IFM Electronic AC402S Owner's manual

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7391150 / 0311 / 2019
Programming Manual
SmartPLC SafeLine AC4S with fieldbus interfaces
AC402S
AC412S
AC422S
AC432S
Firmware: 4.3.9
CODESYS Development System: 3.5.9.7 HF 3
English

SmartPLC SafeLine AC4S with fieldbus interfaces
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Contents
1Preliminary note 5
1.1 Legal and copyright information...........................................................................................5
1.2 Purpose of the document.....................................................................................................5
1.3 Explanation of Symbols .......................................................................................................6
1.4 Overview: User documentation for AC4S............................................................................7
1.5 Overview: CODESYS documentation of 3S ........................................................................8
1.6 Modification history ..............................................................................................................8
2Safety instructions 9
2.1 General safety instructions ..................................................................................................9
2.2 Required background knowledge ........................................................................................9
3System requirements 10
3.1 Hardware............................................................................................................................10
3.2 Software.............................................................................................................................10
3.3 Licensing............................................................................................................................10
4Installation 11
4.1 CODESYS Development System......................................................................................11
4.1.1 Install CODESYS Development System.....................................................................................11
4.2 ifm CODESYS package.....................................................................................................12
4.2.1 Components of the ifm package.................................................................................................12
4.2.2 Install the ifm package................................................................................................................13
4.2.3 Uninstall ifm package .................................................................................................................13
5Getting started 14
5.1 Start CODESYS.................................................................................................................14
5.2 Create CODESYS project..................................................................................................15
5.2.1 Create new project with AC4S....................................................................................................16
5.2.2 Overview: Project structure with AC4S.......................................................................................17
5.3 Use CODESYS online help................................................................................................19
5.4 Create user account...........................................................................................................19
5.5 Configure programming interface ......................................................................................20
5.5.1 Set communication path of Standard PLC..................................................................................20
5.5.2 Set communication path of the fail-safe PLC..............................................................................21
6System configuration 22
6.1 Configure Standard PLC....................................................................................................22
6.2 Configure fail-safe PLC......................................................................................................23
6.3 Configure safe AS-i slaves.................................................................................................24
6.3.1 Remarks.....................................................................................................................................24
6.3.2 Add safe AS-i slaves to the project.............................................................................................26
6.3.3 Remove safe AS-i slave from project.........................................................................................31
6.4 Configure safe devices at local I/O interface .....................................................................32
6.4.1 Remarks.....................................................................................................................................32
6.4.2 Add safe local device to project..................................................................................................34
6.4.3 Create test signal at local output ................................................................................................39
6.4.4 Remove safe local device from project.......................................................................................39

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6.5 Configure standard devices at local I/O interface..............................................................40
6.6 Change IP settings.............................................................................................................40
6.7 Add additional device to the project...................................................................................41
6.8 Extend fieldbus functionality ..............................................................................................42
6.8.1 Available fieldbus stacks ............................................................................................................42
6.8.2 Use EtherCAT master ................................................................................................................43
6.8.3 Add fieldbus stack ......................................................................................................................46
7Programming 47
7.1 Objects of a Standard PLC application..............................................................................47
7.2 Create Standard PLC application ......................................................................................48
7.2.1 Use remanent variables..............................................................................................................49
7.2.2 Supported programming languages ...........................................................................................49
7.2.3 Change system time of the device .............................................................................................49
7.3 Access standard input and output data .............................................................................50
7.3.1 Options to access input and output data ....................................................................................50
7.3.2 Validity of the interface data.......................................................................................................51
7.3.3 Process data of the AS-i slaves..................................................................................................52
7.3.4 Fieldbus data..............................................................................................................................54
7.3.5 Process data of the non-safe local devices................................................................................56
7.4 Use functions of the ifm package.......................................................................................57
7.4.1 Control interface of the ifm function blocks.................................................................................57
7.4.2 Configure system .......................................................................................................................58
7.4.3 Configure AS-i master................................................................................................................59
7.4.4 Configure AS-i slaves.................................................................................................................59
7.4.5 Manage AS-i network.................................................................................................................60
7.4.6 Send commands to the system and the AS-i master..................................................................62
7.5 Use visualisations ..............................................................................................................63
7.5.1 Supported visualisation types.....................................................................................................63
7.5.2 Add visualisation to a project......................................................................................................64
7.5.3 Create a visualisation.................................................................................................................65
7.5.4 Configure visualisation ...............................................................................................................66
7.6 Cross communication ........................................................................................................67
7.6.1 Use network variables................................................................................................................68
7.7 Configure task processing .................................................................................................69
7.7.1 Configure main task ...................................................................................................................69
7.7.2 Set parameters for visualisation task..........................................................................................69
8Programming of the fail-safe PLC 70
8.1 Objects of a safe application..............................................................................................71
8.2 Create safe application ......................................................................................................72
8.2.1 Supported program organization units (POUs)...........................................................................73
8.2.2 Available safety libraries.............................................................................................................73
8.2.3 Supported programming languages ...........................................................................................73
8.2.4 Minimum number of AS-i slaves.................................................................................................74
8.2.5 Variable declaration with data transfer between standard and safety area ................................75
8.2.6 Available memory space ............................................................................................................75
8.2.7 Pin safe project...........................................................................................................................75
8.3 Use safety functions of the ifm AS-i package ....................................................................76
8.3.1 Safe AS-i slaves: Reset logical device .......................................................................................76
8.3.2 Safe AS-i slaves: Provide diagnostic information.......................................................................77
8.3.3 Safe AS-i slaves: Transmit help signals HSI_1 and HSI_2 to safe AS-i output modules............77
8.3.4 Local I/O interface: Reset logical device.....................................................................................77
8.3.5 Local I/O interface: Provide diagnostic information ....................................................................78
8.3.6 Local I/O interface: Access non-safe inputs/outputs...................................................................78
8.3.7 PLCopen Safety: Provide diagnostic information .......................................................................78
8.4 Use safety functions of CODESYS....................................................................................79
8.4.1 SafetyStandard library................................................................................................................79
8.4.2 SafetyPLCopen library................................................................................................................80
8.4.3 SafetyFSoEMaster library...........................................................................................................81

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8.5 Data exchange between standard PLC and fail-safe PLC ................................................82
8.5.1 Remarks about the use of exchange variables...........................................................................82
8.5.2 Use the factory-set replacement variables .................................................................................83
8.5.3 Create additional objects for data exchange ..............................................................................85
8.5.4 Set interval of the data exchange...............................................................................................85
8.6 Safe cross communication.................................................................................................86
8.6.1 Note on the size of the exchange objects...................................................................................87
8.6.2 Set up fail-safe network variables...............................................................................................88
8.6.3 Use fail-safe network variables in the application.......................................................................89
8.7 Safe fieldbus communication.............................................................................................90
8.7.1 Configure FSoE connection........................................................................................................91
8.7.2 Notes on the FSoEMaster..........................................................................................................92
8.8 Set process safety time......................................................................................................93
8.8.1 Process safety time for the AC4S...............................................................................................93
8.8.2 Set variable components of the response time...........................................................................99
8.9 Configure safety task .......................................................................................................100
8.9.1 Set cycle time of the fail-safe PLC............................................................................................100
9Operation 101
9.1 Transfer CODESYS project to device..............................................................................101
9.1.1 Download Standard application to AC4S .................................................................................102
9.1.2 Load safe application to AC4S.................................................................................................103
9.1.3 Note: Projects with network variables.......................................................................................104
9.1.4 Teach code sequences of the safe AS-i slaves........................................................................104
9.1.5 Delete boot application via SD card .........................................................................................105
9.2 Operating states AC4S ....................................................................................................106
9.2.1 Standard PLC...........................................................................................................................106
9.2.2 Fail-safe PLC............................................................................................................................108
9.3 Reset................................................................................................................................112
9.3.1 Standard PLC...........................................................................................................................112
9.3.2 Fail-safe PLC............................................................................................................................114
9.4 Display web visualisation.................................................................................................115
10 Appendix 116
10.1 Library ACnnnn_Utils.library............................................................................................117
10.1.1 Overview: AS-i functions (FB_ASi)...........................................................................................118
10.1.2 Overview: System functions (FB_System) ...............................................................................163
10.1.3 Enumeration types and complex variables...............................................................................170
10.2 Library ACnnnn_SYS_CMD.library..................................................................................179
10.2.1 ACnnnn_SysCmd.....................................................................................................................179
10.3 Library SF_IO.library........................................................................................................187
10.3.1 CtrlASi_InSlave ........................................................................................................................188
10.3.2 CtrlASi_OutSlave .....................................................................................................................190
10.3.3 CtrlASi_ResetAllSlaves............................................................................................................193
10.3.4 CtrlLocalInputs .........................................................................................................................194
10.3.5 Ctrl_SetDiagInfo.......................................................................................................................196
10.3.6 GetLocalInput...........................................................................................................................198
10.3.7 SetLocalOutput.........................................................................................................................199
10.4 Library SF_LogicalInterfaces.library ................................................................................200
10.4.1 Remarks about logical devices.................................................................................................201
10.4.2 Logical devices for safe AS-i slaves.........................................................................................205
10.4.3 Logical devices for the local I/O interface.................................................................................235
10.5 Error codes: Safe AS-i slaves..........................................................................................267
10.6 Error codes: Local I/O interface.......................................................................................269
11 Index 270

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1 Preliminary note
Content
Legal and copyright information ...............................................................................................................5
Purpose of the document .........................................................................................................................5
Explanation of Symbols............................................................................................................................6
Overview: User documentation for AC4S.................................................................................................7
Overview: CODESYS documentation of 3S.............................................................................................8
Modification history...................................................................................................................................8
33203
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1.1 Legal and copyright information 33117
© All rights reserved by ifm electronic gmbh. No part of this manual may be reproduced and used
without the consent of ifm electronic gmbh.
All product names, pictures, companies or other brands used on our pages are the property of the
respective rights owners:
AS-i is the property of the AS-International Association, (→www.as-interface.net)
CAN is the property of the CiA (CAN in Automation e.V.), Germany (→www.can-cia.org)
CODESYS™ is the property of the 3S – Smart Software Solutions GmbH, Germany
(→www.codesys.com)
DeviceNet™ is the property of the ODVA™ (Open DeviceNet Vendor Association), USA
(→www.odva.org)
EtherNet/IP® is the property of the →ODVA™
EtherCAT®is a registered trade mark and patented technology, licensed by Beckhoff Automation
GmbH, Germany
IO-Link®is the property of the →PROFIBUS Nutzerorganisation e.V., Germany
(→www.io-link.com)
ISOBUS is the property of the AEF –Agricultural Industry Electronics Foundation e.V.,
Deutschland (→www.aef-online.org)
Microsoft®is the property of the Microsoft Corporation, USA (→www.microsoft.com)
Modbus® is the property of the Schneider Electric SE, France (→www.schneider-electric.com)
PROFIBUS®is the property of the PROFIBUS Nutzerorganisation e.V., Germany
(→www.profibus.com)
PROFINET®is the property of the →PROFIBUS Nutzerorganisation e.V., Germany
Windows®is the property of the →Microsoft Corporation, USA
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1.2 Purpose of the document 43024
This document applies to the following devices of the "SmartSPS SafeLine AC4S" product family:
SmartPLC SafeLine AC4S with Profinet device interface (AC402S)
SmartPLC SafeLine AC4S with Profinet slave interface (AC412S)
SmartPLC SafeLine AC4S with EtherNet/IP device interface (AC422S)
SmartPLC SafeLine AC4S with EtherCAT slave interface (AC432S)
This document is to complement the device manuals of the a.-m. devices.
These instructions describe the configuration and programming of the device-internal Standard PLC
and the fail-safe PLC of AC4S by means of the CODESYS programming system.
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1.3 Explanation of Symbols 34171
WARNING!
Death or serious irreversible injuries may result.
CAUTION!
Slight reversible injuries may result.
NOTICE!
Property damage is to be expected or may result.
Important note
Non-compliance can result in malfunction or interference
Information
Supplementary note
►...
Request for action
>...
Reaction, result
→...
"see"
abc
Cross-reference
123
0x123
0b010
Decimal number
Hexadecimal number
Binary number
[...]
Designation of pushbuttons, buttons or indications

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1.4 Overview: User documentation for AC4S 42309
ifm electronic provides the following user documentation for the models of the device class "Fail-safe
SmartPLC AC4S":
Document
Content / Description
Data sheet
Technical data of AC4S as a table
Operating instructions *
Notes on mounting and electrical installation of the AC4S
Set-up, description of the operating and display elements, maintenance information, scale
drawing
Device manual
Notes on operation of AC4S via GUI and web interface
Description of the cyclic and acyclic data records, fieldbus parameters and command
interface
Error description
Supplement device manual
Description of the acyclic data sets and the command interface
Programming manual
Creation of a project with the device using CODESYS
Configuration of the device using CODESYS
Programming of the Standard PLC of the device
Programming of the fail-safe PLC of the device
Description of the device-specific CODESYS function libraries
Legend:
*... The operating instructions are supplied with the device.
All documents can be downloaded from ifm's website.

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1.5 Overview: CODESYS documentation of 3S 43063
3S GmbH provides the following user documentation for programming Standard PLC and the fail-safe
PLC of AC4S:
Document
Content / Description
Online help
Context-sensitive help
Description of the CODESYS programming system and the safety extension
CODESYS installation and
first steps
Remarks about the installing of the CODESYS programming system
First steps for handling the CODESYS programming system
Safety user manual
Remarks about the safety-related project development with CODESYS
Remarks about safety-related programming of the fail-safe PLC with CODESYS
After the installation of the CODESYS 3.5 programming system all documents are stored on the hard
disk of the PC/laptop and can be accessed:
Online help:
...\Program Files\3S CoDeSys\CoDeSys\Online-Help
CODESYS installation and first steps:
...\Program Files\3S CoDeSys\CoDeSys\Documentation
Safety user manual:
...\Program File\3S CoDeSys\CoDeSys\Documentation
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1.6 Modification history 34492
Version
Topic
Date
00
New creation of document
12 / 2017
01
Added: Note on the size of exchange objects
09 / 2018
02
Corrected: Description of testpulse at local I/O interface
04 / 2019
03Update to firmware 4.3.9 11 / 2019

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2 Safety instructions
Content
General safety instructions.......................................................................................................................9
Required background knowledge.............................................................................................................9
28333
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2.1 General safety instructions 41415
Read this document before setting up the product and keep it during the entire service life.
Only use the product for its intended purpose.
If the operating instructions or the technical data are not adhered to, personal injury and/or damage to
property may occur.
Improper or non-intended use may lead to malfunctions of the device, to unwanted effects in the
application or to a loss of the warranty claims.
The manufacturer assumes no liability for any consequences caused by tampering with the device or
incorrect use by the operator.
►Observe these operating instructions.
►Adhere to the warning notes on the product.
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2.2 Required background knowledge 43060
This document is intended for specialists. Specialists are people who, based on their relevant training
and experience, are capable of identifying risks and avoiding potential hazards that may be caused
during operation or maintenance of the product.
To program AC4S, the people should also be familiar with the software CODESYS 3.5 and the
CODESYS Safety extension.
The people should also have knowledge of the following topics:
Requirements on safety-relevant programming
Standards DIN EN ISO 13849 and DIN EN 62061

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3 System requirements
Content
Hardware................................................................................................................................................10
Software..................................................................................................................................................10
Licensing.................................................................................................................................................10
38972
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3.1 Hardware 42877
Device of the SmartSPS SafeLine AC4S product family with firmware V4.3.2
PC/laptop for CODESYS development system (→system requirements CODESYS development
system V3.5)
Ethernet connection between CODESYS-PC/laptop and configuration interface (X3) of the device
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3.2 Software 43113
To program the device-internal Standard PLC and the fail-safe PLC of AC4S the following software
components are necessary:
Component
Description
Version
CODESYS Development System
CODESYS programming software for PLC programming
complying with the standard IEC 61131-3
3.5 SP9 Patch 7 Hotfix 3
Package ""CODESYS für ifm SmartPLC
SafeLine""
Safety extension for the CODESYS programming
software
Device and interface description of AC4S
Function libraries for programming of Standard PLC
Certified function libraries for programming the
fail-safe PLC
Certified libraries for the safety-relevant programming
(SafetyPLCopen, safety standard)
1.5.2.10
The features and functions warranted in this manual can only be obtained by using the
software components in the versions stated here.
On its website ifm electronic provides the required software components.
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3.3 Licensing 43397
By buying a device of the SmartSPS SafeLine AC4S the buyer has also purchased a licence valid for
using the CODESYS 3.5 programming software.