IFM Electronic Ecomat 300 AC422S Application guide

Original Device Manual
Fail-safe SmartPLC AC4S
with EtherNet/IP interface
AC422S
for ISO 13849 up to PL e
for IEC 62061 up to SIL CL 3
Firmware: 4.0.2
English
7391068_00_UK 2016-03-02

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ifm Original Device Manual Fail-safe SmartPLC with EtherNet/IP interface (AC422S), Firmware 4.0.2 2016-03-02
Contents
Contents
1Preliminary note 6
1.1 Legal and copyright information...........................................................................................7
1.2 Purpose of the document.....................................................................................................7
1.3 Symbols and formats used ..................................................................................................8
1.4 Overview: User documentation for AC4S............................................................................9
1.5 Modification history ..............................................................................................................9
2Safety instructions 10
2.1 Required background knowledge ......................................................................................11
2.2 Please note........................................................................................................................11
2.3 Tampering with the unit......................................................................................................12
2.4 Start-up behaviour of the controller....................................................................................12
3System description 13
3.1 Intended use ......................................................................................................................14
3.1.1 Permitted use.............................................................................................................................14
3.1.2 Prohibited use ............................................................................................................................14
3.2 Information concerning the device.....................................................................................15
3.2.1 Where is what on the AS-i device?.............................................................................................16
3.2.2 Operating elements....................................................................................................................17
3.2.3 Display elements........................................................................................................................17
3.2.4 Interfaces....................................................................................................................................18
3.2.5 Type label...................................................................................................................................21
3.2.6 Required accessories.................................................................................................................21
3.3 Hardware............................................................................................................................22
3.3.1 Safety architecture .....................................................................................................................23
3.3.2 Operating states of AC422S.......................................................................................................29
3.3.3 Monitoring and securing mechanisms........................................................................................30
3.3.4 Error detection and processing...................................................................................................31
3.4 Software.............................................................................................................................33
3.4.1 Software modules of the device .................................................................................................34
3.4.2 Safety functions..........................................................................................................................34
3.4.3 Certified software components for safe applications..................................................................34
4Installation 35
4.1 Installation..........................................................................................................................36
4.2 Electrical connection..........................................................................................................36
4.2.1 Device supply.............................................................................................................................37
4.3 Connect devices to local I/O interface ...............................................................................38
4.3.1 Safety instructions......................................................................................................................39
4.3.2 Supported connection types.......................................................................................................40
4.3.3 Supported device types..............................................................................................................41
4.3.4 Install safe device to local I/O interface......................................................................................52
4.3.5 Install standard device on local I/O interface..............................................................................52
5Operation 53
5.1 Control of the graphical user interface...............................................................................54
5.1.1 Function keys.............................................................................................................................55
5.1.2 Arrow keys..................................................................................................................................55

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Contents
5.2 Menu view..........................................................................................................................56
5.2.1 Menu navigation.........................................................................................................................56
5.2.2 Navigation aids...........................................................................................................................57
5.3 Page view...........................................................................................................................59
5.3.1 Navigate on a page....................................................................................................................59
5.3.2 Use navigation aids....................................................................................................................59
5.3.3 Description of the control elements ............................................................................................60
5.4 Remote access ..................................................................................................................72
5.4.1 General.......................................................................................................................................73
5.4.2 Recommended browsers............................................................................................................73
5.4.3 Operating instructions ................................................................................................................74
6Menu 77
6.1 Start screen........................................................................................................................78
6.2 Quick setup........................................................................................................................79
6.2.1 Quick setup: Project AS-i networks............................................................................................80
6.2.2 Quick setup: Configure the operating mode of the AS-i masters................................................81
6.2.3 Quick setup: Configure the output access..................................................................................82
6.2.4 Quick setup: Access the device via QR code.............................................................................82
6.2.5 Quick setup: Configure the EtherNet/IP interface.......................................................................83
6.2.6 Quick setup: Set the configuration mode....................................................................................84
6.2.7 Quick setup: Set the configuration interface...............................................................................85
6.2.8 Quick setup: Address the AS-i slaves connected to AS-i master 1 ............................................87
6.2.9 Quick setup: Address the AS-i slaves connected to AS-i master 2 ............................................88
6.3 AS-i 1 / AS-i 2.....................................................................................................................89
6.3.1 AS-i 1 / AS-i 2: Master setup......................................................................................................90
6.3.2 AS-i 1 / AS-i 2: Diagnosis...........................................................................................................92
6.3.3 AS-i 1 / AS-i 2: AS-i slaves.........................................................................................................94
6.4 System .............................................................................................................................100
6.4.1 System: Programmable Logic Controller (PLC)........................................................................101
6.4.2 System: Information .................................................................................................................107
6.4.3 System: Setup..........................................................................................................................108
6.4.4 System: Diagnosis....................................................................................................................119
6.5 Interfaces .........................................................................................................................120
6.5.1 Interfaces: Configuration interface............................................................................................121
6.5.2 Interfaces: EtherNet/IP interface ..............................................................................................124
6.6 Safety...............................................................................................................................136
6.6.1 Safety: AS-i 1 master settings..................................................................................................137
6.6.2 Safety: AS-i 2 master settings..................................................................................................141
6.6.3 Safety: Local IOs......................................................................................................................142
6.6.4 Safety: System.........................................................................................................................146
6.7 ifm system solutions.........................................................................................................147
6.7.1 Notes on ifm system solutions..................................................................................................148
6.7.2 Show information about installed ifm apps...............................................................................149
6.7.3 Install single/basic app .............................................................................................................149
6.7.4 Install multi app ........................................................................................................................150
6.7.5 Update ifm apps.......................................................................................................................151
6.7.6 Uninstall ifm apps.....................................................................................................................151
7Setup 152
7.1 Mounting and electrical connection .................................................................................153
7.2 Install devices on the local I/O interface ..........................................................................153
7.3 Start screen 'Basic settings'.............................................................................................154
7.3.1 Change the basic settings of the device...................................................................................154

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7.4 Notes on the firmware update..........................................................................................156
7.5 Connect and address AS-i slaves....................................................................................156
7.6 Setup of EtherNet/IP........................................................................................................156
7.7 Setup of the configuration interface.................................................................................157
7.8 Replace standard AS-i slave............................................................................................157
7.9 Replace safe AS-i slave...................................................................................................158
8Troubleshooting 159
8.1 Status LED.......................................................................................................................160
8.1.1 Status LED: Basic device.........................................................................................................160
8.1.2 Status LED: fieldbus EtherNet/IP .............................................................................................160
8.2 Online diagnosis function.................................................................................................161
8.2.1 Message types.........................................................................................................................161
8.2.2 Locate error sources ................................................................................................................161
8.3 Online Support Centre (OSC)..........................................................................................162
8.3.1 OSC: Aktuelle Meldungen zeigen.............................................................................................163
8.3.2 OSC: Show message history....................................................................................................164
8.4 Availability of the fail-safe PLC ........................................................................................165
8.5 Display diagnostic protocol ..............................................................................................165
9Appendix 166
9.1 Technical data..................................................................................................................167
9.1.1 Environmental conditions .........................................................................................................168
9.1.2 Safety classification..................................................................................................................168
9.1.3 Power supply connections........................................................................................................168
9.1.4 Electrical data...........................................................................................................................168
9.1.5 Display elements......................................................................................................................169
9.1.6 Housing....................................................................................................................................169
9.1.7 Interfaces..................................................................................................................................170
9.1.8 AS-interface..............................................................................................................................171
9.1.9 Programmable Logic Controller (PLC) .....................................................................................171
9.2 Address assignment in Ethernet networks ......................................................................172
9.3 Configuration interface: connection concepts..................................................................173
9.3.1 Direct link..................................................................................................................................174
9.3.2 Connection via Ethernet network..............................................................................................175
9.4 AS-i master ......................................................................................................................176
9.4.1 Operating modes of the AS-i master........................................................................................177
9.4.2 Master flags..............................................................................................................................179
9.5 AS-i slaves.......................................................................................................................184
9.5.1 Profiles of AS-i slaves...............................................................................................................185
9.6 Fieldbus EtherNet/IP........................................................................................................196
9.6.1 Fieldbus objects .......................................................................................................................197
9.6.2 Fieldbus parameters.................................................................................................................199
9.6.3 Device-specific parameters......................................................................................................200
9.6.4 Cyclic data................................................................................................................................221
9.6.5 Acyclic data..............................................................................................................................254
9.6.6 Configuration mode..................................................................................................................371
9.7 OSC messages................................................................................................................381
9.7.1 OSC messages: System ..........................................................................................................382
9.7.2 OSC messages: AS-i 1 / AS-i 2................................................................................................383
9.7.3 OSC messages: Safety module ...............................................................................................384
9.7.4 OSC messages: Safety PLCopen function blocks....................................................................401

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ifm Original Device Manual Fail-safe SmartPLC with EtherNet/IP interface (AC422S), Firmware 4.0.2 2016-03-02
Contents
10 Index 402
11 ifm weltweit • ifm worldwide • ifm à l’échelle internationale 407

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Preliminary note Legal and copyright information
1Preliminary note
Legal and copyright information ...............................................................................................................7
Purpose of the document .........................................................................................................................7
Symbols and formats used.......................................................................................................................8
Overview: User documentation for AC4S.................................................................................................9
Modification history...................................................................................................................................9
14801

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Preliminary note Legal and copyright information
>
1.1 Legal and copyright information
6088
© 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™
• IO-Link®(→www.io-link.com) is the property of the →PROFIBUS Nutzerorganisation e.V., Germany
• Microsoft®is the property of the Microsoft Corporation, USA (→www.microsoft.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
>
1.2 Purpose of the document
20135
This document applies to devices of the type "SmartPLC AC4S with EtherNet/IP" interface" (art. no.:
AC422S) with the firmware version 4.0.2.
These instructions describe the following topics:
Mounting and electrical connection of AC422S
Installation of additional devices (sensors, actuators) to the local I/O interface
Operation and configuration of the device via the menu (GUI and web interface)
Command channels, cyclic and acyclic data records
Error diagnostics and troubleshooting

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Preliminary note Symbols and formats used
>
1.3 Symbols and formats used
15989
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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Preliminary note Overview: User documentation for AC4S
>
1.4 Overview: User documentation for AC4S
18655
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 AC422S as a table
Operating instructions *
Notes on mounting and electrical installation of AC422S
Setup, description of the operating and display elements, maintenance information, scale
drawing
Device manual
Notes on operation of AC422S via GUI and web interface
Description of the cyclic and acyclic data records, fieldbus parameters and command interface
Error description
Programming manual
Notes on configuration of a AC422S system in CODESYS safety
Notes on programming of the standard PLC of AC422S
Notes on programming the fail-safe PLC of AC422S
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.
→www.ifm.com > Select country > [Data sheet search] > (Article no.) > [Operating
instructions]
>
1.5 Modification history
4165
Version
Subject
Date
1.0
New creation of the document
03-02-2016

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Safety instructions Modification history
2Safety instructions
Required background knowledge...........................................................................................................11
Please note.............................................................................................................................................11
Tampering with the unit..........................................................................................................................12
Start-up behaviour of the controller........................................................................................................12
213

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Safety instructions Required background knowledge
>
2.1 Required background knowledge
13323
This document is intended for people with knowledge of control technology and PLC programming to
IEC 61131-3.
To program the PLC, these people should also be familiar with the CODESYS software.
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. The document contains information about the correct
handling of the product.
►Read this document before use to familiarise yourself with operating conditions, installation and
operation. Keep this document during the entire duration of use of the device.
►Follow the safety instructions.
>
2.2 Please note
6091
11212
No characteristics are warranted with the information, notes and examples provided in this manual.
With the drawings, representations and examples given no responsibility for the system is assumed
and no application-specific particularities are taken into account.
►The manufacturer of the machine/equipment is responsible for ensuring the safety of the
machine/equipment.
►Follow the national and international regulations of the country in which the machine/installation is
to be placed on the market.
WARNING
Non-observance of these instructions can lead to property damage or personal injury.
ifm electronic gmbh does not assume any liability in this regard.
►The acting person must have read and understood the safety instructions and the corresponding
chapters in this manual before working on and with this device.
►The acting person must be authorised to work on the machine/equipment.
►The acting person must have the qualifications and training required to perform this work.
►Adhere to the technical data of the devices!
You can find the current data sheet on ifm's homepage at:
→www.ifm.com > Select your country > [Data sheet search] > (article number.) > [Technical data
in PDF format]
►Note the installation and wiring information as well as the functions and features of the devices!
→supplied installation instructions or on ifm's homepage:
→www.ifm.com > Select your country > [Data sheet search] > (article number.) > [Operating
instructions]
►Please note the corrections and notes in the release notes for the existing documentation,
available on the ifm website:
→www.ifm.com > Select your country > [Data sheet search] > (article number.) > [Operating
instructions]

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Safety instructions Tampering with the unit
>
2.3 Tampering with the unit
11242
WARNING
Tampering with the units can affect the safety of operators and machinery.
Tampering with the units is not allowed.
In case of non-compliance our liability and warranty expire.
►Do not open the devices.
►Do not insert any objects into the devices.
►Prevent metal foreign bodies from penetrating.
>
2.4 Start-up behaviour of the controller
6827
15233
11575
WARNING
Danger due to unintentional and dangerous start of machine or plant sections.
►When creating the program, the programmer must ensure that no unintentional and dangerous
start of machines or plant sections after a fault (e.g. e-stop) and the following fault elimination can
occur.
Realise restart inhibit.
►In case of an error, set the outputs concerned to FALSE in the program.
A restart can, for example, be caused by:
• voltage restoration after power failure
• reset after watchdog response because of too long a cycle time
• error elimination after an E-stop
To ensure a safe behaviour of the controller:
►Monitor the voltage supply in the application program.
►In case of an error switch off all relevant outputs in the application program.
►Monitor actuators which can cause hazardous movements in the application program (feedback).
►Monitor relay contacts which can cause hazardous movements in the application program
(feedback).
►If necessary, ensure that welded relay contacts in the application project cannot trigger or continue
hazardous movements.

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System description Start-up behaviour of the controller
3System description
Intended use...........................................................................................................................................14
Information concerning the device .........................................................................................................15
Hardware................................................................................................................................................22
Software..................................................................................................................................................33
8697
This chapter describes the structure and the components of the system.

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System description Intended use
>
3.1 Intended use
5310
NOTICE
Danger when device is overloaded or incorrectly used.
The device and / or the associated machine / plant may be damaged or destroyed or may malfunction
if the limits of the "Technical data" for this device are exceeded or if the device is used outside the
specified "Intended use".
►Use the device only within the limits of the Technical data (→page 167) (data sheet).
►Use the device only in accordance with the "Intended use".
>
3.1.1 Permitted use
7149
AC422S can assume the following functions:
AS-i master in 2 separate AS-i networks
Fail-safe programmable logic controller (PLC) and standard PLC for acquiring, processing and
providing safe and non-safe data of the connected AS-i slaves and the channels of the local I/O
interface
Gateway for the transmission of standard control and user data between a higher-level
EtherNet/IP controller and the slaves in the AS-i networks
>
3.1.2 Prohibited use
5320
You MUST not use the device in the following areas:
outdoors,
beyond the limits of the technical data (data sheet).

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System description Information concerning the device
>
3.2 Information concerning the device
Where is what on the AS-i device? ........................................................................................................16
Operating elements................................................................................................................................17
Display elements ....................................................................................................................................17
Interfaces................................................................................................................................................18
Type label...............................................................................................................................................21
Required accessories.............................................................................................................................21
5330

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System description Information concerning the device
>
3.2.1 Where is what on the AS-i device?
8719
Legend:
Display
Status LED (H1)
2 function keys
4 arrow keys
Connector (X1) for
AS-i 1, AS-i 2, functional earth
Connector (X2) for AUX
Local inputs and outputs (X4)
(behind the front flap)
Front flap
Slot for SD card (X5)
(behind the front flap)
Ethernet configuration interface (X3)
(behind the front flap)
EtherNet/IP interface 2 (X6) with
status LED (H2, H3)
EtherNet/IP interface 1 (X7) with
status LED (H4, H5)

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System description Information concerning the device
>
3.2.2 Operating elements
15840
The device provides the following operating elements.
>
Arrow and function keys
15867
Below the display is the key panel with two function keys and four arrow keys. The operator controls
the Graphical User Interface (GUI) of the device with the keys.
Technical data: →Operation
>
3.2.3 Display elements
7062
The device provides the following display elements:
>
Display
7083
The display is used to display the Graphical User Interface (GUI) of the device.
Operating notes: →Operation (→page 53)
Technical data: →Display elements (→page 169)
>
Status LEDs
18985
The device features the following status LEDs which display the current status of system components.
Meaning of the LED colours and flashing frequencies: →Status LED (→page 160)

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System description Information concerning the device
>
3.2.4 Interfaces
Ethernet configuration interface .............................................................................................................19
Local input/output interface ....................................................................................................................19
SD card slot............................................................................................................................................20
EtherNet/IP fieldbus interface.................................................................................................................20
7134
AC422S has the following interfaces.

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System description Information concerning the device
>
Ethernet configuration interface
6982
The configuration interface (X3) is located behind the front flap of the device. It allows the user to
access the following device functions:
web interface for device configuration and diagnosis
programming of the device-internal standard PLC using CODESYS
Configuration as fieldbus interface
Possible network topologies: →Configuration interface: connection concepts (→page 173)
Technical data: →Interfaces (→page 170)
>
Local input/output interface
7152
The local input/output interface (X4) is behind the front flap of the device. Safe and non-safe
peripherals without AS-i interface can be connected to the local inputs and outputs.
Connections of the local I/O interface:
4x output channels (OUT1 .... OUT4)
→Local outputs (→page 19)
2x voltage ground GND
→Voltage source / voltage ground
(→page 19)
2x voltage source +24V
→Voltage source / voltage ground
(→page 19)
8x input channels (IN1 ... IN8)
→Local inputs (→page 19)
>
Voltage source / voltage ground
19824
+24V and GND are used as voltage supply for the safety IO PCB of the safety module of AC422S.
Notes on the electrical connection: →Electrical connection (→page 36)
>
Local inputs
19825
The local I/O interface provides 8 input channels for the connection of devices (e.g. sensors, switches,
light curtains). Each input channel can be used as safe or standard input. Configuration is effected via
the programming system CODESYS.
Connection of peripherals: →Connect devices to local I/O interface (→page 38)
Technical data: →Interfaces (→page 170)
>
Local outputs
19826
The local I/O interface provides 4 output channels for the connection of devices (e.g. actuators,
relays). Each output channel can be used as safe or standard output. Configuration is effected via the
programming system CODESYS.
Notes on the connection of peripherals: →Connect devices to local I/O interface (→page 38)
Technical data: →Interfaces (→page 170)
>

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System description Information concerning the device
Possible combinations of input and output channels
12095
The inputs IN1...IN8 can be configured both as safe and non-safe inputs.
The outputs OUT1...OUT4 can be configured both as safe and non-safe outputs.
This permits the following minimum or maximum input and output combinations:
Min. configuration
Max. configuration
8 non-safe inputs
4 non-safe outputs
4 safe inputs, 2 channels (SIL3)
4 safe outputs, 1 channel (SIL3)
>
SD card slot
8699
The SD card slot (X5) is located behind the front flap of the device. The following actions can be
performed with an SD card:
Save and restore the device configuration
Storage medium for access to standard PLC
Technical data: →Interfaces (→page 170)
>
EtherNet/IP fieldbus interface
12113
The device communicates with the higher-level control instance of the EtherNet/IP network via the
EtherNet/IP interface (X6/X7).
Notes regarding connetion concepts: →Konfigurationsschnittstelle: Verbindungskonzepte
(→page 173)
Technical data: →Interfaces (→page 170)