IFM AC412S Application guide

>
>
7391190 / 03
04/ 2019
Device Manual
SmartPLC SafeLine
with PROFIBUS slave interface
AC412S
Master profile: M4
Firmware: 4.3.2
English

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Contents
1Preliminary note 6
1.1 Legal and copyright information...........................................................................................6
1.2 Purpose of the document.....................................................................................................6
1.3Explanation of Symbols .......................................................................................................7
1.4 Overview: User documentation for AC4S............................................................................8
1.5 Modification history ..............................................................................................................8
2Safety instructions 9
2.1 General safety instructions ..................................................................................................9
2.2 Required background knowledge ........................................................................................9
2.3 Tampering with the unit........................................................................................................9
3System description 10
3.1 Intended use ......................................................................................................................11
3.1.1 Permitted use.............................................................................................................................11
3.1.2 Prohibited use ............................................................................................................................11
3.2 Information concerning the device.....................................................................................12
3.2.1 Overview ....................................................................................................................................12
3.2.2 Operating elements....................................................................................................................13
3.2.3 Display elements........................................................................................................................13
3.2.4 Interfaces....................................................................................................................................14
3.2.5 Type label...................................................................................................................................16
3.2.6 Required accessories.................................................................................................................16
3.3Hardware............................................................................................................................17
3.3.1 Safety architecture .....................................................................................................................18
3.3.2 Operating states of AC412S.......................................................................................................22
3.3.3 Monitoring and securing mechanisms........................................................................................23
3.3.4 Error detection and processing...................................................................................................23
3.4 Software.............................................................................................................................26
3.4.1 Software modules of the device .................................................................................................26
3.4.2 Safety functions..........................................................................................................................26
3.4.3 Certified software components for safe applications..................................................................27
4Mounting 28
4.1 Install device ......................................................................................................................28
5Electrical connection 29
5.1 Wiring.................................................................................................................................29
5.2 Connect the supply voltage................................................................................................29
5.2.1 Standard configuration: 24 V power supply and AS-i power supply/supplies.............................30
5.3 Connect devices to local I/O interface ...............................................................................31
5.3.1 Supported connection types.......................................................................................................31
5.3.2 Supported device types..............................................................................................................32
5.3.3 Connect sensors / actuators.......................................................................................................43
6Operation 44
6.1 Control of the graphical user interface...............................................................................44
6.1.1 Function keys.............................................................................................................................45
6.1.2 Arrow keys..................................................................................................................................45

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6.2 Menu view..........................................................................................................................46
6.2.1 Menu navigation.........................................................................................................................46
6.2.2 Navigation aids...........................................................................................................................47
6.3 Page view...........................................................................................................................49
6.3.1 Navigate on a page....................................................................................................................49
6.3.2 Use navigation aids....................................................................................................................49
6.3.3 Description of the control elements ............................................................................................50
6.4 Remote access ..................................................................................................................62
6.4.1 General.......................................................................................................................................62
6.4.2 Recommended browsers............................................................................................................62
6.4.3 Operating instructions ................................................................................................................63
7Menu 66
7.1 Start screen........................................................................................................................66
7.2 Menu functions...................................................................................................................67
7.2.1 Additional functions ....................................................................................................................67
7.3 Quick setup........................................................................................................................68
7.3.1 Quick setup: Project AS-i networks............................................................................................69
7.3.2 Quick setup: Configure the operating mode of the AS-i masters................................................70
7.3.3 Quick setup: Configure the output access..................................................................................71
7.3.4 Quick setup: Access the device via QR code.............................................................................71
7.3.5 Quick setup: Configure the PROFIBUS interface.......................................................................72
7.3.6 Quick setup: Set the Konfigurationsschnittstelle.........................................................................73
7.3.7 Quick setup: Address the AS-i slaves connected to AS-i Master 1 ............................................75
7.3.8 Quick setup: Address the AS-i slaves connected to AS-i Master 2 ............................................76
7.4 AS-i 1 / AS-i 2.....................................................................................................................77
7.4.1 AS-i 1 / AS-i 2: Master setup......................................................................................................78
7.4.2 AS-i 1 / AS-i 2: Diagnosis...........................................................................................................80
7.4.3 AS-i 1 / AS-i 2: AS-i slaves.........................................................................................................82
7.5 System ...............................................................................................................................88
7.5.1 System: Programmable Logic Controller (PLC)..........................................................................89
7.5.2 System: Information ...................................................................................................................95
7.5.3 System: Setup............................................................................................................................96
7.5.4 System: Diagnosis....................................................................................................................108
7.6 Interfaces .........................................................................................................................109
7.6.1 Interfaces: Konfigurationsschnittstelle......................................................................................110
7.6.2 Interfaces: PROFIBUS interface...............................................................................................114
7.7 Safety...............................................................................................................................120
7.7.1 Safety: Status of the fail-safe slaves at AS-i Master 1..............................................................121
7.7.2 Safety: Status of the fail-safe slaves at AS-i Master 2..............................................................125
7.7.3 Safety: Local IOs......................................................................................................................126
7.7.4 Safety: FSoE............................................................................................................................130
7.7.5 Safety: System.........................................................................................................................131
7.8 ifm system solutions.........................................................................................................132
7.8.1 Notes on ifm system solutions..................................................................................................132
7.8.2 Show information about installed ifm apps...............................................................................134
7.8.3 Install single/basic app .............................................................................................................135
7.8.4 Install multi app ........................................................................................................................136
7.8.5 Update ifm apps.......................................................................................................................137
7.8.6 Uninstall ifm apps.....................................................................................................................137
8Setup 138
8.1 Install device ....................................................................................................................138
8.2 Connect the device to the periphery................................................................................138
8.2.1 PROFIBUS interface ................................................................................................................138
8.2.2 Configuration interface .............................................................................................................138
8.2.3 Install devices on the local I/O interface...................................................................................139
8.3 Install devices on the local I/O interface ..........................................................................139
8.4 Start screen 'Basic settings'.............................................................................................140
8.4.1 Change the basic settings of the device...................................................................................140

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8.5 Notes on the firmware update..........................................................................................142
8.6 Connect and address AS-i slaves....................................................................................142
8.7 Set the Profibus interface.................................................................................................143
8.8 Setup of the configuration interface.................................................................................143
8.9 Replace standard AS-i slave............................................................................................144
8.10 Replace safe AS-i slave...................................................................................................144
9Troubleshooting 145
9.1 Status LED.......................................................................................................................145
9.1.1 Status LED: Basic device.........................................................................................................145
9.2 Start screen: Status LEDs................................................................................................146
9.2.1 Status of the web interface.......................................................................................................146
9.2.2 Operating mode of the AS-i master..........................................................................................146
9.2.3 Control instance of the AS-i outputs.........................................................................................146
9.3 Online diagnosis function.................................................................................................147
9.3.1 Message types.........................................................................................................................147
9.3.2 Locate error sources ................................................................................................................147
9.4 Online Support Centre (OSC)..........................................................................................148
9.4.1 OSC: Display current messages ..............................................................................................149
9.4.2 OSC: Show message history....................................................................................................150
9.5 Availability of the fail-safe PLC ........................................................................................151
9.6 Display diagnostic protocol ..............................................................................................151
10 Appendix 152
10.1 Technical data..................................................................................................................153
10.1.1 Environmental conditions .........................................................................................................153
10.1.2 Safety classification..................................................................................................................153
10.1.3 Power supply connections........................................................................................................153
10.1.4 Electrical data...........................................................................................................................154
10.1.5 Display elements......................................................................................................................154
10.1.6 Housing....................................................................................................................................154
10.1.7 Interfaces..................................................................................................................................155
10.1.8 AS-interface..............................................................................................................................155
10.1.9 Programmable Logic Controller (PLC) .....................................................................................156
10.2 Address assignment in Ethernet networks ......................................................................157
10.3 Configuration interface: connection concepts..................................................................158
10.3.1 Direct link..................................................................................................................................158
10.3.2 Connection via Ethernet network..............................................................................................158
10.4 AS-i master ......................................................................................................................159
10.4.1 Operating modes of the AS-i master........................................................................................160
10.4.2 Master flags..............................................................................................................................162
10.5 AS-i slaves.......................................................................................................................163
10.5.1 Profiles of AS-i slaves...............................................................................................................164
10.6 Fieldbus Profibus .............................................................................................................173
10.6.1 Fieldbus parameters.................................................................................................................173
10.6.2 Device-specific parameters......................................................................................................174
10.6.3 Cyclic data................................................................................................................................178
10.6.4 Acyclic data..............................................................................................................................202
10.6.5 I&M data...................................................................................................................................209
10.6.6 Fieldbus alarms........................................................................................................................212
10.7 OSC messages................................................................................................................221
10.7.1 OSC messages: System ..........................................................................................................221
10.7.2 OSC messages: AS-i 1 / AS-i 2................................................................................................222
10.7.3 OSC messages: Safety module ...............................................................................................223
10.7.4 OSC messages: Safety PLCopen function blocks....................................................................238
11 Index 239

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1Preliminary note
Content
Legal and copyright information ............................................................................................................ 6
Purpose of the document ...................................................................................................................... 6
Explanation of Symbols......................................................................................................................... 7
Overview: User documentation for AC4S ............................................................................................. 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®(→www.io-link.com) is the property of the →PROFIBUS Nutzerorganisation e.V.,
Germany
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)
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
42287
This document applies to devices of the type "SmartPLC AC4S with PROFIBUS" interface" (art. no.:
AC412S) with the firmware version 4.3.2.
These instructions describe the following topics:
Mounting and electrical connection of AC412S
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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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 AC412S as a table
Operating instructions *
Notes on mounting and electrical installation of the AC412S
Set-up, description of the operating and display elements, maintenance information, scale
drawing
Device manual
Notes on operation of AC412S 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-SPS 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.
>
1.5 Modification history
34492
Version
Topic
Date
00
New creation of document
12 / 2017
01
Update to firmware 4.3.1
Changed: Restore device configuration
09 / 2018
02
Deleted: chapter 5.2.2 „Device supply via a joint power supply”
01 / 2019
03
Update to firmware 4.3.2
04/ 2019

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2Safety instructions
Content
General safety instructions.................................................................................................................... 9
Required background knowledge.......................................................................................................... 9
Tampering with the unit......................................................................................................................... 9
28333
>
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.
>
2.2 Required background knowledge
41648
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.
For programming these people should also have knowledge of control technology experience in PLC
programming to IEC 61131-3.
The document contains information about the correct handling of the product.
>
2.3 Tampering with the unit
33190
WARNING!
Tampering with the unit.
>In case of non-compliance:
Possible affects on safety of operators and machinery
Expiration of liability and warranty
►Do not open the devices!
►Do not insert any objects into the devices!
►Prevent metal foreign bodies from penetrating!

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3System description
Content
Intended use........................................................................................................................................ 11
Information concerning the device ...................................................................................................... 12
Hardware............................................................................................................................................. 17
Software .............................................................................................................................................. 26
42275
This chapter describes the structure and the components of the system.

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3.1 Intended use
Content
Permitted use ...................................................................................................................................... 11
Prohibited use...................................................................................................................................... 11
36928
>
3.1.1 Permitted use
42316
AC412S 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
PROFIBUS controller and the slaves in the AS-i networks
>
3.1.2 Prohibited use
34228
The device may not be used beyond the limits of the technical data (→Technical data (→S. 153))!

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3.2 Information concerning the device
Content
Overview.............................................................................................................................................. 12
Operating elements............................................................................................................................. 13
Display elements................................................................................................................................. 13
Interfaces............................................................................................................................................. 14
Type label............................................................................................................................................ 16
Required accessories.......................................................................................................................... 16
36905
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3.2.1 Overview
42308
Legende:
Display
Status-LED (H1)
2 Funktionstasten
4 Pfeiltasten
Anschlussstecker (X1) für
AS-i 1, AS-i 2, Funktionserde
Anschlussstecker (X2) für AUX
Lokale Ein- und Ausgänge (X4)
(hinter der Frontklappe)
Frontklappe
Steckplatz für SD-Karte (X5)
(hinter der Frontklappe)
Ethernet-Konfigurationsschnittstelle (X3)
(hinter der Frontklappe)
PROFIBUS-Schnittstelle (X6)

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3.2.2 Operating elements
36790
The device provides the following operating elements.
>
Arrow and function keys
36959
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.
Operating notes: →Operation (→S. 44)
>
3.2.3 Display elements
36917
The device provides the following display elements:
>
Display
36894
The display is used to display the Graphical User Interface (GUI) of the device.
Operating notes: →Operation (→S. 44)
Technical data: →Technical data (→S. 153)
>
Status LEDs
36784
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 (→S. 145)

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3.2.4 Interfaces
Content
Ethernet configuration interface .......................................................................................................... 14
Local input/output interface ................................................................................................................. 14
SD card slot......................................................................................................................................... 15
PROFIBUS fieldbus interface.............................................................................................................. 15
42306
AC412S has the following interfaces.
>
Ethernet configuration interface
42193
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-SPS and the fail-safe PLC using CODESYS
Configuration as fieldbus interface
Possible network topologies: →Configuration interface: connection concepts (→S. 158)
Technical data: →Technical data (→S. 153)
>
Local input/output interface
42303
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 (→S. 15)
2x voltage ground GND
→Voltage source / voltage ground
(→S. 14)
2x voltage source +24V
→Voltage source / voltage ground
(→S. 14)
8x input channels (IN1 ... IN8)
→Local inputs (→S. 14)
>
Voltage source / voltage ground
42272
+24V and GND are used as voltage supply for the safety IO PCB of the safety module of AC412S.
Notes on the electrical connection: →Electrical connection (→S. 29)
>
Local inputs
42304
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 (→S. 31)
Technical data: →Technical data (→S. 153)
>

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Local outputs
42291
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 (→S. 31)
Technical data: →Technical data (→S. 153)
>
Possible combinations of input and output channels
42315
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
42194
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-SPS
Technical data: →Technical data (→S. 153)
>
PROFIBUS fieldbus interface
41428
The device communicates with the higher-level control instance of the PROFIBUS network via the
PROFIBUS interface (X6).
Notes regarding connetion concepts: →Configuration interface: connection concepts (→S. 158)
Technical data: →Technical data (→S. 153)

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3.2.5 Type label
42274
The type label is on the right housing side of the device. It provides the following information:
QR code for product website
CE/cULus marking
Protection class
AS-i certification
TÜV certification
Hardware version
Operating voltage for
–Aux / local IO PCB
–AS-i
max. current consumption of the
device
max. load per output channel of the
local I/O interface
Type designation incl. device
functionality
–number of AS-i fieldbus gateways
–classification of the AS-i masters
–fail-safe PLC
–fieldbus
Manufacturer identification
>
3.2.6 Required accessories
42259
To be able to operate the device in a sensible way you need the following accessories (not supplied
with the device):
Depending on the selected voltage supply (Operating instructions) you need:
a power supply for the 24 V power supply (e.g. art. no. DN3011)
for each AS-i master one AS-i power supply each (e.g. art. no. AC1236)
a data decoupling module AC1250 (accessory, optional)
Fail-safe and standard AS-i slaves
Fail-safe and standard devices for connecting with the local I/O interface

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3.3 Hardware
Content
Safety architecture............................................................................................................................... 18
Operating states of AC412S .............................................................................................................. 22
Monitoring and securing mechanisms................................................................................................. 23
Error detection and processing ........................................................................................................... 23
42223

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3.3.1 Safety architecture
Content
System architecture............................................................................................................................. 18
Process safety time............................................................................................................................. 21
42266
>
System architecture
42268
The hardware structure of the safety module of AC412S corresponds to the implementation to DIN EN
ISO 13849-1:2008, IEC 62061:2010 and IEC61508:2010 with a two-channel architecture with
hardware fault tolerance (HFT = 1).
The device achieves the following characteristic safety values:
SIL 3 / SIL CL 3 referred to IEC 61508:2010 and IEC 62061:2010
Performance Level e EN ISO 13849-1:2008)
Category 4 (EN ISO 13849-1:2008)
The reachable characteristic safety values of the automation system implemented with
AC412S depend on the following components:
Safety classification of the peripherals installed at the local I/O interface (→Supported device
types (→S. 32))
Safety classification of the installed safe AS-i slaves

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AC412S has the following system architecture:
>
Main module
42292
The main module is the central component of AC412S. It contains the recovery system and the
firmware of the device and controls the communication between the individual system components via
the backplane. The main module has interfaces to the following components:
Display (→Display (→S. 19))
COM module (→COM module (→S. 20))
Ethernet configuration interface
AS-i module (→AS-i module (→S. 20))
Safety module (→Safety module (→S. 20))
>
Display
42230
The display is the graphic user interface of AC412S via which the user can configure and diagnose the
device. The display exchanges the resulting data with the main module.

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COM module
42210
The COM module provides the PROFIBUS functionality of AC412S. This comprises the PROFIBUS
connection and the necessary firmware. The COM module receives the fieldbus data from the main
module via an interface and transfers it to the fieldbus. Simultaneously it receives data from the
fieldbus and transfers it to the main module for further processing.
>
AS-i module
42242
The AS-i module provides the AS-i functionality of AC412S such as receiving, evaluating and
transmitting AS-i telegrams without any logical preprocessing. It contains 2 AS-i masters controlling 2
separate AS-i circuits.
The following number of AS-i slaves can be connected to each AS-i master:
up to 62 non safe AS-i slaves or
up to 31 safe AS-i input slaves or
up to 15 AS-i control slaves to control safe AS-i output slaves
The AS-i module exchanges the data of the safe AS-i slaves with the safety module via the backplane.
All AS-i data is provided to the main module for representation on the display.
>
Safety module
42251
The safety module contains the safety-related hardware of AC412S. The architecture of the safety
module provides the following structural features:
1oo2 hardware architecture (1 out of 2 architecture)
2-channel structure with separate diagnostics in both channels
2-channel safe inputs selectable
1-channel and 2-channel safe outputs selectable
Built-in tests on both safe processing units (safety CPU 1/2)
Hardware failure tolerance (HFT) = 1
The safety module consists of the following components:
Safety CPU PCB with 2 processors for the control technology signal processing (safety CPU1/2)
Safety I/O PCB with a separate voltage supply for the local I/O interface
Both PCBs are separated from each other galvanically. They are supplied from separate voltage
sources.
Both safety CPUs have separate watchdogs and reset circuits. They are interconnected via cross
communication.
Both PCBs are interconnected via a serial interface for bidirectional data exchange.
The safety module has interfaces to the main module and the AS-i module.