IFM AL4002 User manual

Operating instructions
Remote I/O module 16 DI
PROFINET
IP65 / IP66 / IP67
AL4002
11425600 / 0004 / 2022
GB

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Contents
1 Preliminary note ............................................................. 5
2 Safety instructions............................................................ 6
2.1 Cyber security.......................................................... 6
3 Intended use................................................................ 7
4 Function ................................................................... 8
4.1 Visual indication ........................................................ 8
4.2 Parameter setting....................................................... 8
4.3 Inputs................................................................ 8
4.3.1 Sensor supply...................................................... 8
4.4 Digital input filters....................................................... 8
4.4.1 Debouncing........................................................ 9
4.4.2 Holding........................................................... 9
4.4.3 Inverting .......................................................... 10
4.4.4 Filter combination................................................... 10
4.5 Counters.............................................................. 10
4.5.1 Counter mode CTU.................................................. 10
4.5.2 Counter mode CTD.................................................. 11
4.5.3 Counter mode CTUD ................................................ 11
4.5.4 Counter mode CTDIR................................................ 12
4.6 PROFINET............................................................ 12
5 Installation.................................................................. 14
5.1 Install device........................................................... 14
6 Electrical connection.......................................................... 15
6.1 Overview.............................................................. 15
6.2 General wiring information ................................................ 15
6.2.1 Connection technology............................................... 15
6.3 Ethernet .............................................................. 15
6.4 Process connections..................................................... 16
6.5 Voltage supply ......................................................... 16
6.5.1 Derating behaviour.................................................. 17
7 Operating and display elements................................................. 18
7.1 LEDs................................................................. 18
7.1.1 Status............................................................ 18
7.1.2 Ethernet .......................................................... 18
7.1.3 Voltage supply ..................................................... 19
7.1.4 Process connections................................................. 19
8 Set-up..................................................................... 20
9 Settings.................................................................... 21
9.1 Parameter setting software................................................ 21
9.1.1 Supported parameter setting software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1.2 Getting started ..................................................... 21
9.1.2.1 Configure the PROFINET interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1.3 Fieldbus: Read the interface configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1.4 Fieldbus: Read the connection status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1.5 Ports: Configure input filters ........................................... 22
9.1.6 Ports: Read digital input data .......................................... 23
9.1.7 Counters: Configure counter modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.1.8 Counters: Read counter values......................................... 25
9.1.9 Counters: Control counter modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1.10 Gateway: Read identification information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1.11 Gateway: Read status and diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1.12 Gateway: Set the application tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1.13 Firmware: Read firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1.14 Firmware: Reset the device............................................ 27
9.1.15 Firmware: Restart the device .......................................... 27
9.2 ifm IoT Core ........................................................... 28

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9.2.1 ifm IoT Core: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.2.1.1 Accessing the ifm IoT Core....................................... 28
9.2.2 Getting started ..................................................... 30
9.2.2.1 Notes on configuration .......................................... 30
9.2.3 General functions................................................... 30
9.2.3.1 Example: Outputting the subtree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.2.3.2 Example: Reading several elements sequentially . . . . . . . . . . . . . . . . . . . . . . 31
9.2.3.3 Example: Changing a parameter value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2.4 Fieldbus: Read the interface configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2.5 Ports: Configure input filters ........................................... 33
9.2.6 Ports: Read digital input data .......................................... 33
9.2.7 Counters: Configure counter modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2.8 Counters: Control counters............................................ 34
9.2.9 Counters: Read and write counter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2.9.1 Example: Write counter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2.10 Gateway: Read device information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2.11 Gateway: Read status and diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.2.12 Gateway: Set the application tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.2.13 Gateway: Update firmware............................................ 36
9.2.14 IoT-Core Visualizer.................................................. 37
9.2.14.1 Start the ifm IoT Core Visualizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2.14.2 Search for elements in the device description . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2.14.3 Configure the device............................................ 38
9.2.14.4 Access process data............................................ 38
9.2.14.5 Update firmware............................................... 38
9.3 PROFINET............................................................ 40
9.3.1 Install the GSD file .................................................. 40
9.3.2 Integrate the device into a PROFINET project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.3.2.1 Use S2 redundancy............................................. 40
9.3.2.2 Use Configuration-in-Run........................................ 40
9.3.2.3 Use Isochronous Realtime (IRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3.3 Configure the device................................................. 41
9.3.3.1 Use Prioritized Startup .......................................... 41
9.3.3.2 Use Fast Startup............................................... 41
9.3.4 Configure input filters ................................................ 42
9.3.5 Configure counter modules............................................ 43
9.3.6 Read process data of the ports......................................... 44
9.3.7 Read counter values................................................. 44
9.3.8 Control counters.................................................... 44
9.3.9 Acyclic access...................................................... 45
9.3.10 Read counter events................................................. 45
9.3.11 Use I&M data records................................................ 46
10 Maintenance, repair and disposal................................................ 47
10.1 Cleaning.............................................................. 47
10.2 Update firmware........................................................ 47
11 Appendix................................................................... 48
11.1 ifm IoT Core ........................................................... 48
11.1.1 Profiles........................................................... 48
11.1.2 Types ............................................................ 48
11.1.3 Services .......................................................... 48
11.1.3.1 Service: factoryreset............................................ 48
11.1.3.2 Service: force_counter_values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1.3.3 Service: getblobdata............................................ 49
11.1.3.4 Service: getdata ............................................... 49
11.1.3.5 Service: getdatamulti............................................ 49
11.1.3.6 Service: getelementinfo.......................................... 50
11.1.3.7 Service: getidentity............................................. 50
11.1.3.8 Service: gettree................................................ 50
11.1.3.9 Service: install................................................. 51
11.1.3.10 Service: querytree.............................................. 51
11.1.3.11 Service: reboot................................................ 52

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11.1.3.12 Service: setblock............................................... 52
11.1.3.13 Service: setdata ............................................... 52
11.1.3.14 Service: signal................................................. 52
11.1.3.15 Service: start_stream_set........................................ 52
11.1.3.16 Service: stream_set ............................................ 53
11.2 PROFINET............................................................ 54
11.2.1 Parameters........................................................ 54
11.2.1.1 Modules: 8x2DI + Qualifier....................................... 54
11.2.1.2 Modules: Counter module........................................ 55
11.2.2 Cyclic data ........................................................ 59
11.2.2.1 Modules: 8x2DI + Qualifier....................................... 59
11.2.2.2 Submodule: CTU .............................................. 60
11.2.2.3 Submodule: CTD .............................................. 61
11.2.2.4 Submodule: CTUD ............................................. 62
11.2.2.5 Submodule: CTDIR............................................. 63
11.2.3 Acyclical data ...................................................... 64
11.2.3.1 Data record: Filter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
11.2.3.2 Data record: Counter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.2.3.3 Data record: Counter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.2.3.4 I&M data..................................................... 67

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1 Preliminary note
You will find instructions, technical data, approvals and further information using the QR code on the
unit / packaging or at www.ifm.com.

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2 Safety instructions
• The unit described is a subcomponent for integration into a system.
– The system architect is responsible for the safety of the system.
– The system architect undertakes to perform a risk assessment and to create documentation in
accordance with legal and normative requirements to be provided to the operator and user of
the system. This documentation must contain all necessary information and safety instructions
for the operator, the user and, if applicable, for any service personnel authorised by the
architect of the system.
• Read this document before setting up the product and keep it during the entire service life.
• The product must be suitable for the corresponding applications and environmental conditions
without any restrictions.
• Only use the product for its intended purpose (Ò Intended use).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage
to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with
the product or incorrect use by the operator.
• Installation, electrical connection, set-up, operation and maintenance of the product must be
carried out by qualified personnel authorised by the machine operator.
• Protect units and cables against damage.
• Replace damaged units, otherwise the technical data and safety will be impaired.
2.1 Cyber security
ATTENTION
Operating the machine in an unprotected network environment
wUnauthorised read or write access to data is possible.
wUnauthorised manipulation of the device function is possible.
uCheck and restrict access options to the device.

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3 Intended use
The unit may only be used for the following purposes:
• Gateway between digital sensors and a higher-level control system
The device is designed for use outside of a control cabinet.

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4 Function
4.1 Visual indication
The device displays the following indications:
• Status and error indication of the gateway and the system
• Status and activity indication of the Ethernet connection
• Status display of the voltage supply
• Status, error and short circuit/overload indication of the sensor ports
4.2 Parameter setting
The device can be configured using the following options:
• parameter setting software
– ifmmoneo
– ifm moneo|configure SA
• ifm IoT Core
– REST-API
– IoT-Core Visualizer
• PROFINET projection software
4.3 Inputs
The device has 8 ports. Each port has 2 digital inputs.
4.3.1 Sensor supply
The device has a total of 8 sensor supplies (1 sensor supply per port).
4.4 Digital input filters
The device supports preprocessing of the digital input signals. The filter result is forwarded as a
process value. The following filters can be applied to the input signals in the sequence specified.
1. Debouncing
2. Stretching
3. Inverting
Digital input Debouncing Stretching Inverting
Counter input
Process data
Filter module
Each filter can be configured separately.
The device detects signals of a length of min. 0.23 ms. Shorter signals are not detected.

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Periodic signals are only detected reliably if the signal period is at least twice as long as the
cycle time.
4.4.1 Debouncing
The filter suppresses noise signals. The filter provides the input signals at the filter output with a delay
(debounce time). All signals shorter than the set debounce time are ignored by the filter.
Time diagram debounce filter:
2
11 11
0
1
0
1
0
1
t
Process data
Filter output
Filter input
1: debounce time
2: cycle time
4.4.2 Holding
The filter prolongs short input pulses. Level changes that occur during a holding period are ignored.
The filter is configured via the following parameters:
• Hold time: pulse duration to which short pulses are to be prolonged. Pulses that are present for a
longer time than the hold time are not prolonged.
• Hold level: signal level to be prolonged (HIGH or LOW)
Time diagram hold filter (status HIGH):
2
1 1 1
0
1
0
1
0
1
t
Process data
Filter output
Filter input
1: hold time
2: cycle time
Time diagram hold filter (status LOW):
2
1 1 1
0
1
0
1
0
1
t
Filter input
Filter output
Process data
1: hold time
2: cycle time

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4.4.3 Inverting
The filter inverts signals.
4.4.4 Filter combination
The filters can be combined.
Example: All 3 filters are activated
Time diagram:
0
1
0
1
0
1
0
1
0
1
t
1
Digital input
Filter Debounce
Filter Hold
Filter Inverter
Process data
Digitaleingang
Filter Entprellen
Filter Halten
Filter Invertieren
Prozessdaten
1: cycle time
4.5 Counters
The device features one counter module per port.
A counter module consists of 2 separate counters:
• Main counter: The main counter counts the rising edges of the filtered digital input signals. The
main counter has a value range that is defined by a threshold value. If the value range of the main
counter is exceeded or not reached, an overflow or underflow signal is sent to the batch counter.
• Batch counter: The batch counter counts the overflow or underflow signals of the main counter.
Filter module pin 4
Filter module pin 2
Count input
Count input/
control input
Main counter
Batch counter
Process data
Process data
Counter module
A counter module can be operated in different operating modes. The following operating modes are
available.
4.5.1 Counter mode CTU
In CTU (Count Up) mode, the counter module operates as an up counter with overflow detection and
overflow counter.
Behaviour:
• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The
main counter has a threshold value CT. The batch counter has a threshold value CTb.

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• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is
incremented (m = m+1).
• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).
Due to the overflow detection, the value of the batch counter is incremented (b = b+1).
• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).
CTb
CT
0
0
t
Main Counter
Batch Counter
4.5.2 Counter mode CTD
In CTD (Count Down) mode, the counter module operates as a down counter with underflow detection
and underflow counting.
Behaviour:
• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The
main counter has a threshold value CT. The batch counter has a threshold value CTb.
• The first time a positive edge is detected at pin 4, the value of the main counter is set to the
threshold value CT-1 (m = CT-1). At the same time, the value of the batch counter is set to the
threshold value CTb-1 (b = CTb-1).
• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is
decremented (m = m-1).
• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due
to the underflow detection, the value of the batch counter is decremented (b = b-1).
• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).
CTb
CT
0
0
t
Main Counter
Batch Counter
4.5.3 Counter mode CTUD
In CTUD (Count Up Down) mode, the counter operates as a simultaneous up and down counter with
overflow and underflow detection.
Behaviour:
• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The
main counter has a threshold value CT. The batch counter has a threshold value CTb.
• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is
incremented (m = m+1).
• If the counter module detects a positive edge at pin 2 of the port, the value of the main counter is
decremented (m = m-1).

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• If the counter module simultaneously detects a positive edge at pin 4 and pin 2 of the port, the
counter value of the main counter does not change.
• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).
Due to the overflow detection, the value of the batch counter is incremented (b = b+1).
• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due
to the underflow detection, the value of the batch counter is decremented (b = b-1).
• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).
• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).
CTb
CT
0
0
t
Main Counter
Batch Counter
4.5.4 Counter mode CTDIR
In CTDIR (Count Direction) mode, the counter module operates either as an up counter with overflow
detection or as a down counter with underflow detection. The counting direction can be set.
Behaviour:
• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The
main counter has a threshold value CT. The batch counter has a threshold value CTb.
• The user can determine the counting direction. The counter module initially operates as an up
counter with overflow detection.
• If the counter module detects a positive edge at pin 4 of the port and the counting direction of the
port is set to “up”, the value of the main counter is incremented (m = m+1).
• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).
Due to the overflow detection, the value of the batch counter is incremented (b = b+1).
• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).
• If the counter module detects a positive edge at pin 4 of the port and the counting direction at pin 2
of the port is set to “down”, the value of the main counter is decremented (m = m-1).
• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due
to the underflow detection, the value of the batch counter is decremented (b = b-1).
• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).
CTb
CT
0
0
t
Main Counter
Batch Counter
4.6 PROFINET
Supported PROFINET functions:

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• Device profile: PROFINET IO device
• Fast Startup (FSU)
• Prioritized Startup
• Participation in network with activated IRT protocol
• System redundancy S2
• Dynamic reconfiguration
• Device description: GSD file

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5 Installation
5.1 Install device
uDisconnect the power of the machine before installation.
uUse a flat mounting surface for installation.
uPlease observe the maximum tightening torque.
uFasten the module onto the mounting surface using M5 screws and washers (tightening torque: 1.8
Nm).

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6 Electrical connection
6.1 Overview
X22
X02
X04
X06
X08X07
X05
X03
X01
X31
X21
X21: Ethernet 1 (PROFINET)
X22: Ethernet 2 (PROFINET)
X31: power IN
X01: process connection 1 (sensor)
X02: process connection 2 (sensor)
X03: process connection 3 (sensor)
X04: process connection 4 (sensor)
X05: process connection 5 (sensor)
X06: process connection 6 (sensor)
X07: process connection 7 (sensor)
X08: process connection 8 (sensor)
6.2 General wiring information
The unit must be connected by a qualified electrician.
uObserve the national and international regulations for the installation of electrical equipment.
The device is only suitable for operation using SELV/PELV voltages.
This device contains components that may be damaged or destroyed by electrostatic discharge
(ESD).
uPlease observe the required precautions against electrostatic discharge.
The circuits are insulated from each other and from touchable surfaces of the device with basic
insulation according to EN61010-1.
The communication interfaces are insulated from each other and from touchable surfaces of the
device with basic insulation according to EN61010-1.
6.2.1 Connection technology
The threaded connections in the device correspond to the M12 standard. To ensure compliance with
the specified protection rating, only cables that comply with this standard may be used. In the case of
self-assembled cables, the system manufacturer is responsible for the protection rating.
uUse connectors with gold-plated contacts.
uDuring installation, place the connectors vertically so that the coupling nut will not damage the
thread.
uObserve the coding of the connectors during installation.
uCover unused connections with protective covers. Tightening torque: 0.3 ± 0.1Nm
6.3 Ethernet
The device is connected to the PROFINET network via the Ethernet ports X21 / X22 (e.g. PROFINET
control, additional PROFINET device). In addition, the device can be connected to an IT network via
the Ethernet ports. Via the IT network, the user can access functions of the ifm IoT Core (configuration
tools, REST API, IoT Core Visualizer).

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uConnect the device to the PROFINET network via a free Ethernet port.
uOptional: Connect the device to the IT network via a free Ethernet port.
uFor connection, use an M12 connector (with at least protection rating: IP65 / IP66 / IP67).
uTighten the cable plug using 1.3 ± 0.1Nm.
Wiring:
1 2
34
5
1: TX+
2: RX+
3: TX-
4: RX-
5: not used
6.4 Process connections
The sensors are connected to the device via the process connections.
The total current supply of the ports X01...X08 is limited to 3.6 A.
The ports feature short-circuit/ overload detection.
uConnect the sensors to ports X01...X08.
uFor connection, use M12 connectors (with at least protection rating: IP65 / IP66 / IP67; max. cable
length: 30m).
uTighten the cable plug using 1.3 ± 0.1Nm.
Wiring:
3
1 2
4
5
1: sensor supply L+ (US)
2: digital output 2 (DI2)
3: sensor supply L- (US)
4: digital output 1 (DI1)
5: functional earth (FE)
6.5 Voltage supply
The device is connected to the supply voltage US via the power IN port.
The US supply voltage supplies the device and the sensors connected to the ports X01...X08 with
voltage.
Port X31 has overvoltage protection (US).
Port X31 has reverse polarity protection (US).
Port X31 has an inrush current limitation.
uDisconnect power!
uConnect the device via port X31 to 24VDC (20…30V SELV/PELV).
uFor connection, use an L-coded M12 connector (with at least protection rating: IP65 / IP66 / IP67).
uTighten the cable sockets according to the torque specifications indicated by the cable
manufacturer. Maximum permissible tightening torque: 0.8Nm
uObserve the derating behaviour of the device (Ò Derating behaviour/17).
Wiring:
43
2 1
1: +24VDC (US)
2: not used
3: GND (US)
4: not used

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6.5.1 Derating behaviour
The current IUS available at ports X01...X08 depends on the ambient temperature of the device.
-40 -30 -20 -10 0 10 20 30 40 50 60 70
1
2
3
4
2000 m
3000 m
4000 m
Current [A]
Temperature [°C]
0.5
1.5
2.5
3.5
1
1: IUS at ports X01...X08

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7 Operating and display elements
7.1 LEDs
2 3
4
5
8
1
4
5
6
6
6
66
6
6
6
7
7
7
77
7
7
7
1: status: RDY
2: status: BF
3: status: SF
4: PROFINET: LNK
5: PROFINET: ACT
6: process connection: DI1
7: Process connection: DI2
8: voltage supply: US
7.1.1 Status
LED Description Colour State Description
RDY Gateway status - Off Not active or reboots
Green Flashes 3s (1Hz) DCP signalling service initiated via fieldbus
Flashes (5Hz) Error
Flashes (200ms
on, 800ms off)
Firmware update running
On OK
Red On Error during firmware update (e.g. firmware not compatible)
BF PROFINET connec-
tion status (bus fail-
ure)
Red Off No error
Flashes (2Hz) No data transmission
On • No configuration or
• physical connection with low speed or
• no physical connection
SF System status (sys-
tem failure)
Red Off No error
Flashes 3s (1Hz) DCP signalling service initiated via fieldbus
On • Watchdog expired or
• channel diagnosis, general or extended diagnosis
available or
• system error
7.1.2 Ethernet
LED Description Colour State Description
LNK Status of the con-
nection
Green Off no Ethernet connection

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LED Description Colour State Description
LNK Status of the con-
nection
Green On Ethernet connection established
ACT Status of the data
transmission
Yellow Off no data transmission
Flashes Data transmission
7.1.3 Voltage supply
LED Description Colour State Description
US Voltage supply sta-
tus
- Off No supply voltage is applied or the applied supply voltage is
too low
Green On Supply voltage applied
Red On Overvoltage, undervoltage, short circuit at sensor supply
7.1.4 Process connections
LED Description Colour State Description
DI1 Digital input signal
level (pin 4)
Yellow Off Digital input - pin 4: LOW
On Digital input - pin 4: HIGH
DI2 Digital input signal
level (pin 2)
Yellow Off Digital input - pin 2: LOW
On Digital input - pin 2: HIGH

AL4002 Remote I/O module 16 DI
20
8 Set-up
uInstall the unit correctly.
uEstablish a correct electrical connection with the device.
wOnce connected to the supply voltage, the unit will start.
wThe LEDs show status and error conditions.
wThe unit is ready for operation.
wThe device can be configured.