AC5251 - Controller IFM - Free user manual and instructions

Product type	AS-i controller with 4 inputs and 1 pneumatic reversing output (AirBox)
Model	AC5251 (IFM)
Inputs	4 inputs (sensors) via M12 connectors, Y circuit
Pneumatic output	1 solenoid valve 5/2, reversing, manual override
AS-i profile	S-7.A.E, extended addressing mode
Power supply	AS-i (via yellow flat cable); AC5253 also AUX power (black cable)
Operating pressure	3...8 bar
Pneumatic connection	Rilsan tubes, external diameter according to CETOP RP 54 P
Maximum number of slaves	62 per master
AS-i version	3.0, backward compatible
LED display	PWR (green), FAULT (red), AUX (green, AC5253), input (yellow), logic output (yellow)
Addressing	Via AC1144 addressing unit and E70213 cable; extended mode possible
Protection degree	IP 67 (IP 65 with silencer)
Electromagnetic compatibility	Contact discharge ±4 kV, air discharge ±8 kV (EN 61000-4-2)
Required air quality	Non-lubricated air: classes 6-3-1; lubricated air: classes 6-3-4 (ISO 8573-1:2001)
Maintenance	Not user-repairable; contact manufacturer if defective
Special functions	Manual override (push/release or push/turn/lock), electrical priority
Operating temperature	Not specified in the manual, refer to the online datasheet

Frequently Asked Questions - AC5251 IFM

How to address the AC5251 module?

The module must be mounted and wired. Use the addressing unit AC1144 with the addressing cable E70213 via the integrated addressing interface. In extended mode, assign an address between 1A and 31A if used with an AS-i master version 2.0.

What does the red FAULT LED mean?

A solid red FAULT LED indicates an AS-i communication error: the slave is not participating in normal data exchange, for example if the address is 0. If it flashes, it signals a peripheral fault such as overload or short circuit of the sensor supply.

Can I use lubricated compressed air with the AirBox module?

Yes, the module is suitable for lubricated air with purity class 6-3-4 (oil content < 5 mg/m³). Caution: once used with lubricated air, it must always be used with lubricated air, as the initial lubrication is no longer effective after switching to non-lubricated air.

What is the tightening torque for M12 connectors?

The recommended tightening torque for M12 connectors is 0.6...0.8 Nm. To ensure IP 67 protection, use the supplied sealing gaskets and cover unused connectors with protective caps.

How to connect pneumatic tubes to the AirBox?

Cut the tubes straight and push them into the fittings. To remove, press the gray pressure ring while pulling the tube. Ensure the system is depressurized before any intervention.

What is the maximum number of AS-i slaves per master?

The maximum number of modules (slaves) per AS-i master is 62, according to AS-interface version 3.0.

What to do if the red FAULT LED flashes?

A flashing FAULT LED indicates a peripheral fault, such as overload or short circuit of the sensor supply. Check sensor connections and power supply status.

Can the module be repaired?

No, the product must not be modified and no internal repair is possible. In case of a defect, please contact the manufacturer IFM.

How to orient the AS-i flat cable on the AC5251?

The base allows three directions. Select the position (1, 2 or 3) on the base, then adjust the arrow on the top part with a screwdriver or the cable guide. Ensure a straight length of at least 15 cm before the first bend.

What are the precautions against electrostatic discharge?

The module is tested for contact discharge ±4 kV and air discharge ±8 kV according to EN 61000-4-2. For risk environments, take measures such as potential equalization, separation of signal and bus cables, and use of equipotential bonding conductors.

USER MANUAL AC5251 IFM

Functions and features

maximum number of modules per master: 62
- AS-interface version 3.0, downward compatible
- connection to the pneumatic system via tube fitting, outside calibration according to CETOP standards RP 54 P
- operating pressure range 3...8 bar

Operation outside the indicated operating pressure range or use of incorrectly processed compressed air can cause permanent leaks and irreparable damage to the pneumatic components and may lead to malfunctioning.

Operating and display elements

Installation

Notes on installation from page 20.

Addressing

At the factory the address is set to 0.

Addressing with the AC1144 addressing unit

When mounted and wired the module can be addressed with the addressing cable (E70213) via the implemented addressing interface.

If a slave with the extended addressing mode is used in combination with a master of the first generation (version 2.0), the parameter P3 must be 1 and the output bit D3 must be 0^ . The output bit D3 and

the parameter bit P3 must not be used. *

Default setting

If a slave with the extended addressing mode is used in combination with a master of the first generation (version 2.0), an address between 1A and 31A must be assigned to this slave.

Electrical connection

Connect the plugs of the sensors to the M12 sockets.

Cover the unused sockets with protective caps (E73004)*, the addressing socket with the supplied protective cap. Tightening torque 0.6...0.8 Nm.

To guarantee protection rating IP 67 you also have to

• use the flat cable end seal (E70413)* if the module is at the end of the cable line

• discharge exhaust air via the tube connection

• to be ordered separately

If the AirBox is operated with silencer, the protection rating is IP65.

AC5251

4 inputs / 1 pneumatic output (NO/NC selectable)

AS-i profile S-7.A.E / extended addressing mode: yes

Data bit D0 D1 D2 D3
Input 1 2 3 4
Socket I1/2 I1/2 I2 I3/4 I3/4	I4
Pin 4 2 4 4	2 4
Pneumatic output	2 4 -

AC5253

4 inputs / 1 pneumatic output (NO/NC selectable)

AS-i profile S-7.A.E / extended addressing mode: yes

Data bit D0 D1 D2 D3
Input 1 2 3 4
Socket I1/2 I1/2 I2 I3/4 I3/4	I4
Pin 4 2 4 4	2 4
Pneumatic output	2 4 -

Inputs (Y-circuit)

Pneumatics

Circuit diagram pneutatics 1x 5/2-way valve

Compressed air

Adhere to the safety regulations and provisions for the installation of pneumatic systems. Switch off pressure. Connect the compressed air supply 1, the operating connections 2 and 4 and if necessary the exhaust 3 and 5 to the pneumatic system. Cut the connection tube straight and push it into the tube fitting.

Removal of the tubes

To remove the tube push the grey clamping ring and pull out the tube at the same time.

Manual override

The pneumatic output can be activated manually using the manual override (pressing/releasing or pressing/turning/locking).

For trouble-free operation sufficiently treated air must be used.

The electrical triggering has priority over the mechanical triggering.

Specification of the compressed air purity

According to ISO 8573-1: 2001 the air purity is divided into three classes:

1. The purity class of the solid particle content
2. The purity class for the humidity content
3. The purity class for the total oil content

The AirBoxes are suitable for non-lubricated compressed air of the purity classes 6-3-1 and for lubricated compressed air of the purity classes 6-3-4.

Meaning:

1. Solid particle contamination according to class 6: Max. particle size 5 m , max. particle density 5mg / m^3
2. Maximum water content according to class 3: Pressure dew point -20°C
3. Maximum total oil content according to class 1: for non-lubricated compressed air 0.01mg / m^3 Maximum total oil content according to class 4: for lubricated compressed air < 5mg / m^3 , this corresponds to approx. 1 oil drop / 4000 litres of air

Once the AirBox has been operated with lubricated air, it always has to be operated with lubricated air as the oil removes the initial lubrication.

Electromagnetic compatibility (EMC)

The AirBox is rated for operation in industrial environments. The test of the electrostatic discharge was carried out in accordance with EN 61000-4-2 with the following test levels:

• contact discharge ± 4kV
• air discharge ± 8kV

Special applications such as the conveying and distribution of bulk material can generate higher electrostatic charges.

To avoid electrostatic discharge the following remedial actions are possible, among others:

• Equalisation of potential according to the installation instructions

• Separate laying of

• signal and bus cables

• equipotential bonding conductors

• power cables

• Physical separation of the AirBox and all cables from all parts carrying or discharging electrostatic charges.

If these discharges are not avoided there is the danger of:

• injury to/incapacitation of operators and maintenance staff
• spark formation
• damage to the AirBox
• damage to the electrical equipment

Operation

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

Check the reliable functioning of the unit. Display by LEDs:

• LED 2 yellow: input switched
• LED PWR green: AS-i voltage supply ok
• LED FAULT red lights: AS-i communication error, slave does not participate in the „normal“ exchange of data, e.g. slave address 0
• LED FAULT red flashing: peripheral fault, e.g. overload or short circuit of the sensor supply

Important notes on LED AUX and LED 1

• LED AUX green: AUX voltage supply OK (AC5253) Application of the AUX voltage is only indicated if the AS-i voltage is also available.

• LED 1 yellow: Only indicates the logic state of the PLC outputs. The pneumatic output status does not necessarily correspond to the indicated status of LED 1.

• The pneumatic output status is not indicated on the unit.

Maintenance / repair

The unit must not be modified nor can it be repaired. In case of a fault please contact the manufacturer.

Technical data

Technical data and further information at www.ifm-electronic.com --> Select your country --> Data sheet direct

Orientation of the flat cable on delivery

Carefully place the yellow and optionally the black AS-i flat cable (AC5253) into the profile slot.

Mount the upper part.

With the supplied lower part the flat cable can be aligned in three directions.

For the requested direction place the flat cable guide (1) accordingly.

Settings at the lower part

Select the position 1, 2 or 3 depending on the requested flat cable alignment () .

A = Factory setting

Settings at the upper part

Then set the selected position at the upper part. To do so, turn the arrow to the corresponding number (figure D1 and D2).

Use a tool, e.g. a screwdriver (figure D1) or the yellow / black flat cable guide (figure D2).

Open the unit using a tool as shown (e.g. screwdriver).

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