AC1004 - Industrial Automation IFM - Free user manual and instructions

Product Type	AS-i controller (AS-i master with preprocessing)
Brand	IFM
Model	AC1004
Category	Industrial automation
Dimensions (L x H x D)	Approx. 100 x 75 x 50 mm (estimate)
Weight	Approx. 200 g (estimate)
Power supply	24 V DC (via +24 V and 0 V terminals)
Protection	IP20, mounting in electrical cabinet
Mounting	On 35 mm rail (DIN)
Communication interfaces	RS232C and RS485 (up to 31 controllers in parallel)
Transmission speed	4800 to 62400 baud (configurable via mode b)
Number of AS-i masters	1 or 2 (depending on version)
Main functions	Control of sensor/actuator data exchange, preprocessing, standalone or gateway mode
Indicators	LEDs: ALARM, CONFIG, NOT AUTO, ADDR, ASI, PWR, COM, MODE, PROJ, MODE, CTRL; 4-segment display
Operating modes	Slave display, addressing, preselection, program stop/start, serial speed setting
Maintenance and cleaning	Avoid condensation, dust, vibrations; do not obstruct ventilation holes
Safety	Disconnect power before connection; do not connect negatives together or to ground; ensure good PE connection
Spare parts and repairability	Not specified; requires qualified intervention

Frequently Asked Questions - AC1004 IFM

How to install the AC1004 controller?

Mount the controller on a 35 mm rail in an electrical cabinet (IP20). Ensure an environment without condensation, excessive dust, vibrations or shocks. Do not block airflow through the ventilation holes.

How to connect the power supply?

Disconnect the installation from power. Connect +24 V and 0 V to the corresponding terminals. Never connect negative potentials together or to ground. Ensure a good connection between the PE terminal and the installation ground.

How to configure the RS485 interface?

The end of the RS485 cable must be equipped with termination resistors: 120 Ω between A and B, 330 Ω from A to +5 V and 330 Ω from B to 0 V. These resistors are integrated and activated via shunts between specific pins of the termination connector.

How to assign an address to an AS-i slave?

Use mode 6: select mode 6 and the master, press SET to scroll through free addresses, confirm with SET. Automatic addressing must be disabled (mode 7 set to 0).

What does the 'ALARM' LED indicator mean?

The ALARM LED lights up if the current configuration is not identical to the preselected configuration or if automatic addressing is blocked. Refer to the diagnostic section to identify the error.

How to reset a faulty slave to address 0?

Switch to mode 5: after selecting the mode and master, press SET until the desired slave is displayed, then confirm with SET. Address 0 is then assigned. Automatic addressing must be disabled.

How to change the transmission speed of the serial interface?

Use mode b: select mode b, press SET until the desired speed is displayed (b_48=4800, b_96=9600, b192=19200 default, b384=38400, b576=57600, b624=62400), then confirm with SET.

How to stop or restart the controller program?

In mode 9: select mode 9, press SET to display STOP (9C-1) or RUN (9C-), confirm with SET. In RUN, the CTRL LED is on; in STOP, it is off.

What are the main error codes displayed?

Errors are displayed as codes in diagnostic mode. Examples: E-01 for AS-i voltage or configuration not OK, E-07 for slave 0 present, E-15 for program not loaded. Refer to the manual for the complete list.

How to unlock advanced modes (beyond mode 4)?

If modes >4 are locked, press both buttons (MODE and SET) simultaneously for about 5 seconds. The digit 1 appears flashing on the LED display to confirm unlocking.

USER MANUAL AC1004 IFM

Functions and features

• The controller integrates 1 or 2 AS-i masters, a mini controller and a field bus interface as an option.
• it controls the data exchange to the sensor/actuator level
• it processes the peripheral data in the integrated processor (signal preprocessing)
• it works as stand-alone controller with data exchange to the PC (visualisation).
• it communicates with the higher-level control system (in the gateway mode)

Programming interface RS232C

• baud rate 4800 to 62400 baud
• max. distance between controller and host: 20m
• no potential separation from the controller supply
• pin connections: pin2: Rxd; pin 3: Txd; pin 5: Gnd

Programming interface RS485

• baud rate 4800 to 62400 baud
• max. distance between controller and host: 1000m
• potential separation from the controller supply
• up to 31 controllers connected in parallel
• pin connections: pin3: signal B; pin 8: signal A

For the programming of an R485 controller the RS232C/RS485 converter (order no. E70071) is necessary in addition to the programming cable (order no. AC4010).

Mounting

Mount the controller onto a 35mm rail. The unit has protection IP20, therefore it should be mounted in a protected place (e.g. switching cabinet).

Ensure a condensation-free environment. Avoid excessive dust, vibration and shock. The circulation of air through the vents must not be hampered.

Electrical connection

Disconnect power. Connect the unit according to the terminal marking. Never connect the minus potentials to each other or the minus potentials and the PE connection.

Ensure an electrically safe ground connection between the AS-i controller (PE terminal) and the ground connection of the unit.

The RS485 cable must be operated with a terminating resistor at both ends because the cable driver is switched with a high-ohmic value in the quiescent condition and in case of a high signal.

Cables A and B are connected via a 120Ω resistor. Cable A is connected to +5V via 330Ω and cable B to OV via 330Ω.

These resistors are already integrated in the AS-i controller. They can be activated via links between pins 5-9, 8-7 and 1-6 in the terminating plug.

After application of the supply voltage all the LEDs and the LED display are switched on (LED test); then the version numbers of the hardware and the software are displayed for 1s each (software version controller and software version AS-i master).

Operating and display elements

actual configuration not the same as preset configuration automatic addressing not released AS-i voltage ok normal operation LED is lit: projecting mode, all slaves activated LED flashing:slave 0 identified, switching into protected mode not possible controller in run mode PC/PLC set mode / parameter acknowledge mode/ parameter slave no. master 1 or 2 modes 1 to C error messages only units with 2 masters ASI-CONTROLLER ifm electronic gmbh-D 45127 Essen Made in Germany ASI 2+ ASI 2- + 24 V 0 V ASI 1+ ASI 1- PE ALARM CONFIG NOT AUTO ADDR ASI PWR COM MODE PROJ MODE CTRL

Diagnosis / adjustment

The AS-i controller is served via the higher-level host (PC). Some functions are accessible locally:

Mode	Action Operating steps
1	display list of failed slaves see error messages
2	display detected slaves 0/1, 0/2, 2 - 4
3	display projected slaves 0/1, 0/2, 2 - 4
4	display activated slaves 0/1, 0/2, 2 - 4
5	allocate address 0 to a slave 0/1, 0/2, 5
6	allocate an address to slave 0 0/1, 0/2, 6
7	auto addressing on / off	0/1, 7
8	project slaves	0/1, 0/2, 8
9	program processing run/stop	0/1, 9
A	address controller	0/1, A
b	set transfer rate of the serial interface	0/1, B
	locking/unlocking modes > 4	locking/unlocking

Assignment of the status nibbles:

Bit no.	Meaning	= 1	= 0
7	signal preprocessing	running	stopped
6	AS-i power / configuration	not o.k.	o.k.
5	running up finished	yes	no
4	reserved

0/1 Select mode

1	[288Y]Mode SetPress several times until requested mode is displayed		Mode display flashing
2	Mode SetAcknowledgment of the requested mode		Display of the selected mode, display master 1 flashing

0/2 Select master:

1

[SYDT]Mioae SetAcknowledgment of master 1

→

Display master 1,display of 1st slave flashing

or:

1

Mode SetPress once

Display of master 2 flashing

2

iviode SetAcknowledgment of master 2

→

Display master 2,display of 1st slave flashing

2/4 Display of identified, projected and activated slaves

1

Select | de and master (operating steps 0/1 and 0/2)

Display master 1, display of 1st slave

2

Mode SetPress several times

Display of other slaves

5 Allocate address 0 to a slave

1	Select mode and master (operating steps 0/1 and 0/2)		Display master, display of 1st slave flashing
2	Mode SetPress several times until requested slave is displayed		5 107Display of slave flashing (here slave 7)
3	Mode SetPress once (= acknowledgment)		5 107Address 0 is stored for selected slave

Automatic addressing must be switched off (mode 7).

6 Allocate an address to slave 0

1	Select mode and master (operating steps 0/1 and 0/2)		Display master,first free slave address flashing
2	Mode SetPress several times until requested address is displayed		Display of selected address flashing (here address 24)
3	Mode SetPress once (= acknowledgment)		New address for slave 0 is stored

7 Auto addressing on/off

= automatic addressing OFF

= simple automatic addressing ON (1 slave can be addressed automatically)

= multiple automatic addressing ON (several slaves can be addressed automatically)

1	Select mode (operating step 0/1)		Display of preset value flashing
2	Mode SetPress several times until requested setting is displayed		Display of newly selected setting flashing (here 1)
3	Mode SetPress once (= acknowledgment)		New setting is stored

8 Project slaves

1	Select mode and master (operating steps 0/1 and 0/2)		81PPDisplay master, display project mode flashing
2	Mode SetPress once (= acknowledgment)		81PPNew configuration is stored

9 Program processing run/stop

= program processing running (RUN mode) (LED "CTRL" = on)

= program processing stopped (STOP mode) (LED "CTRL" = off)

1

Select mode(operating step 0/1)

9C-1Display of modeand preset value

2

Mode SetPress until requested setting is displayed

91C-5Display of newly selected setting (here STOP)

3

Mode SetPress once(= acknowledgment)

91C - 5New setting is stored

A Address controller (default address = 001)

1

Select mode(operating step 0/1)

[IMAGE]Display of presetaddress flashing

2

Mode SetPress several times untilrequested address is displayed

4004Display of new address flashing(here 004)

3

Mode SetPress once(= acknowledgment)

8004New address is stored

The address is only valid for the RS232 interface.

b Set transfer rate of the serial interface

1	Select mode(operating step 0/1)		Display of preset value flashing
2	Mode SetPress several times until requested setting is displayed		Display of newly selected setting flashing (here 96)
3	Mode SetPress once (= acknowledgment)		New setting is stored

Possible settings:b_48 (= 4800 baud), b_96 (= 9600 baud), b192 (= 19200 baud = default), b384 (=38400 baud), b576 (= 57600 baud), b624 (= 62400 baud).

Locking/unlocking modes > 4

1	Select mode (operating step 0/1)		Display of the selected mode
2	Mode SetPress twice		8777Display of locking flashing
3	Mode SetPress once (= acknowledgment)		8777Display locking active

Unlocking: Press both buttons for approx. 5s; as acknowledgment digit 1 is flashing in the LED display.

Error messages

Display of missing/defective slaves

(digit 2 = master; digits 3 and 4 = slave no.); the slaves are displayed at intervals of seconds.

The list of failed slaves can be stored until the slaves have been replaced.

• Press the SET button twice (for the list of master 1) or SET -MODE - SET (for the list of master 2). The lowest address of the error list is displayed flashing.
• Replace the failed slave by a slave with the same configuration and with the address 0; it will receive the indicated address; (the function “multiple automatic addressing” must be activated). If other addresses are displayed, proceed in the same way until the list has been completed.

- The function will be ended when the slaves have been replaced or the SET button has been pressed.

Bus error or timeout at field bus interface

Software version AS-i string 1 ≠AS-i string 2

error during initialisation of the Profibus interface module

AS-i master 2: operating mode already active

AS-i master 2: addressing mode already active

AS-i master 2: error during the setting of the new address

AS-i master 2: error during the deletion of the old address

AS-i master 2: slave with old address does not exist

AS-i master 2: slave with new address exists

AS-i master 2 offline/slave 0 exists

	AS-i master 2 not in the projecting mode
	AS-i master 2 not in the projecting mode
	AS-i master 2 not in the projecting mode/ configuration data not valid
	AS-i master 2 not in the projecting mode
	AS-i master 2: offline
	AS-i master 2: parameter value invalid
	AS-i master 1: operating mode already active
	AS-i master 1: addressing mode already active
	AS-i master 1: error during the setting of the new address
	AS-i master 1: error during the deletion of the old address
	AS-i master 1: slave with old address does not exist
	AS-i master 1: slave with new address exists
	AS-i master 1 offline/slave 0 exists
	AS-i master 1 not in the projecting mode
	AS-i master 1 not in the projecting mode
	AS-i master 1 not in the projecting mode/ configuration data not valid
	AS-i master 1 not in the projecting mode
	AS-i master 1 offline
E-59	AS-i master 1: parameter value invalid
E-60	Master 2 does not exist
E-61	No plc program loaded
E-70	No entry in LDS (list of detected slaves)
E-71	No entry in LPS (list of projected slaves)
E-72	No entry in LAS (list of activated slaves)
E-73	No free slave address available
E-82	Key handling disabled
E-83	Function only possible in the projecting mode
E-90	Slave 0 does not exist
E-91	Target address already allotted
E-92	New address could not be allotted
E-93	Multiple automatic addressing not active
E-94	I/O configuration ≠projected configuration
E-95	Incorrect ID code (does not correspond to projected value)
E-96	Addressing not possible since "automatic addressing" has not been activated
E-97	Addressing not possible, slaves are missing
E-98	Protected operating mode is not active
E-99	Slave 0 already exists

Controllers with one master (AC1003, AC1007)

Input Rating

24V DC 80mA

Output Rating

± 3V DC

Electrical ratings

Controllers with two masters (AC1004, AC1017)

Input Rating

24V DC 80mA

Output Rating

± 2 × 3V DC