AC505S - Sensor IFM - Free user manual and instructions

USER MANUAL AC505S IFM

Original operating instructions Safe AS-Interface module Classic
Line

AC507S

Contents

1 Preliminary note 3

1.1 Symbols used 3
1.1.1 Safety symbol on the device 3
1.2 Warnings.... 3

2 Safety instructions.... 4

2.1 Safety-related requirements regarding the application 4

3 Transport, handling and storage 5
4 Items supplied.... 6
5 Intended use.... 7
6 Function description 8
7 Installation.... 9

7.1 General notes on wiring 14
7.2 Removing the connector with vibration protection 15

8 Electrical connection.... 16

8.1 Pin assignment 16
8.2 Functional earth 17
8.3 Wiring examples 17
8.4 Electronic contacts 18

9 Operating and display elements 20

9.1 Troubleshooting 20

10 Parameter setting 21

10.1 Addressing 21

11 Operation 22

11.1 Data bits 22
11.2 Parameters 23
11.3 Response times 24

12 Technical data.... 25
13 Approvals / certificates 29
14 Maintenance, repair and disposal 30

1 Preliminary note

You will find instructions, technical data, approvals, accessories and further information using the QR code on the device / packaging or at documentation.ifm.com.

1.1 Symbols used

√ Requirement
Instructions
Reaction, result

[...] Designation of keys, buttons or indications

→ Cross-reference

Important note

Non-compliance may result in malfunction or interference.

Information

Supplementary note

1.1.1 Safety symbol on the device

Safety symbol on the device:

▶ Adhere to the operating instructions for the safe operation of the unit.

1.2 Warnings

Warnings indicate the possibility of personal injury and damage to property. This enables safe product handling. Warnings are graded as follows:

WARNING

Warning of serious personal injury

▷ If the warning is not observed, fatal and serious injuries are possible.

CAUTION

Warning of minor to moderate personal injury

▷ If the warning is not observed, minor to moderate injuries are possible.

ATTENTION

Warning of damage to property

▷ If the warning is not observed, damage to property is possible.

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 (→ 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.
• Observe applicable documents.

2.1 Safety-related requirements regarding the application

It must be ensured that the safety requirements of the respective application correspond to the requirements stated in these instructions.

Observe the following requirements:

▶ Adhere to EN 14119 for interlocking devices associated with guards.
▶ Adhere to the specified operating conditions ( → Technical data). Use of the device in the vicinity of chemical and biological media is not permitted.
▶ In case of faults within the device which result in the defined safe state: Take measures to maintain the safe state when the complete control system continues to be operated.

Installation must be in accordance with EN 60204 and EN 62026-2.

If an AS-i network is controlling a machine with potentially dangerous movements and EN 60204-1 applies, a special insulation monitoring device must also be installed.

▶ Disconnect the device externally before handling it. Also, disconnect any independently supplied relay load circuits.
▶ In case of faults within the device which result in the defined safe state: Take measures to maintain the safe state when the complete control system continues to be operated.
▶ After installation of the system perform a complete function check.

3 Transport, handling and storage

▶ Store the device in its original packaging.
▶ When the device is to be stored again, use the original packaging.
▶ Otherwise, provide unused connections with either a mating connector or a protective cap and pack the device in suitable packaging.
▶ Observe the permissible ambient conditions for the device during storage ( → Technical data).
▶ In case of return shipment, ensure that the unit is free from soiling, especially from dangerous and toxic substances.

4 Items supplied

• 1 safe AS-i module AC507S
• 1 original operating instructions AC507S
• 1 EU Declaration of Conformity

If one of the above-mentioned components is missing or damaged, please contact one of the ifm branch offices.

5 Intended use

The safe AS-i module detects safety-related switching states of an ESPE (electro-sensitive protective equipment) with two self-testing semiconductor outputs (OSSD), e.g. fail-safe inductive sensors, safe light grids, safe light curtains, etc.

For this purpose, a code table is transferred via the AS-i system with 8 x 4 bits which is evaluated by the safety monitor.

The safety function of the device is achieved by the closed-circuit current principle (input disconnected = safe state).

The device can be used in applications up to Performance Level e, category 4 to ISO 13849-1 and SIL 3 to IEC 61508.

Depending on the safety components used the complete safety system can also be classified for a lower Performance Level PL or Safety Integrity Level SIL.

Application area taking into account the technical data:

• Industrial environments
- Wet environments
• Indoor use without control cabinet

6 Function description

The products described here are designed to be components of a safety-oriented machine or control system. A complete safety-related system normally includes sensors, evaluation units, signalling components and concepts for safe switch-off. It is the responsibility of each manufacturer of a machine or installation to ensure a correct functioning of the whole system. The manufacturer of the safe AS-i module, his subsidiaries and affiliates are not in a position to ensure all of the characteristics of a given machine or product not designed by it.

The manufacturer accepts no liability for any recommendation that may be implied or stated herein.

The warranty contained in the contract of sale is the sole warranty. Any statements contained herein do not create new warranties or modify existing ones.

All information in the description of the configuration software, the original operating instructions for the AS-i safety monitor and the original operating instructions for the device must be adhered to. These documents provide all the required instructions regarding installation, configuration, operation and maintenance of the safe AS-i module.

Information on the configurable safety functions of the safe AS-i control cabinet module can be found in the chapter Monitoring devices of the configuration software manual.

Maintenance requirement

A minimum of one testing per year is compulsory by a demand on the safety function.

▶ Test both inputs individually.

7 Installation

▶ Disconnect power before installation.

The device is preferably designed for DIN rail mounting.

Alternatives:

• Mount the device directly using the mounting plate with two screws.
• Use an optional mounting plate that replaces a rail (accessories: www.ifm.com).

Fig. 1: DIN rail mounting

Fig. 2: Removal from the DIN rail

▶ Open the device using a tool (e.g. screwdriver).

CAUTION

Risk of injury from piercing contacts that are sharp-edged due to their function when the device is opened.

▶ Take special care during installation.

▶ Carefully place the yellow AS-i flat cable into the profile slot.

▶ Fit the upper part.

▶ Lock the device.

With the supplied lower part the flat cable can be aligned in three directions. Insert the flat cable guide for the required direction.

Settings at the lower part
▶ Select the required orientation of the flat cable - Position 1, 2 or 3.

Fig. 3: Factory setting

Settings at the upper part

▶ Set the selected position at the upper part.
▶ Rotate the triangle to the corresponding number (image 1 and 2).

▶ Use a tool, e.g. a screwdriver (image 1) or the yellow-black flat cable guide (image 2).

②

▶ Take care in laying the AS-i flat cable, it should be laid straight for about 15 cm.

7.1 General notes on wiring

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.

▶ Use connectors with gold-plated contacts.
▶ During installation, place the connectors vertically so that the coupling nut will not damage the thread.
▶ Observe the coding of the connectors during installation.

If sockets in the device:

▶ Tighten the cable plug using 0.6...0.8 Nm.

▶ Cover unused connections with protective covers. Tightening torque: 0.6...0.8 Nm

Cover the addressing interface using the supplied protective cap. Tightening torque 0.6...0.8 Nm.

▶ Provide all outgoing cables with suitable strain relief after a maximum of 200 mm. Observe the minimum bending radius of the cables ( → information from the cable manufacturer).

The IP rating of the overall system depends on the protection ratings of the individual devices, the applied connection elements and the corresponding protective caps.

Attach a flat cable seal if the module is at the end of the cable line (to be ordered separately).

ATTENTION

No protection rating / no protection of the contacts without mounted connectors / protective caps.

▷ Inadmissible soiling / moisture possible.
▶ Before installation / when replacing the device, observe pollution degree 2.

7.2 Removing the connector with vibration protection

▶ Press the connector against the unit and simultaneously loosen the coupling nut.

8 Electrical connection

The unit must be connected by a qualified electrician.

Observe the national and international regulations for the installation of electrical equipment.

Voltage supply according to SELV, PELV.

▶ Disconnect power.

▶ Disconnect any independently supplied relay load circuits, if necessary.

Do not connect inputs and outputs to an external potential.

8.1 Pin assignment

	M12 socket 1 (receiver)	Pin
	Supply +24 V	1
	OSSD2	2
	Supply 0 V	3
	OSSD1	4
	FE	5

	M12 socket 2	Pin
	n.c. (not used)	1
	O-4	2
	Supply 0 V	3
	O-3	4
	n.c. (not used)	5

	M12 socket 3 (transmitter)	Pin
	Supply +24 V	1
	0 V	2
	Supply 0 V	3
	Supply + 24 V test	4
	FE	5

	M12 socket 4	Pin
	n.c. (not used)	1
	n.c. (not used)	2
	Supply 0 V	3
	O-4	4
	n.c. (not used)	5

The pin connection of the "transmitter" socket on the module allows the protected area width of an ESPE (electro-sensitive protective equipment) to be set to "range high".

The configuration signal on the AS-i module for setting the protected area width is not safety-related.

If the protected area width is to be set to "range low", use an EY3092 adapter cable which can be ordered separately.

ESPE receivers usually have an 8-pole M12 connector.

Use an adapter cable for connection to a 5-pole M12 socket. The EY3090 adapter cable which can be ordered separately is rated for the automatic operating mode of the ESPE.

8.2 Functional earth

	Functional earthing tasks and applications
	Functional earthing improves electromagnetic compatibility Discharge of interference currents Establishing a common reference potential Connection of shields to this potential

8.3 Wiring examples

Connection of light grids or light curtains

1: Socket 3

3: Transmitter

2: Socket 1

4: Receiver

Connection of a laser scanner

1: Socket 3

2: Socket 1

3: Laser scanner

Connection of a fail-safe inductive sensor

1: Socket 3

2: Socket 1

3: Fail-safe inductive sensor

8.4 Electronic contacts

The safe inputs correspond to type 2 digital inputs of EN 61131-2.

The electronic switching contacts are connected via the SI-1/2 socket.

The device supports the connection of fail-safe electronic sensors with 2 OSSD outputs. The duration of the switch-off test pulses of electronic sensors must not be longer than 1 ms.

Ensure a safe separation between the external LED and the normally closed contact. In the configuration software for the safety monitor the monitoring modules can be used as dual-channel positively guided module, dual-channel dependent module and dual-channel dependent module with filtering.

Do not connect any of the pins to an external potential since they are electrically connected to the AS-i cable.

The wiring influences the achievable Performance Level PL or the Safety Integrity Level SIL. The requirements for Performance Level d to ISO 13849-1 or SIL 2 to IEC 61508 are met.

Performance Level e according to ISO 13849-1 or SIL 3 to 61508 can be reached if both outputs of the protective equipment feature cross-fault monitoring.

If the protective equipment does not provide this feature, the cabling between the contacts to be monitored and the module must be selected in a way to exclude cross faults between the wires (see ISO 13849-2).

9 Operating and display elements

1: Addressing interface

2: 4 M12 sockets

3: LEDs

4: Labels

5: Transmitter

9.1 Troubleshooting

The LEDs of the safe AS-i module indicate faulty operating states.

10 Parameter setting

10.1 Addressing

▶ Address the module via the AC1154 addressing unit.

When mounted and wired the module can be addressed with an addressing cable via the integrated addressing interface.
▶ Assign a free address between 1 and 31.

The address is set to 0 at the factory.

11 Operation

▶ Avoid build-up of dirt and dust on the upper and lower parts so that the locking mechanism is not affected.

1: PWR LED, green

2: FAULT LED, red

3: O1... O4 output LEDs

4: Input LEDs, yellow

O1, O2 alarm LEDs, red

O3, O4 signal output LED, yellow

LED designation	LED state	Colour	Operating status
FAULT	flashes	red	peripheral fault, e.g. overload or short circuit of the sensor supply
	on	red	AS-i communication error, slave does not participate in the "normal" exchange of data, e.g. slave address 0
PWR	off	green	no voltage
	on	green	voltage supply OK
Alarm O1, O2	on	red	alarm outputlogic state of the alarm LED outputs O1 and O2
Signal output O3, O4	on	yellow	signal outputlogic state of the signal outputs O3 and O4
Input	off	yellow	safety contact opened
	on	yellow	safety contact closed

LED indications are no safe information.

Overload and short circuit of the input and output are signalled to the AS-i master (from version 2.1) via the “peripheral fault” flag in the status register.

11.1 Data bits

Data bit	D3	D2	D1	D0
Input	SI-2	SI-2	SI-1	SI-1
Output	Output O-4	Output O-3	LED alarm O-2	LED alarm O-1

The output bits D0... D3 are intended for signalling. Bits D0 and D1 have effect on the red alarm LEDs on the front panel (O-1, O-2) and can be used for signalling directly on the module.

Bits D2 and D3 have effect on the switching outputs O-3 and O-4 and can be used for external alarm LEDs, e.g. muting function blocks.

WARNING

Ensure safe separation between the safety-related NC contact circuit and the connections of the external alarm LED.

▷ Observe all notes on installation and handling in these instructions.
▶ The device must only be used under the specified operating conditions and in accordance with use as prescribed.

Activated input channel	Bit sequence D3-D0
SI-1	XX00
SI-2	00XX
SI-1 and SI-2	0000
None	XXXX

Activated alarm output	Bit sequence D3-D0
O-1	XXX1
O-2	XX1X

Activated output channel	Bit sequence D3-D0
O-3	X1XX
O-4	1XXX

X = random

The code words 0000, XX00 and 00XX cause the AS-i safety monitor to bring the installation into the safe state.

For more details on the effect of the data bits on the transmission sequence refer to the configuration software manual ASIMON (chapter Monitoring devices).

11.2 Parameters

The module allows the current module parameters to be read and informs which of the two switching contacts to be connected was opened during the demand on the safety function.

This parameter information is not part of the safe AS-i transmission and should not be treated as safe data transmission.

It must in no case be linked with any safety functions nor evaluated in this context.

Assignment of the parameter bits

Parameter bit	P0	P1	P2	P3
Switching contact socket	SI-1	SI-2	not used	not used

Meaning of the logic states P0... P3

1: Contact closed
0: Contact open

11.3 Response times

The response time of the safe AS-i module for a safety demand is max. 10 ms. For the calculation of the response time of the complete system the response times of the other components also have to be added (mechanical contacts, safety monitor and external relays or contactors possibly connected to the safety monitor output).

12 Technical data

AC507S

Safe AS-Interface Classic
Line module with quick mounting technology

ClassicL 2SI 2DOT 2LO OSSD

Application

Design	housing for DIN rail mounting
Application	AS-i Safety at Work

Electrical data

Operating voltage	[V]	26.5...31.6 DC; ("supply class 2" to cULus)
Max. current consumption from AS-i	[mA]	280
Protection class		III
Reverse polarity protection		yes; (AS-i)
Reverse polarity protection		yes
Max. current load per module/slot	[A]	0.2
Integrated watchdog		yes

Inputs / outputs

Number of inputs and outputs

Number of digital inputs: 2; Number of digital outputs: 2

Inputs

Number of digital inputs		2; (2 x safety input)
Input circuit of digital inputs		PNP
Sensor supply of the inputs		AS-i
Power supply	[V]	19.2...30
Max. total current rating of inputs	[mA]	200
Input current limitation	[mA]	8
Input current High	[mA]	>6

AC507S

Safe AS-Interface Classic
Line module with quick mounting technology

ClassicL 2SI 2DOT 2LO OSSD

Input current Low	[mA]	< 2
Switching level high	[V]	>11
Switching level low	[V]	< 5
Overload protection digital inputs		yes
Short-circuit detection		yes
Cross-fault monitoring		no
Short-circuit proof		yes

Outputs

Output signal		switching signal
Number of digital outputs		2
Voltage range DC	[V]	18...28.8; (AS-i)
Max. current load per output	[mA]	50
Short-circuit protection		yes
Short-circuit proof		yes
Overload protection		yes
Electrically separated		no
Actuator supply outputs		AS-i

Operating conditions

Ambient temperature [°C]		-25...55
Note on ambient temperature		with switched outputs: -25...40 °C
Max. relative air humidity [%]		95
Max. height above sea level [m]		2000
Protection		IP 67
Pollution degree		2

Tests / approvals

EMC	EN 62026-2
	EN 61326-3-1
Shock resistance	EN 60068-2-27
Vibration resistance	EN 60068-2-6

Safety classification

Complies with the requirements	ISO 13849-1 category 4, PL e
	IEC 61508 SIL 3
Mission time TM (additional indication)	20 years
PFH [1/h]	2,33E-11

AS-i classification

AS-i version		2.11; 3.0
AS-i addressing		addressing socket
Extended addressing mode		no
AS-i master profile		M3; M4
AS-i profile		S-7. B. E
AS-i I/O configuration	[hex]	7
AS-i ID code	[hex]	B. E
AS-i certificate		126301

AC507S

Safe AS-Interface Classic
Line module with quick mounting technology

ClassicL 2SI 2DOT 2LO OSSD

Assignment of the data bits	data bit	D0	D1	D2	D3
	assignment	O1	O2	O3	O4

Mechanical data

Weight [g]	294.5
Housing	rectangular
Type of mounting	AS-i flat cables directly connectable; mounting on DIN rail; (TH35 (EN 60715))
Dimensions [mm]	103 x 45 x 44.7
Materials	housing: PA; piercing contacts: CuSn6 nickel-plated and tin-plated

Displays / operating elements

Display	operation	1 x LED, green
	errors	1 x LED, red
	switching status	1 x LED, yellow
	alarm	1 x LED, red

Electrical connection

Module connection

Flat cables

Accessories

Items supplied	lower part
Accessories (optional)	Addressing cable:, E70213
	Protective cap: M12, E73004

Remarks

Remarks	PL e, cat. 4, SIL 3 only if the fault exclusions described in the manual are used
Pack quantity	1 pcs.

Electrical connection

quick mounting technology for AS-i flat cable: ; three orientations possible

Electrical connection - O-3/4

Connector: 1 x M12; coding: A; Maximum cable length: 10 m

1	n.c.
2		O-4
3 (I-)	L-
4		O-3
5	n.c.

AC507S

Safe AS-Interface Classic
Line module with quick mounting technology

ClassicL 2SI 2DOT 2LO OSSD

Electrical connection - O-4

Connector: 1 x M12; coding: A; Maximum cable length: 10 m

1	n.c.
2	n.c.
3 (I-)	L-
4
5	n.c.

Electrical connection - SI-1/2

Connector: 1 x M12; coding: A; Maximum cable length: 10 m

1 (I+)	L+
2		SI-2
3 (I-)	L-
4		SI-1
5		FE

Electrical connection - Trans

Connector: 1 x M12; coding: A; Maximum cable length: 10 m

1 (I+)	L+
2 (I-)	L-
3 (I-)	L-
4 (I+)	L+
5	FE

FE: functional earth; n.c.: not used

13 Approvals / certificates

• EU Declaration of Conformity
- TÜV Rheinland
- AS-Interface
- UL (cULus)

Supply the device via an appropriate class 2 source so that the supply class requirements in accordance with UL 508 are met.

14 Maintenance, repair and disposal

If used correctly, the unit is maintenance-free.

The device must only be repaired by the manufacturer. Observe the safety instructions ( → Safety instructions).
▶ After use, dispose of the unit in an environmentally friendly way in accordance with the applicable national regulations.