IFM Electronic AC030S User manual

Operating instructions
Safe AS-i output module
AC030S
7390740 / 02 11 / 2009
UK

2
Contents
1 Safety instructions ������������������������������������������������������������������������������������������������3
2 Installation / Set-up�����������������������������������������������������������������������������������������������4
3 Operating and display elements���������������������������������������������������������������������������6
4 Installation ������������������������������������������������������������������������������������������������������������6
5 Electrical connection���������������������������������������������������������������������������������������������6
6 Response times����������������������������������������������������������������������������������������������������9
7 Consideration of the residual error probability to IEC 61508������������������������������10
8 Addressing���������������������������������������������������������������������������������������������������������� 11
9 Programming������������������������������������������������������������������������������������������������������ 11
10 Operation����������������������������������������������������������������������������������������������������������12
11 Technical data���������������������������������������������������������������������������������������������������13
12 Approvals����������������������������������������������������������������������������������������������������������14
13 Scale drawing���������������������������������������������������������������������������������������������������15

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1 Safety instructions
Follow the operating instructions�
Non-observance of the instructions, operation which is not in accordance with use
as prescribed below, wrong installation or handling can affect the safety of people
and machinery�
For installation and prescribed use of the unit the notes in the operating
instructions must be carefully observed and the applicable technical standards
relevant for the application have to be considered�
In case of non-observance of notes or standards, specially when tampering with
and/or modifying the unit, any liability is excluded�
The unit must be installed, connected and put into operation by a qualified
electrician trained in safety technology�
After installation the system has to be subjected to a complete function check�
Disconnect the unit externally before handling it� Also disconnect any
independently supplied relay load circuits�
For installation the requirements according to EN 60204-1 must be observed�
In case of malfunction of the unit please contact the manufacturer� Tampering with
the unit can seriously affect the safety of operators and machinery� This is not
permitted and leads to an exclusion of liability and warranty�

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2 Installation / Set-up
Applications
The safe AS-i relay output module with conventional inputs is a decentralised
output module for safe triggering of actuators in the AS-Interface Safety at Work
system�
For this purpose, a code table with 7 x 4 bits is transmitted via the AS-i system;
sent by the AS-i safety monitor (e�g� AC031S / AC032S) and received by the safe
AS-i output module�
When operated correctly, the system can be used in applications up to the control
category 4 according to EN 954-1 / PL e to EN ISO 13849-1 or IEC 61508/SIL3
(see notes Electrical connection)�
Attention!
Depending on the safety components used the complete safety system
can also be classified for a lower control category�
Function and electrical connection:
Observe all information in the description of the configuration software (e�g�
E7040S) and the operating instructions of the AS-i safety monitor� These
documents provide all required instructions concerning installation, configuration,
operation and maintenance of the AS-i safety system�
Information on the parameterizable safety functions of the safe AS-i output module
can be found in the chapter "Monitoring devices" of the configuration software
manual�

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Important note:
The products described herein are designed to be components of a safety-
oriented machine or control system� A complete safety-related system
normally includes sensors, evaluation units, actuators and signalling
components� It is the responsibility of each manufacturer of a machine
or installation to ensure a correct functioning of the whole system� The
manufacturer of the safe AS-i output module, his subsidiaries and affiliates
are not in a position to evaluate all of the characteristics of a given
machine or product�
The manufacturer accepts no liability for any recommendation that may be implied
or stated herein�
The warranty contained in the contract of sale is the sole warranty� Any statements
contained herein do not create new warranties or modify existing ones�
The complete description of the configuration software, the operating
instructions of the AS-i safety monitor and the operating instructions of the
safe AS-i output module must be taken into account!
Maintenance requirement
A minimum of one testing per year is compulsory by a demand on the
safety function!

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3 Operating and display elements




Slide switch R/P1:
Addressing plug2:
Combicon connector with screw terminals (option)3:
4 Installation
Install the safe AS-i output module on a 35 mm raised rail� The protection rating
of the unit is IP 20, therefore it should be mounted in a protected location (e�g�
control cabinet)�
The mounting orientation has no adverse effect on the function� Ensure that there
is sufficient air circulation in the control cabinet�
5 Electrical connection
Mechanical switches or inductive sensors, for example, can be connected to the
inputs� Connect the non-safe inputs e�g� with the screw terminals of the Combicon
connectors�
Attention!
Do not connect the non-safe inputs to an external potential!

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Wiring
A+: AS-i +
 
 
   
   
   
   





A-: AS-i -
I+: sensor supply from AS-i
(+24 V output)
I-:: sensor supply from AS-i (0 V)
I1���I3 / 1�Y1: non-safe switching inputs
13-14 / 23-24: safe relay output
LEDs 1: switching status indication
inputs / input feedback circuit
LEDs 2: AS-i, FAULT
LEDs 3/4: switching status indication code
release / LED alarm output /
process release
ADR: addressing interface
R/P slide switch
run / programming mode
Wiring example safe relay output

  



 
 
   
   
   
   




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Data bits
Data bit D3 D2 D1 D0
In/Out 1�Y1 I-3 I-2 / O-2 I-1 / O-1
Activated inputs Bit D3-D0
I-1 XXX1
I-2 XX1X
I-3 X1XX
1�Y1 1XXX
Activated alarm output Bit D3-D0
O-1 XXX1
Activated process output Bit D3-D0
O-2 XX1X
X = random
Parameter bits
Parameter bit P3 P2 P1 P0
default: - 1 1 1
Parameter bit Description
P0 1: input I1
0: auxiliary signal 1 (error reset)
or auxiliary signal 2 (restart disable)
P1 1: process release
0: process release via output O-2 = 1
P2 1: feedback safe internal release
0: input I3
The code words 0000, XX00 and 00XX cause the AS-i safety monitor to bring the
installation into the safe state�
For more details on the effect of the data bits on the transmission sequence refer
to the configuration software manual (see the chapter "Monitoring devices")�

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Note: safe relay output
The safe relay output is implemented with two positively driven relay
contacts� If one of the two internal relays does not switch (e�g� due to
fusing of the contacts), this is detected in the safe output module�
The relay contacts 13-14 and 23-24 are potential-free normally open
contacts�
Attention!
The wiring influences the achievable control category.
The requirements for external wiring and the selection of the
connected switching contacts refer to the functionality to be
accomplished and to the required control category (EN 954-1
/ ISO 13849-1 or EN/IEC 61508). The control category is either
determined by means of a risk analysis (e.g. to EN 1050) or taken
from a C standard. The control category or SIL level of the AS-i safety
monitor must at least correspond to the control category or SIL level
necessary for the application.
6 Response times
The response time of the safe AS-i relay output module to a safety request is
maximum 50 ms from the application of the code sequence until the switch-off of
the safe relays�
Calculation of the total response time
For the calculation of the response time of the total system, the response times of
the other components also have to be added (mechanical switching contacts, data
transmission, safety monitor and external relays or contactors possibly connected
to the safe relay output)�
Here, the switching times of the mechanical contacts (e-stops) and external relays
or contactors possibly connected to the relay output of the output module have not
been taken into account�

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7 Consideration of the residual error probability to
IEC 61508
To calculate the PFH (probability of a dangerous failure per hour) of a safety-rela-
ted function the PFH values of all components used in this function must be taken
into account�
The probability of failure on demand (PFD) is 2�0 x 10-5�
The probability of a dangerous failure per hour (PFH) is 3�3 x 10-9 /h (per hour)�
The indicated PFD and PFH values refer to the maximum switch-on time of 12
months�
The maximum service life (T) is 20 years� The unit can be used in applications up
to SIL 3 (PLe / EN ISO 13849-1 or cat� 4 / EN954-1)�
Explanation of the abbreviations:
PFD = probability of failure on demand
PFH = probability of a dangerous failure per hour
SIL = safety integrity level
T = life time (= service life)
The PFD / PFH values of the other components, especially of the AS-i safety
monitor, can be found in the corresponding documentation�

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8 Addressing
The safe AS-i output module can be addressed, when mounted and wired, via the
addressing unit AC1144 with the cable (EVC076); the address is set to 0 at the
factory�
A special feature of the safe AS-i output module are the two types of AS-i
addresses:
the safe AS-i address• detects the communication on the safe address of the
safety monitor and switches on the basis of the detected data�
the non safety-related AS-i address• serves for diagnosis and switching under
normal operating conditions�
On delivery, all safe output modules with the same safe AS-i address switch in
parallel� This can be changed by means of the parameter bits�
9 Programming
Programming of the safety-related AS-i address
Set the switch on the unit to P (programming) (running light of the inputs I1-1�
I3/1�Y1)�
Set the desired address with the addressing unit or the AS-i master�2�
Check the programmed address with the addressing unit or the AS-i master�3�
Check the ID code of the slave with the addressing unit or the AS-i master� The4�
code should be "F"�
Check the ID1 code of the slave with the addressing unit or the AS-i master�5�
The code should correspond to the tens digit of the address�
Check the ID2 code of the slave with the addressing unit or the AS-i master�6�
The code should correspond to the units digit of the address�
Check the IO code of the slave with the addressing unit or the AS-i master� The7�
code should be "7"�
When all steps from 3 to 7 have been carried out correctly, you can proceed8�
with step 9� Otherwise, repeat from step 1�
Set the switch of the unit to R (RUN)�9�

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Programming of the non safety-related AS-i address
This address can be programmed in the R position of the switch with the
addressing unit or the AS-i master (green release LED flashes)�
10 Operation
Check whether the unit operates correctly� Display by LEDs:
LEDs 1 yellow:• inputs switched
LED 2 green:• voltage supply ok
LED 2 red lit:• AS-i communication error, slave does not partici-
pate in the "normal" exchange of data, e�g� slave
address 0
LED 2 red flashing:• peripheral fault, e�g� overload or short circuit of the
sensor supply
LED 3 red:• alarm output O-1 (non-safe)
(through the host system the alarm output LED can
be set as a static or dynamic output)
LED 4 yellow:• process output O-2 (non-safe)
LED 5 green:• release: code release
off:- safe output relay switched off
flashes, 1 Hz:- restart disable (auxiliary signal 2), waits for start
signal; after start signal the safe output relay
switches on
flashes, 8 Hz:- waiting for error reset (auxiliary signal 1); when the
safety monitor sends the signal "error reset", the
safe output relay switches on
lights:- safe output relay switched on

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11 Technical data
Electrical design
4 non-safe inputs /
2 non-safe LED outputs /
1 safe relay output
Operating voltage 26�5 ��� 31�6 V DC
„supply class 2“ to cULus
Current consumption ≤200mA
Inputs
Wiring DC PNP
Input voltage range sensor 18���30 V DC
Voltage supply via AS-i
Short circuit detection yes
Input current typ� 10 mA
Sensor supply from AS-i 24 V DC / 100 mA
LED output
Supply via AS-i yes
Integrated watchdog yes
LED process output
Power via AS-i yes
Integrated watchdog yes
Relay output
Electrically separated yes
Cross fault monitoring no
Integrated watchdog yes
Current rating per output 3 A, 24 V, DC-13 or 3 A, 230 V, AC-15
External supply yes
Voltage range 10���240 V AC / 24 V DC
Current rating per module 3 A
LED function display
Operation / fault / function green / red / yellow
Operating temperature -25���55°C
Protection IP 20
Overvoltage category III

14
AS-Interface /
extended addressing mode possible
version 2�1 /
yes
AS-i profile S-7�A�E
I/O configuration / ID code 7 [Hex] / A�E [Hex]
AS-i certificate pending
EMC EN 50295
Housing materials PA
Dimensions (H x W x D) 108 x 25 x 105 mm
Additional technical specification for AC030S in context with cULus approval
(UL508)
Operating voltage 30 V, 9 W
External protection An isolated source with a secondary open
circuit voltage < 30 V dc with a 3 amp
maximum over current protection� Over
current protection is not required when a
Class 2 source is employed�
In general UL mark does not provide UL certification
for any functional safety rating or aspects
of the above devices�
Current rating per output Only for Class 2 power supplies
Voltage range
12 Approvals
cULus (UL508)-
TÜV Nord-

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13 Scale drawing
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 