of bytes, 15: 16 bytes or words Header special format

Determining inputs/outputs of the module: 0 0 Empty 0 1 Ports are inputs, 1 length byte for input data 1 0 Ports are outputs, 1 length byte for output data 1 1 Ports can be inputs or outputs, for each, 1 length byte for

output and input data

Length Byte

Coding The head module has no process data. The length bytes are only designed for modules

with process data.

Bit layout of length byte 7 6 5 4 3 2 1 0

Length of the I/O data (0…63) 00: 1 byte/word 63: 64 bytes/words

0 Length in bytes 1 Length in words (2 bytes for each)

0 Consistency over a word or a byte 1 Consistency over the module

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7 Startup

DPI/IP Modules The data modules are attached to the head module in slot order for analog inputs and for the DPI/IP ports. A maximum total of 64 bytes (16 positions x 4 bytes) of input data are provided for one DPI/IP port. Each data module has a specific data length, which must be selected for each port in accordance with the data width (desired position number). The sum of all data modules may not exceed 240 bytes.

Data Module

Coding Data module for the DPI/IP ports

Data module Data width Coding

Port empty 0 bytes / 0 words 02hex, 00hex, 00hex DPI port, 1 Position 4 bytes / 2 words 41hex, 83hex, 01hex DPI port, 2 Position 8 bytes / 4 words 41hex, 87hex, 02hex DPI port, 3 Position 12 bytes / 6 words 41hex, 8Bhex, 03hex DPI port, 4 Position 16 bytes / 8 words 41hex, 8Fhex, 04hex DPI port, 5 Position 20 bytes / 10 words 41hex, 93hex, 05hex DPI port, 6 Position 24 bytes / 12 words 41hex, 97hex, 06hex DPI port, 7 Position 28 bytes / 14 words 41hex, 9Bhex, 07hex DPI port, 8 Position 32 bytes / 16 words 41hex, 9Fhex, 08hex DPI port, 9 Position 36 bytes / 18 words 41hex, A3hex, 09hex DPI port, 10 Position 40 bytes / 20 words 41hex, A7hex, 0Ahex DPI port, 11 Position 44 bytes / 22 words 41hex, ABhex, 0Bhex DPI port, 12 Position 48 bytes / 24 words 41hex, AFhex, 0Chex DPI port, 13 Position 52 bytes / 26 words 41hex, B3hex, 0Dhex DPI port, 14 Position 56 bytes / 28 words 41hex, B7hex, 0Ehex DPI port, 15 Position 60 bytes / 30 words 41hex, BBhex, 0Fhex DPI port, 16 Position 64 bytes / 32 words 41hex, BFhex, 10hex

Data modules for the analog inputs

Data module Data width Coding

Port empty 0 bytes / 0 words 02hex, 00hex, 00hex Voltage input 2 bytes / 1 word 41hex, 01hex, 11hex Current input 2 bytes / 1 word 41hex, 01hex, 12hex

Auxiliary Modules

Data module Data width Coding

Station diagnostics 1 byte 41hex, 00hex, 14hex Peripheral error 1 byte 41hex, 00hex, 15hex Sensor short circuit 1 byte 41hex, 00hex, 16hex DPI/IP error 1 byte 41hex, 00hex, 17hex

Note

Project planning software offers mostly graphical assistance in configuration; the configuration string is automatically created.

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7 Startup

Process Data Coding

DPI/IP modules:

Byte 0 Byte 1 Byte 2 Byte 3 Position value 0

Byte 4 Byte 5 Byte 6 Byte 7 Position value 1

Byte 60 Byte 61 Byte 62 Byte 63 Position value 15

Analog input (current or voltage)

The current value is shown in µA increments; the voltage value in mV increments. For example: 1000dec = 1000 mV = 1 V or 1000dec = 1000 µA = 1 mA

Byte 0 Byte 1 Current and voltage value

Station diagnostics

Byte 0

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 DPI/IP error

Analog port error

Config. error

Sensor SC. Reserved Undervolt.

US Undervolt.

UD UD: Bus and DPI/IP port power supply US: Power supply for the analog inputs KS: Short circuit Sensor short circuit/peripheral error:

Byte 0 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Port 7 Port 6 Port 5 Port 4 Port 3 Port 2 Port 1 Port 0

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7 Startup

7.3 Parameter Configuration

For the BNI PBS modules the parameter telegram is a maximum of 88 bytes long. The first 7 bytes are defined by the Profibus standard EN 50170. The following bytes are user parameters.

Standard-specific

Parameters Structure of the standard-specific parameters (bytes 0 to 6, see below for coding):

Byte Bit 7 6 5 4 3 2 1 0

0 Station status 1 WD_Fact_1 2 WD_Fact_2 3 MinTSDR 4 Ident_Number_High 5 Ident_Number_High 6 Group_Ident

Note

For coding parameters: 1 = enabled, 0 = disabled.

Station Status Byte 0, station status

Bit Parameter Meaning 0 ... 2 - Reserved

3 WD_On Activate/deactivate watchdog (access monitoring in the slave) 4 Freeze_req Operate DP slave in Freeze mode 5 Sync_req Operate DP slave in Sync mode 6 Lock_req

(see below for coding) 7 Unlock_req Coding of Lock and Unlock: Lock Unlock

0 0 minTSDR and slave-specific parameters may be overwritten 0 1 Enable DP slave for other masters 1 0 DP slave blocked for other masters, all parameters are copied 1 1 DP slave released for other masters (Unlock has priority over Lock)

WD_Fact_1 and

WD_Fact_2 Bytes 1 and 2, Watchdog factor 1 and 2:

Time until response monitoring in DP slave expires. After a failure of the DP master, the outputs assume the safe state after this time expires. Timeout (TWD) = 10 ms x WD_Fact_1 x WD_Fact_2. Times from 10 ms to 650 s can be set. WD_Fact_1

Byte 1 7 6 5 4 3 2 1 0

0 ... 255 (0x00 ... 0xFF) WD_Fact_2

Byte 2 7 6 5 4 3 2 1 0

0 ... 255 (0x00 ... 0xFF)

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7 Startup

MinTSDR MinTSDR: Minimum time before sending a slave reply (in Tbits). The standard prescribes a minimum value of 11 Tbits. The value must be less than MaxTSDR.

Byte 3 7 6 5 4 3 2 1 0

0, 11 ... 255 (0x00, 0x0B ... 0xFF)

Ident_Number_High Ident_Number_High: Identity number High byte

Byte 4 7 6 5 4 3 2 1 0

0 ... 255 (0x00 ... 0xFF)

Ident_Number_Low Ident_Number_Low: Identity number Low byte

Byte 5 7 6 5 4 3 2 1 0

0 ... 255 (0x00 ... 0xFF)

Group_Ident Group_Ident: Group number of the BNI PBS module.

Each bit represents a group. Is only applied if Lock_Req is activated. Byte 6

7 6 5 4 3 2 1 0 Group 8 Group 7 Group 6 Group 5 Group 4 Group 3 Group 2 Group 1

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7 Startup

User Parameters The BNI PBS modules differ in how the functions are set for the ports. The user parameters are different for the head module and for the DPI/IP modules, but have the same layout for all DPI/IP modules. The modules for the analog inputs do not have any changeable parameters. Bytes 7 to 9 of the user parameters are reserved and can be ignored. The required settings are made using the user parameters beginning with byte 10. Header module settings:

Byte Name Meaning

10 General settings

Bit 0 Global diagnostics

0 – Blocked 1 – Approved

Bit 1 Channel-specific diagnostics

Bit 2 Undervoltage Ud Bit 3 Undervoltage US Bit 4

Reserved Bit 5 Bit 6 Bit 7

11 DPI/IP port settings

Bit 0 DPI Port 1 0 – Unused 1 – Used

Bit 1 DPI Port 2 Bit 2 DPI Port 3 Bit 3 DPI Port 4 Bit 4

Reserved

Bit 5 Bit 6 Bit 7

Settings for the analog ports:

12 Analog port 0

Voltage input – 20hex Current input – C0hex

13 Analog port 1 14 Analog port 2 15 Analog port 3

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7 Startup

Settings for a DPI/IP port:

Byte Name Meaning 16 No. of magnets Bit 0-4 No. of desired magnets

Bit 5-7 Reserved (=00hex)

17 Control byte

Bit 0 Scaling 0 – Switched off 1 – Switched on

Bit 1 IP communication 0 – Blocked 1 – Approved

Bit 2 Averaging 0 – Switched off 1 – Switched on

Bit 3 Position output 0 – Rising 1 – Falling

Bit 4 Position data format 0 – Intel 1 – Motorola

Bit 5 Error status 0 – 0 1 – Last value

Bit 6...7 Reserved 18

Offset value Zero-point offset value, in the resolution of the sensor 19 20 21 22

Resolution Specification of the desired sensor resolution in 0.001 µm increments

23 24 25 26

US speed

Specification of the US speed of the sensor in 0.01m/s increments

27 28 29 30

Length of the sensor

Specification of the length of the BTL in 1 mm increments

31 32 33

Meaning of the individual fields

No. of magnets Bits 0-4 define the permitted number of magnets or positions of the sensor. This field is automatically filled with the selected module: For example if the module "P Interface with 6 Pos." is selected, this field is automatically set to 6.

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7 Startup

Control byte Scaling Bit scaling enables the following calculations:

Enabling IP communication

If a bit is set, then the BNI module attempts to query the US speed and the sensor length using the IP interface (see Section 4). If the connected sensor does not support IP communication, then the "IP comm. error" diagnostics are triggered.

Averaging

This bit switches averaging on or off. This calculation averages the last 4 measured values. The result of this calculation is then transmitted as a position value. The average is calculated only for the first 4 position values.

Position output

This parameter determines whether the minimum value or the maximum value is located on the connector side of the transducer.

Start

Scaling On

Position = Position + Offset value

Rising / Falling

Position = Length – Position

Stop

No

Yes

Rising

Falling

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7 Startup

Position data format Defines the format of the position values: Intel (little-endian)

Byte 0 Byte 1 Byte 2 Byte 3 LSB … MSB

Motorola (big-endian)

Byte 0 Byte 1 Byte 2 Byte 3 MSB … LSB

Offset value

If scaling is enabled, then this value is used to correct the measured value. (see flowchart). The offset value should be entered in the increments of the configured resolution.

Resolution

Using this parameter, the transducer resolution to be output can be adjusted in 0.001 µm increments. For example a value of 5000 should be entered for a resolution of 5 µm. Setting a resolution smaller than 5 µm is not recommended.

US speed

This parameter defines the ultrasonic speed of the sensor. This value is used to calculate the measured time to the position value. The speed value is always shown on the sensor. If IP communication is enabled, then the speed is determined directly by the sensor.

Length of the sensor

Measuring length specification of the sensor in mm increments.

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7 Startup

Configuration Example

The layout of user parameters depends on the module's port configuration. The following examples show the layout of user parameters for different port configurations.

Port 0 – 1 voltage input

Port 2 – 3 current input Port 4 – transducer with 4 positions Port 5 – transducer with 2 positions Port 6 – 7 unused

Byte Value Meaning Module 0 Station status

Standard parameter

1 WD_Fact_1 2 WD_Fact_2 3 MinTSDR 4 Ident_Number_High 5 Ident_Number_High 6 Group_Ident 7 0x00 DPV1 status 1

DPV1 parameter 8 0x00 DPV1 status 2 9 0x00 DPV1 status 3 10 0x0F Global settings 11 0x03 DPIIP settings 0x20 Analog port 0 – voltage 0x20 Analog port 1 – voltage 0x20 Analog port 2 – voltage 0x20 Analog port 3 – voltage 0x04 No. of magnets

14 0x10 Control byte 15 0x00

Offset value – 0 µm

16 0x00 17 0x00 18 0x00 19 0x00

Resolution – 10 µm

20 0x00 21 0x27 22 0x10 23 0x00

US speed – 2850.00 m/s

24 0x04 25 0x59 26 0x48 27 0x00

Measuring length – 1500 mm

28 0x00 29 0x05 30 0xDC 32 0x02 No. of magnets 33 0x10 Control byte 34 0x00

Offset value – 0 µm

35 0x00 36 0x00 37 0x00 38 0x00

Resolution – 10 µm

39 0x00 40 0x27 41 0x10 42 0x00

US speed – 2850.00 m/s

43 0x04 44 0x59 45 0x48 46 0x00

Measuring length – 1500 mm

47 0x00 48 0x05 49 0xDC 0xE0 Unused Third DPI port 0xE0 Unused Fourth DPI port

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7 Startup

Port 0 – voltage input Port 1 – 2 current input Port 3 – unused Port 4 – unused Port 5 – transducer with 1 position Port 6 – 7 unused

Byte Value Meaning Module 0 Station status

Standard parameter

1 WD_Fact_1 2 WD_Fact_2 3 MinTSDR 4 Ident_Number_High 5 Ident_Number_High 6 Group_Ident 7 0x00 DPV1 status 1

DPV1 parameter 8 0x00 DPV1 status 2 9 0x00 DPV1 status 3 10 0x0F Global settings Header module - "BNI DPI/IP Gateway" 11 0x02 DPIIP settings 12 0x20 Voltage Analog port 0 - "Voltage Input" 13 0xC0 Current Analog port 1 - "Current Input" 14 0xC0 Current Analog port 2 - "Current Input" 15 0xE0 Unused Analog port 3 - "Port Empty" 16 0xE0 Unused First DPI port – "Port Empty" 17 0x01 No. of magnets

Second DPI port – "DPI Port, 1 Position"

18 0x10 Control byte 19 0x00

Offset value – 0 µm 20 0x00 21 0x00 22 0x00 23 0x00

Resolution – 10 µm 24 0x00 25 0x27 26 0x10 27 0x00

US speed – 2850.00 m/s 28 0x04 29 0x59 30 0x48 31 0x00

Measuring length – 1500 mm 32 0x00 33 0x05 34 0xDC 35 0xE0 Unused Third DPI port – "Port Empty" 36 0xE0 Unused Fourth DPI port – "Port Empty"

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7 Startup

7.4 Functional Principle of a DPI/IP Port

The following flowchart shows the functional principle of a DPI/IP port.

After switching it on, the port switches to the "Not configured" status. It remains in this status until a valid configuration is set from the Profibus. If the port is switched on during configuration, then the module attempts to retrieve the IP data from the connected sensor. Regardless of the result, the port is configured. If the IP configuration is approved during configuration but determination of the IP data was unsuccessful, then the "IP communication error" diagnostics are triggered, and the LED on the port flashes red. If the IP data is available and IP communication was approved, then the read-out data (length of the sensor and the US speed) are used for the configuration. If IP communication is blocked during configuration, then the data from the Profibus telegram is used. After configuration, the port switches to the "Measurement" status. In this status, the measurement is carried out and the measurement status is checked. If a measurement error occurs, then the port switches to the "Measurement error" status. If the sensor is disconnected, the "Sensor not connected" status is activated. The port switches from this status to the "Read in IP data" status if a measurement has been successfully carried out.

Not configured

Configuration

Read in IP data

Measurement

Measuring error

Sensor not connected

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7 Startup

7.5 Integration into Project Planning Software

The example shows the connection of the BNI PBS modules to a Siemens S7 controller with "SIMATIC Manager". The exact procedure depends on the project planning software used.

Installing the

GSD File To perform project planning on the PC, the GSD file for the module must be installed:

• Open a new project. • Open hardware configurator. • Select menu command "Tools | Install new GSD...". The window "Install new GSD" opens.

• Select directory and GSD file. The [Install] button only becomes active if a GSD file is selected.

• Click on [Install]. The GSD file is installed. When the process is finished, a message appears.

• Confirm the message and close the window. • Select the menu command “Tools | Update catalog”. The modules are displayed in the project tree.

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7 Startup

Requirements To integrate the Profibus slave, a functioning configuration of the PLC and of DP interface is necessary.

Integrating the

Module Select the Profibus slave from the catalog and integrate it into the Profibus master system.

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7 Startup

Select the desired modules from the list and integrate them into the slave

Configuring

the Slots Double clicking the DPI/IP module allows you to configure its parameters:

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7 Startup

7.6 The DPV1 Interface

The IP data for the DPI/IP sensors is displayed below what is known as the I&M data (identification & maintenance). This data can be accessed via the acyclical services of the Profibus standard. All I&M data is accessible via Index 255 and Slot 0. In order to read out data, a write command with the address of the desired entry must first be output. After successful completion of the command, a read telegram can be sent out. The desired data is obtained in the response to this telegram. The following figure shows the structure of the telegrams:

Write request:

Byte Value Parameter Remarks

0 0x5F DPV1 function number

DPV1 header 1 0x00 Slot number 2 0xFF Index number 3 0x06 Length of the telegram 4 0x08 I&M CALL_Request

I&M header 5 1..4 Port ID 6 0xFE FI_Index high byte 7 0x4C FI_Index low byte 8 0x03 Control byte 3: A read operation follows Data 9 1…10 Address

Write response:

Byte Value Parameter Remarks

0 0x5F DPV1 function number

DPV1 header 1 0x00 Slot number 2 0xFF Index number 3 0x06 Length of the telegram

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7 Startup

Read request: Byte Value Parameter Remarks

0 0x5E DPV1 function number

DPV1 header 1 0x00 Slot number 2 0xFF Index number 3 0x06 Length of the telegram

Read response:

Byte Value Parameter Remarks

0 0x5E DPV1 function number

DPV1 header 1 0x00 Slot number 2 0xFF Index number 3 - Length of the telegram 4 0x08 I&M CALL_Request

I&M header 5 1..4 Port ID 6 0xFE FI_Index high byte 7 0x4C FI_Index low byte 8 0x00 Control byte

Data 9 1…10 Address … …

The read-out data bytes … …

The various IP records have the following addresses

Address Parameter Example

1 Manufacturer code in ASCII format 'B' 'A' 'L' 'L' 'U' 'F' 'F' 2 Type code in ASCII format 'BTL7-P511-M0500-B-S115' 3 Serial number in ASCII format '07112200054321DE' 4 Ultrasonic speed in BCD format vus=2850.00 m/s = 0x28 0x50 0x00 5 Reserved 6 Manufacturer code in hex format 0x00000001 for Balluff 7 Serial number in hex format 0x000286D9CFC7EB25 8 Ultrasonic speed in hex format vus=2850.00 m/s = 0x00045948 9 Zero-point offset1) in um 0x000088B8 = 36000 µm

10 Measuring length of the sensor in mm 0x00001F4 = 500 mm 1): Distance of zero-point notch from the edge

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8 Diagnostics

8.1 LED Displays

Fig. 4-2: LED indicators

Status LEDs LED Indicator Function

LED1 Green UD power supply available for bus electronics and DPI/IP LED2 Green US power supply available for the analog ports LED3 Red UD undervoltage for bus electronics and DPI/IP LED4 Red UA undervoltage for the analog ports LED5 Green, continuous

green, flashing BUS data transmission with master active BUS data transmission with master inactive

LED Display

Ports In order to display the operating statuses and configurations, two LEDs are assigned to each

M12 port. LED display analog port Indicator LED 1 Red Sensor short circuit* LED 2 Off Port not configured Yellow, continuous Port configured, measurement OK Yellow, flashing Input = OV/OC** *Short circuit detection on Pin1. **OV/OC = Input voltage or input current greater than or equal to the maximum voltage/maximum current. LED display P111 port Indicator LED 1 Red Overcurrent or short-circuit Red, flashing Configuration error, IP comm. error LED 2 Off Port not configured Yellow, continuous Transducer connected and functioning Yellow, flashing Transducer error

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8 Diagnostics

8.2 Diagnostics Telegram

The diagnostics telegram consists of various blocks. The first 6 bytes are defined by the Profibus standard EN 50170. The subsequent bytes contain device-specific and ID-specific diagnostics information. For each channel-specific diagnostic, three bytes of diagnostics information are added. (min. 6 and max. 244 bytes)

8.3 Standard

Diagnostic Byte Bit 7 6 5 4 3 2 1 0 0 Status 1 1 Status 2 2 Status 3 3 Master address 4 High byte ident number

0Bhex 5 Low byte ident number

12hex Note

For coding standard-specific diagnostics: 1 = enabled, 0 = disabled Standard

Diagnostics Coding

The coding for bytes 0 to 3 of the standard diagnostics is described next. Byte 4 and 5 (identification number) are fixed.

Status 1 Byte 0, Status1:

Bit Meaning

0 Station_non_existent The DP slave always sets the bit to 0. The DP master sets it to 1 if the DP slave cannot be reached.

1 Station_not_ready The DP Slave sets the bit to 1 if it is not yet ready for the data exchange.

2

Cfg_Fault The DP Slave sets the bit to 1 if the configuration data last received from the Master does not agree with that which the DP Slave detected.

3

Ext_diag If the bit is set to 1, there is a diagnostics entry in the slave-specific diagnostics area (Ext_Diag_Data). An expanded diagnostic follows in the telegram.

4 Not supported The DP slave sets the bit to 1 if an unsupported function was requested.

5

Invalid_Slave-Response The DP slave always sets the bit to 0. The DP-Master sets it to 1 if it receives an implausible response from the DP slave.

6

Prm_fault The DP slave sets the bit to 1 if the last parameter telegram was incorrect. (e.g. incorrect length, incorrect identification number, invalid parameters).

7

Master_lock The DP Slave always sets the bit to 0. The DP Master sets it to 1 if the parameters for the DP Slave were configured by a different Master (Lock from another Master; In this case: Address in Byte 3 not equal to FFhexand not equal to its own address).

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8 Diagnostics

Status 2 Byte 1, status 2: Bit Meaning

0

Prm_req The DP slave always sets the bit to 1 if it needs to be reconfigured and parameterized. The bit remains set until the parameters have been configured.

1

Stat_Diag (statistical diagnostics) The slave sets the bit to 1 if, for example, it cannot send valid data. In this case, the DP master fetches diagnostic data until the bit is reset to 0.

2 Fixed at 1 3 WD_On

Response monitoring enabled/disabled (watchdog on). 4 Freeze_Mode

The Slave sets the bit to 1 if it has received the Freeze command. 5 Sync_Mode

The Slave sets the bit to 1 if it has received the Sync command.

6 Not_Present The DP slave always sets the bit to 0. The DP master sets it to 1 for DP slaves not contained in the master parameter set.

7

Deactivated The DP Slave always sets the bit to 0. The DP Master sets it to 1 if the DP Slave is removed from the Master parameter set.

Status 3 Byte 2, status 3

Bit Meaning

0…6 Reserved

7

Ext_Diag_Overflow If this bit is set, there is more diagnostics information than indicated in Ext_Diag_Data. For example the DP slave sets the bit to 1 if there is more channel-specific diagnostics information than the DP slave can enter in its send buffer. A DP Master sets the bit to 1 if the DP Slave sends more diagnostic information than the Master can hold in its diagnostics buffer.

Address Byte 3, master address

Bit Meaning

0…7

Master_Add After configuring the parameters, the address is entered for the DP Master that configured the parameters for the DP Slave. If a DP slave's parameters were not configured by a master, it uses the FFhex address.

Identity Byte 4, ident high

Bit Meaning

0…7 0Bhex Byte 5, ident low Bit Meaning 0…7 12hex

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8 Diagnostics

8.4 Device-specific Diagnostics

Byte Bit 7 6 5 4 3 2 1 0

0 Header 1 Status type 2 Slot number 3 Status specifier 4 Status message 1 5 Status message 2 6 Status message 3

Coding of

device-specific Diagnostics

Bit layout – header byte 7 6 5 4 3 2 1 0 0 0 Number of bytes in this block: 2-63 Header: Device-specific diagnostics

Bit layout – status type

7 6 5 4 3 2 1 0 1 Status code: 02hex Module Status Status block

Bit layout – slot number

7 6 5 4 3 2 1 0 Slot number

Bit layout – status specifier

7 6 5 4 3 2 1 0 Status specifier is always 0

Bit layout – status message 1

7 6 5 4 3 2 1 0 Status of module 3 Status of module 2 Status of module 1 Status of module 0

00 – Valid data from this module 01 – Invalid data, defect in module 10 – Invalid data, incorrect module 11 – Invalid data, missing module

Bit layout – status message 2

7 6 5 4 3 2 1 0 Status of module 7 Status of module 6 Status of module 5 Status of module 4

00 – Valid data from this module 01 – Invalid data, defect in module 10 – Invalid data, incorrect module 11 – Invalid data, missing module

Bit layout – status message 3

7 6 5 4 3 2 1 0 Status of module 11 Status of module 10 Status of module 9 Status of module 8

00 – Valid data from this module 01 – Invalid data, defect in module 10 – Invalid data, incorrect module 11 – Invalid data, missing module

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8 Diagnostics

The following modules are defined

Number Function 0 Header module 1 Analog input port 0 2 Analog input port 1 3 Analog input port 2 4 Analog input port 3 5 DPI/IP port 4 6 DPI/IP port 5 7 DPI/IP port 6 8 DPI/IP port 7

ID-specific

Diagnostics Byte Bit

7 6 5 4 3 2 1 0 0 Header 1 Modules 0-7 2 Modules 8-15

Coding of

ID-specific Diagnostics

Bit layout – header byte 7 6 5 4 3 2 1 0 0 1 Number of bytes in this block: 2-63 Header: ID-specific diagnostics

Bit layout – modules 0-7

7 6 5 4 3 2 1 0 Module

7 Module

6 Module

5 Module

4 Module

3 Module

2 Module

1 Module

0 0 – Module No. x has no diagnostics 1 – Module No. x has diagnostics

Bit layout – modules 8-15

7 6 5 4 3 2 1 0 Module

15 Module

14 Module

13 Module

12 Module

11 Module

10 Module

9 Module

8 0 – Module No. x has no diagnostics 1 – Module No. x has diagnostics

8.5 Channel-

specific Diagnostics

Byte Bit 7 6 5 4 3 2 1 0

0 Header 1 Channel 2 Error

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8 Diagnostics

Coding of channel-specific Diagnostics

Bit layout – header byte 7 6 5 4 3 2 1 0 1 0 Number of bytes in this block: 2-63 Header: Channel-specific diagnostics

Bit layout – channel

7 6 5 4 3 2 1 0 Number of affected channels in the module

0 1 Input 1 0 Output 1 1 Input and output

Bit layout – error

7 6 5 4 3 2 1 0 Error code

1: Short-circuit 2: Undervoltage 3: Overvoltage 4: Overload 5: Overtemperature 6: Cable break 7: Upper limit exceeded 8: Lower limit exceeded 9: Error

10–15: Reserved 16–22: Manufacturer-specific 16: Position Underflow 18: Position Overflow 20: IP Communication error 22: Measuring error 25: Undervoltage Ud 27: Incorrect configuration 28: Undervoltage Us

0 0 1 Bit 0 1 0 2 bits 0 1 1 4 bits 1 0 0 Byte 1 0 1 Words 1 1 0 2 words

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9 Appendix

9.1 Scope of Delivery

• IO module • 4x M12 dummy plugs • Ground connection strap • M4x6 screws • 20 labels • Quick Start Instructions

9.2 Order Code BNI PBS-552-001-Z001-C04

Balluff Network Interface Profibus Function 552 = DPI/IP module with 4 analog inputs Variant 001 = Expanded functions Mechanical version Z001 = Material is die-cast zinc, matte nickel-plated Bus connection: 1 x M12x1 internal thread, 1x M12 external thread Power supply: 7/8" external thread, 7/8" internal thread DPI/IP Ports: 8 x M12 internal thread, 8-pin Special version Only functions with BTL7-P511-Mxxx-xxx-SA352-xxx sensors

9.3 Ordering

Information Type code Order code

BNI PBS-552-001-Z001 BNI0065 BNI PBS-552-001-Z001-C04 BNI0068

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9 Appendix

9.4 ASCII Table Decimal Hex Control Code

ASCII Decimal Hex ASCII Decimal Hex ASCII

0 00 Ctrl @ NUL 43 2B + 86 56 V 1 01 Ctrl A SOH 44 2C , 87 57 W 2 02 Ctrl B STX 45 2D - 88 58 X 3 03 Ctrl C ETX 46 2E . 89 59 Y 4 04 Ctrl D EOT 47 2F / 90 5A Z 5 05 Ctrl E ENQ 48 30 0 91 5B [ 6 06 Ctrl F ACK 49 31 1 92 5C \ 7 07 Ctrl G BEL 50 32 2 93 5D [ 8 08 Ctrl H BS 51 33 3 94 5E ^ 9 09 Ctrl I HT 52 34 4 95 5F _ 10 0A Ctrl J LF 53 35 5 96 60 ` 11 0B Ctrl K VT 54 36 6 97 61 a 12 0C Ctrl L FF 55 37 7 98 62 b 13 0D Ctrl M CR 56 38 8 99 63 c 14 0E Ctrl N SO 57 39 9 100 64 d 15 0F Ctrl O SI 58 3A : 101 65 e 16 10 Ctrl P DLE 59 3B ; 102 66 f 17 11 Ctrl Q DC1 60 3C < 103 67 g 18 12 Ctrl R DC2 61 3D = 104 68 h 19 13 Ctrl S DC3 62 3E > 105 69 i 20 14 Ctrl T DC4 63 3F ? 106 6A j 21 15 Ctrl U NAK 64 40 @ 107 6B k 22 16 Ctrl V SYN 65 41 A 108 6C l 23 17 Ctrl W ETB 66 42 B 109 6D m 24 18 Ctrl X CAN 67 43 C 110 6E n 25 19 Ctrl Y EM 68 44 D 111 6F o 26 1A Ctrl Z SUB 69 45 E 112 70 p 27 1B Ctrl [ ESC 70 46 F 113 71 q 28 1C Ctrl \ FS 71 47 G 114 72 r 29 1D Ctrl ] GS 72 48 H 115 73 s 30 1E Ctrl ^ RS 73 49 I 116 74 t 31 1F Ctrl _ US 74 4A J 117 75 u 32 20 SP 75 4B K 118 76 v 33 21 ! 76 4C L 119 77 w 34 22 „ 77 4D M 120 78 x 35 23 # 78 4E N 121 79 y 36 24 $ 79 4F O 122 7A z 37 25 % 80 50 P 123 7B { 38 26 & 81 51 Q 124 7C | 39 27 ‘ 82 52 R 125 7D } 40 28 ( 83 53 S 126 7E ~ 41 29 ) 84 54 T 127 7F DEL 42 2A * 85 55 U

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Notes

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www.balluff.com

Balluff GmbH Schurwaldstrasse 9 73765 Neuhausen a.d.F. Germany Phone +49 7158 173-0 Fax +49 7158 5010 balluff@balluff.de

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