Technology for

Mining Industry
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Technology for Mining Industry

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ifm electronic -
your partner for mining industry.



The name ifm electronic stands for a large range of different sensors and systems
for automation technology.
For more than 40 years the family-run company has been researching, developing
and producing with the aim of optimising technical processes and conserving
resources.
With industry and application know-how, ifm electronic - one of the leading
manufacturers of automation technology - provides successful system solutions
that are both innovative and economical.
A product range which meanwhile amounts to more than 7800 articles provides
sufficient flexibility to meet customer requirements in the most varied industries:
from an individual sensor, matching accessories to a complete system solution.
Of course, all relevant approvals are available.
As one of the global players, ifm guarantees worldwide availability of the units.
More than 70 branch offices worldwide ensure competent advice on-site.
ifm - close to you!




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ifm - the company 4 - 5
General information 6 - 7
Conveyor control solution 8 - 9
Conveyor overview 10 - 11
ifm products 12 - 37
ifm addresses 38


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trade partner

ifm subsidiary


ifm electronic portrait

Close customer contact - presence with potential.

The customer has been at the focus of our activities since the company was
founded in 1969.

More than 4,300 employees

Competent local support for more than 100,000 customers in more than
70 countries.

More than 2,500 customers worldwide receive our personal attention every day.
99 % of sales are direct sales.











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ifm local services

More than 3.500 customers daily are consulted with competent on-site customer and
application support by more than 1.000 sales engineers and service staff world-wide.
Workshops and seminars for our customers.
The ifm service center: 85 % of the calls world-wide are directly answered - without
waiting loop.
The ifm internet service:
All the important information in 18 languages can be directly accessed world-wide.
The ifm delivery service:
98 % of the catalogue units are available world-wide within max. 4 days

Industry in focus

In the OEM sector
conveyor technology
handling, mounting and robotics
mobile vehicles
machine tools

In End User industries
Automotive industry
Food industry
Pharmaceutical, cosmetic and chemical industry
Steel + Mining industry
Environmental technology and building automation





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www.ifm.com
Information around the clock and
around the globe in 23 languages on the internet.




Information Selection
- product innovations - interactive product selection aids
- company news - configuration tools
- exhibition info - data sheet direct
- locations
- jobs
Animation
Documentation - virtual product animations
- data sheets - flash movies (video sequences)
- operating instructions
- manuals Application
- approvals - applications
- CAD data - product recommendations
- calculation aids
Communication*
- request for documents Transaction*
- recall service - e-shop processing
- live advice - e-procurement catalogues
- newsletter




*Some offered information is available country-specific



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Convenient order processing
via the e-shop** on the internet.





Secured authentication Individual order history

Customer-related price Convenient quick input form
Indication

Real time availability check Simple order processing


Personal product favourites Management of shipping
addresses

Online parcel tracking Confirmations by e-mail











** Already available in many countries.




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Conveyor control solution

In the mining industry there are lots of raw material conveyors to transport the raw material
from underground facilities to the processing plant. The mineral bearing rock has to be moved
over a long distance via robust conveyor systems. These conveyors can be longer than 2 km
and have to be very flexible due to changings in the locations of the mining fields. ifm
electronic developed a conveyor control system which allows connection of all the stations of a
conveyor system e.g. rope switches, emergency stop switches, belt alignment switches,
temperature sensors, speed sensors, start-up alarms etc. The conveyor control system is
called AS-i (Actuator Sensor Interface).
The Actuator Sensor Interface is a hot-pluggable alternative to conventional wiring
technologies that is easy to use and easy to extend. Speed, reduction of installation, plant and
maintenance costs, and high availability are features of this manufacturer-independent
interface system. The AS-Interface is ideally suited for the robust transmission of small
quantities of data under rugged industrial conditions. It has proven itself and has become
accepted as the standard for the networking of sensors and actuators in many application
areas for economic amongst other reasons. The two-core cable for data and energy
transmission, the connection in the clamping technology, the mapping in the PLC as I/O
component assembly, and extensive diagnostic possibilities lead to significant savings in
project planning, installation, documentation, maintenance, and downtime in the case of
failures.
The AS-Interface is designed for the lowest level of the automation hierarchy where it offers an
easy, reliable, and fast transfer with optimal price-performance ratio. Higher-level systems
such as Profibus DP, EtherNet IP, Modbus, DeviceNet or CANopen are connected via
gateways. Decentralised solutions relieve the control system. Depending on the extent of the
setup, this permits cycle times of typically 5 ms for one AS-Interface branch. The system can
be flexibly extended, may be commissioned in partial areas only, reduces the communication
on higher-level field buses and offers an increased failure resistance through autonomous
subareas.
The AS-Interface shadow logo designates devices that have been certified by the independent
AS-Interface test centre. This permits simultaneous problem-free operation of devices from
different manufacturers on one AS-Interface branch.
The heart of the system is the AS-Interface master or the AS-Interface gateway with
respective diagnostic possibilities. Current PLC or PC software solutions can continue to be
used as the AS-Interface acts like an I/O card in a downward direction. The devices control
and monitor the data exchange with the modules and/or AS-Interface sensors/actuators
according to the master-slave principle. Viewed from the primary field bus, the gateway acts
as slave participant with up to 248 bits of input and 186 bits of output data (V 2.1). Power is
supplied via AS-Interface power supply units with data decoupling. Bus-terminators or tuners
and repeaters permit line extension beyond 100 m.






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For this purpose, the repeater separates the primary and secondary side electrically to achieve
increased safety in case of a short circuit. An unlimited amount of repeaters may be operated in star
configuration but no more than two in sequence. Together with the repeater, a further AS-interface
power supply unit must be used to provide power to the additional AS-Interface circuit.
Slaves are available in many designs, binary or analogue, for use in the field, either in a switch
cabinet or in the terminal box. For the EX areas, solutions with ATEX approval are also available.
With a manual address-programming device, individual modules can be addressed/configured easily
at the desk or directly on site. However, it is also possible to address an entire AS-Interface branch
via the AS-Interface master.
Based on the same technology and the same protocol, safety-oriented components such as rope
switches, emergency-stop devices, opto-electronic protective devices and safety guard interlocking
devices can also be integrated. This only requires the installation of one safety monitor and some
safe slaves on the branch.
A mixed operation of both safe and nonsafe AS-interface slaves is possible without problems. The
safety monitor monitors the data communication on the AS-Interface line. For the safe slaves,
dynamic code sequences (8x4-bit data sequence) that are stored in each slave are transmitted.
These are "learned" by the safety monitor during commissioning. During operation, the safety
monitor compares the expected with the actual sequence in each cycle and carries out a safe shut-
down within 40 ms if there are any deviations, e.g., as a result of device failure, communication
problems or the like. The time for re-activation is 100 ms. Safe field and switch cabinet modules are
available as slaves, including intelligent safety sensors and safety command devices with AS-
Interface chip. The system can be used up to control category 4 according to EN 954-1 or up to SIL
3 according to IEC 61508 and may be used for stop category 0 and 1 according to EN60204-1.
The conveyor control system consist of the AS-i master, AS-i power supply, the safety monitor/relay
device, AS-i cable and various I/O modules (safe and non-safe). The main benefits and features of
ifm Electronics conveyor control system is a safe control system that is cost effective, which allows
for fast and flexible expansion and status of Rope Pull Switches and Emergency Stop switches are
displayed locally by the AS-i master display and also remotely in the PLC and on SCADA.







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E2D400 panel PC
















































AS-i gateways with ultra
Short transfer times
The central control
components of the AS-i
network
Online Vibration
Diagnostics


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Safety rope switch
solution for conveying
automation

















































Pt100
Bolt-on sensors
ClassicLine: Quickly and
reliably ready for
operation due to quick
mounting technology
Belt Speed Monitoring


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Keep track even in harsh environments!








Technical data
The industrially compatible small computer is
equipped with a 12.1" touch-screen with a resolution
of 1024 x 768 pixels. The required performance is
achieved by using a fan-less Intel

Atom
TM
N270
processor with a clock frequency of 1.6 GHz, 1 GB
RAM and a 2 GB compact flash card as a robust hard
disc substitute.
Windows XP Embedded
TM
has been installed as
operating system, besides the ifm user software, for
the vision sensors.

Industrially-compatible design
A power consumption of only 32 watts combined with
a fan-less design form a sound basis for a continuous
use of the display. When installed in the control panel
the front face of the plastic housing has a protection
rating of IP 64.




12.1" touch-screen display with a
resolution of 1024 x 768 pixels.

Windows XP Embedded
TM
operating
system, ifm software pre-installed.

WLan and USB 2.0, Gbit LAN,
RS-232, RS-422, RS-485 interfaces.

Robust and industrially-compatible
housing with protection rating IP 64
(on the front face).



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Dimensions

1: Insertion slots for control cabinet mounting


Monitor for object recognition and identification sensors
Type Description Order no.

Touch Panel PC 12.1" colour display Intel Atom CPU 1.6 GHz 1 GByte RAM Windows XP Embedded Ambient
temperature: -10...50 C Weight 1,8 kg Protection IP 64
E2D400

Mounting accessories for wall mounting E2D401

Mounting accessories for control cabinet mounting E2D402

Parameter setting cable cross-over 2 m PUR M12 D-coded / RJ45 E11898


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Diagnostic systems for vibration
monitoring of rolling element bearings








Introduction
The rolling element bearing is a standard element for
the construction of machinery and equipment. The
correct function of this force-transmitting and moving
component is critical for uptime of machinery and
equipment. Due to the high dynamic and static loads
during operation as well as design limitations the
rolling element bearing is often the Achilles' heel with
regard to lifetime. Thus unforeseen damage to the
bearing often leads to production or quality loss.
State-of-the-art for industrial monitoring of rolling
element bearings is presently restricted to the
intermittent measurement with handheld measuring
instruments and to expensive central measuring
systems which due to their enormous acquisition
costs only make sense economically for monitoring
expensive machines like turbines or large gears.

Low-cost permanent vibration
monitoring

Reliable measuring principle by
acoustic emission detection

Condition-based maintenance
increases machine uptime

Easy parameter setting and set-up

Direct local reading of the bearing
condition, progr. switching outputs


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Innovative technology
With the ifm efector octavis brings the first
vibration sensor with integrated rolling element
bearing diagnosis based on frequency analysis
on the market. Due to the implementation of a
proprietary diagnostic algorithm several different
rolling element bearings can be monitored
separately and their condition can be displayed
via a green-yellow-red logic. Monitoring and
diagnosis are performed in real time. Thus
vibration measurement technology is integrated
into automation technology so that expensive
expert know-how for a reliable bearing
diagnosis is not required. Therefore permanent
monitoring of small machines and components
is possible for the first time without losing the
diagnostic quality of expensive systems.

Easy parameter setting
For the easy parameter setting of the rolling
element bearing monitor, it is only necessary to
take the relevant bearing data from the rolling
element bearing database. For variable speed
drives information on speed must be provided.
The speed can either be provided by an
analogue signal or a pulse generator connected
to the sensor.

VSE002 diagnostic electronics
By means of the diagnostic electronics it is
possible to continuously analyse and evaluate
the measured signals of up to 4 vibration
sensors with the octavis technology at the same
time. Pre-alarm and alarm are electrically
signalled via the switching outputs. The trend
can be electrically signalled via the analogue
output. 2000 values can be stored in the
diagnostic electronics.

By means of the Ethernet interface the
decentralised diagnosis can also be integrated
into higher-level systems. Due to the
compatibility of the data (OPC) the diagnostic
values can be easily integrated into all usual
visualisation environments and can be made
accessible to remote diagnosis within the
framework of teleservice concepts.

The products
Type Description Order no.

Frequency-selective machine monitoring of up to 4
measurement points and 2 other process quantities
Ethernet interface TCP/IP PC-software required
RMS, a-peak, a-RMS integrated history function
with real-time clock 2 switching outputs or 1
switching and 1 analogue output 12 freely
configurable counters (operating hours, events,
load)
VSE002

Frequency-selective machine monitoring of up to 4
measurement points and 2 other process quantities
Ethernet interface TCP/IP PC-software required
RMS, a-peak, a-RMS integrated history function
with real-time clock 2 switching outputs or 1
switching and 1 analogue output up to 8 freely
configurable I/O 12 freely configurable counters
(operating hours, events, load)
VSE100

Parameter setting software for VSExxx VES003

Jumper straight / straight Ethernet Cross-
over patch cable 2 m Housing materials: PUR
EC2080

Jumper straight / straight Ethernet Cross-
over patch cable 5 m Housing materials: PUR
E30112


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Vibration sensor for diagnostic electronics









Sensor type VSA001
The acceleration sensor is used to log measured data
especially for the VSE002 octavis diagnostic
electronics. The special analogue output ensures the
correct transmission of high-frequency vibration
signals even over distances of up to 30 m.
The compact and highly robust design provides good
long-term stability even under adverse environmental
conditions. Due to the use of modern silicon
technology the sensitivity of the sensor is both long-
term stable and temperature independent.






The right enclosure for harsh
environmental conditions

Compact and robust stainless
steel housing

Temperature range -30 to 125 C

Integrated self-test



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Dimensions




Vibration sensors for connection to external diagnostic electronics VSE
Type Description Order no.

Vibration sensors based on MEMs technology measuring range +/- 25g IP 68 /IP 69k frequency range 0...6000 Hz
linearity 0.2% overload protection 500g ambient temperature -30...125C M12 connector recommended cable length
30m
VSA001

conical washer 8.4 / 15 mm stainless steel 316Ti / 1.4571
E30115




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Continuous vibration monitoring









The sensor
The vibration transmitter type VT monitors machinery
and equipment according to ISO 10816. The sensor
measures the true rms velocity of non-rotating
component surfaces. The values are then transmitted
as an analogue signal (4...20 mA) directly to the PLC.

The applications
Due to its robust design, high IP Rating as well as the
maximum ambient temperature of 105 C the sensor
is suitable for use in harsh environments.

The installation
The unit is quick and easy to install. No extra
parameter software is required.


Vibration transmitter in stainless
steel housing

2-wire loop powered

4...20 mA signal output

Robust metal housing provides
high protection rating



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Dimensions

1), 2) customer specific connection configuration


Wiring diagram




Vibration transmitters for vibration monitoring of machines and plants to ISO 10816
Type Description Order no.

Vibration transmitter Connection via M12 connector Vibration transmitter to ISO 10816 Measuring range veff: 0...25
mm/s Analogue output 4...20 mA stainless steel 316L / 1.4404
VTV122

Cable socket M12 connector angled free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP
69k Ambient temperature: -2590 C 5 m PUR cable 4 x 0.34 mm
EVC005




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Pt100 bolt-on sensors








For complex applications with different
requirements
Every application has its own requirements as
regards the temperature sensors to be used. Criteria
such as housing material or mechanical design are
as important as the connection to control monitors,
plcs or AS-i modules. The housings and materials of
the new bolt-on sensors of ifm electronic have been
designed for a wide range of applications.

TS522A for ATEX applications
In addition, the bolt-on sensor TS522A has the ATEX
approval to group II, category 3D /3G.

Flexible mounting

Bolt-on sensors for M6 screws

Temperature measurement of
-25...115 C


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Dimensions



























Pt100 bolt-on sensors
Type Description Order no.

Bolt-on sensor 12 x 8,7 x 51 mm 2 m PUR cable with connector halogen-free free from silicone gold-plated contacts
Measuring range: -25...90 C / -13...194 F Measuring element: 1 x Pt 100, to DIN EN 60751, class B
TS2229

Bolt-on sensor 10 x 10 x 42 mm 5 m silicone cable ATEX approval Group II, category 3D/3G Measuring range for
ATEX applications: -20...115 C / -4...239 F Measuring range for standard applications: -20...150 C / -4...302 F
Measuring element: 1 x Pt 100, to DIN EN 60751, class A
TS522A

Measured signal converter for temperature sensors, Pt100 and Pt1000 measuring elements Analogue output 4...20 mA
IP 67 Ambient temperature -2570 C Measuring range: -50...150 C M12 connector
TP3231

Wirable plug M12 connector straight halogen-free free from silicone gold-plated contacts IP 68 Ambient
temperature: -2585 C
E11504

Wirable plug M12 connector angled halogen-free free from silicone gold-plated contacts IP 68 Ambient
temperature: -2585 C
E11505
TS2229

TS522A



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Speed monitor








Introduction
The compact speed monitor M18 is suitable for
simple speed monitoring for underspeed or blockage
on conveyors, elevators and ventilation systems, as
overspeed monitors in wind power systems or load
monitoring on hoists.
The unit detects without contact if a set rotational
speed is exceeded or not reached and signals this by
means of a switched output. The pulse output
enables the external evaluation of the damping
pulses.


Compact speed monitor M18

Switching output and pulse output

Sensing range 12 mm [nf]

non-flush mountable



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Applications:
Conveyor technology in all industries
Mining, machine construction, machine tools,
mills and animal feed plants

Unit with integrated sensor
Compact speed monitor M18
with switching output transistor
and additional pulse output
10...36 V DC
M12 connector
12 mm sensing range [nf]
You can adjust:
switch point
start-up delay
output function


Operation
The parameters of the compact speed monitor
can be set via an integrated pushbutton. To do
so, the rotational speed to be monitored is
measured and the switch point is automatically
calculated.



Speed monitor
Type Description Order no.

Compact speed monitor M18 Switching output and pulse output Sensing range 12 mm [nf] IP 67 Housing materials:
stainless steel 316Ti / 1.4571; PBT
DI6001

Target wheel Plastic disk with 8 screws as "target" Centered drill holes E89010

Angle bracket 2 lock washers (Steel galvanised) 18 mm (for M18 sensor) E10736
Dimensions

1: 3 LED
2: setting pushbutton


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Rope switch for field applications








Introduction
The new rope switch is a heavy duty safety rope
emergency stop switch designed to protect long
conveyor belts. The die-cast housing is robust to
survive indoor or outdoor use.
A bi-colour LED ensures switch status can be seen
easily from a distance. They have 4 NC and 2 NO
contacts to guarantee flexibility with all modern
control applications e.g. AS-Interface Safety at Work
system.







Integrated E-stop with blue reset
button

4 NC safety contacts and 2 NO
auxiliary contacts

Rope tension indicator

Long rope spans up to 125 m each
side possible

LED function display:
Operation - LED permanently green
Error - LED flashing red



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Rope switch for field applications

Application
The safety rope emergency stop switch is
used to provide safety-related switching
statuses where large danger areas have to be
secured and housings or covers are not
possible.
Typical applications are conveyor systems and
rotating machines and large danger areas.
The safety rope emergency stop switch meets
the requirements of EN ISO 13850, IEC / EN
60947-5-1 and IEC / EN 60947-5-5.
The safety rope emergency stop switch can
be used in applications up to performance
level e according to EN ISO 13849-1.

Function
Pulling the tensioned rope, rope breakage or
impact on the E-stop cause activation of the
switching function of the safety rope
emergency stop switch.
There is a window on the switch via which the
correct rope tension can be monitored during
setting and maintenance. Setting,
troubleshooting and maintenance are made
much easier.
After activation of the E-stop function a
latching mechanism maintains the E-stop
command until it is unlocked manually by
pressing the blue reset button. Before
resetting the E-stop signal the cause of the
activation has to be determined. Reset is only
possible with correct rope tension (position
indication in middle position).













Installation of the components


Technical data

Safety contacts 4 NC
Auxiliary contacts
2 NO
Termination clamp up to
2.5 mm
2

max. switching voltage
240 V
max. rope span
125 m
Opterating temperature [C]
-25 ... +80
Cover
yellow

ZB0051


Dimensions


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Rope switch for field applications
Type Description Order no.


Safe rope pull emergency stop switch dual hand type 4 NC / 2 NO no LED yellow cover
ZB0050
Safe rope pull emergency stop switch dual hand type 4 NC / 2 NO bi-colour LED 24 V DC yellow cover ZB0051


Safe rope pull emergency stop switch left hand type 4 NC / 2 NO bi-colour LED 24 V DC yellow cover ZB0052
Safe rope pull emergency stop switch right hand type 4 NC / 2 NO bi-colour LED 24 V DC yellow cover ZB0053

Safe rope pull emergency stop switch dual hand type 4 NC / 2 NO bi-colour LED 110 V AC silver cover stainless
steel
ZB0070

Safe rope pull emergency stop switch dual hand type 4 NC / 2 NO bi-colour LED 110 V AC yellow cover ZB0071


Safe rope pull emergency stop switch left hand type 4 NC / 2 NO bi-colour LED 110 V AC yellow cover ZB0072
Safe rope pull emergency stop switch right hand type 4 NC / 2 NO bi-colour LED 110 V AC yellow cover ZB0073

Safe rope pull emergency stop switch dual hand type 2 NC / 2 NO no LED silver cover stainless steel ATEX - can
be used in Zone 21 + 22 (gas + dust) [Exd IIC T6 (-20C Ta +60C) Gb] [Ex tb IIIC T85C (-20C Ta +60C) Db]
ZB0074


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Accessories rope switch
Type Description Order no.

Rope Tension Kit Stainless Steel, 5m
ZB0054
Rope Tension Kit Stainless Steel, 10m ZB0055
Rope Tension Kit Stainless Steel, 20m ZB0056

Rope Tension Kit Stainless Steel, 50m ZB0057

Rope Tension Kit Stainless Steel, 80m ZB0058

Rope Tension Kit Stainless Steel, 100m ZB0059

Rope Tension Kit Stainless Steel, 126m ZB0060

Safety Spring Stainless Steel ZB0061

Universal Pulley Stainless Steel reversing the direction of the rope ZB0062

Tensioner / Gripper stainless steel ZB0063

Replacement LED 24V DC for rope switch permanently green / red flashing ZB0064

AS-i safety PCB connection of mechanical contact and LED components complies with the requirements: ISO 13849-1
PL e and SIL 3 to EN62061 / IEC 61508
E7015S

Adapter plug straight, M20 to M12 connector E11295

Cable gland M20 x 1.5 E21010


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Belt drift switch for field applications








Introduction
The new belt drift switch is designed for heavy duty
application and used for drift monitoring of conveyor
belt installations. The belt drift switches are used to
protect the installations from damage or destruction in
the event of belt drift and are positioned in pairs on
both sides of the conveyor belt. The ball bearing
stainless steel actuating roller is resistant to wear and
is used for belt speeds up to approx. 5 m/s.
The device features a robust aluminum housing and
is equipped with 2 force-actuated changeover
contacts with snap-action function with two adjustable
switching points.



2 changeover contacts

belt speeds up to 5 m/s

Cylindrical roller stainless steel,
50 mm

2 adjustable switching points:
5 15, 15 35



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Belt drift switch for field applications

Function
Inadmissible belt drift occurs when the belt edge
approaches the end of the supporting rollers
through lateral movement and surpasses it.
Then the actuator (roller lever) is operated and
displaced. In case of displacement of the
actuator, the cam operating switches are
activated.

The switching angle can be set via an
adjustable camshaft. In this way, a pre-warning
can be implemented in addition to the safety
shutdown. As soon as the belt moves correctly,
the roller lever will automatically return to its
home position.
The products
Type Description Order no.

Belt drift switch 2 changeover contacts
cylindrical roller stainless steel, 50 mm yellow
cover housing materials: Aluminium switching
points: default setting: 2 x 10 conduit entries:
M25 x 1,5 one included
ZB0090

Replacement actuating roller for belt drift switch,
50 mm stainless steel
ZB0091

AS-i pcb connection of mechanical contacts and
LED components
E70529

Technical data

Contacts 2 SPDT
Termination clamp up to
2.5 mm
2

max. switching voltage
230 V
Thermal current
6 A
Suited fo belt speed up to
5 m/s
Opterating temperature [C]
-25 ... +70
Cover
yellow


Dimensions


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AS-Interface








Bus system AS-Interface
AS-Interface (AS-i = actuator sensor interface) is a
manufacturer - independent standard for the
connection of actuators and sensors of the first field
level. It is the only wiring system accepted worldwide.
With 20 million slaves installed AS-i has been tried
and tested as a low-cost feeder for all common
fieldbuses for many years.
The product range includes AS-i components for
different areas from packaging and conveying via silo
applications, machine tools, robotics and automation
to the food industry and mobile vehicles.

Safe
The sophisticated AS-i technology and the extended
diagnostic possibilities provide high reliability and
machine uptime.
Safety at Work is the extension of the AS-interface
by safety-related components. Safety components up
to the highest performance level e to EN ISO13849-1
and SIL 3 to IEC 61508 can be connected to AS-i.
Manufacturer-independent
standard

Worldwide acceptance as a
wiring system

Communication from the sensor
to the controller

Safety at Work for
safety-related applications

Intelligent system solutions for
special tasks
With Safety at
Work AS-i also
solves safety
related tasks



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Version 1.3 / April 2014 31

Easy
Due to the standardised system, the low wiring complexity and
the quick connection technology, AS-i enables simple Plug &
Play. The reduction of terminals leads to reduced
documentation.
Data and energy are jointly transmitted via a two-wire cable.
The reverse polarity protected insulation displacement
technology helps avoid errors. The modularity and the tree
structure smoothly fit to the way the plant is put together.

Cost-optimised
Its the end result that matters: Wiring complexity,
documentation and set-up times are significantly reduced. The
decentralisation of the AS-i participants leads to smaller and
less expensive control cabinets. Simple diagnosis and a clear
system design result in high machine uptime and avoid
downtimes.

Wiring Solution: AS-Interface
The actuator-sensor interface (AS-i) sets new technological
standards in the design and automation of installations. AS-i
considerably reduces wiring complexity since conventional
parallel wiring of each sensor or actuator to the controller is no
longer necessary. This saves the user a great number of
terminals, splitter boxes, input / output cards and cable lines.
Via its field connections AS-i allows low-cost connection of
conventional devices. Up to 248 binary sensors and 186
actuators can be connected per AS-i network.

Voltage supply and data via one cable
Voltage supply and data communication of all sensors are
normally performed via a (yellow) AS-i cable. For some
modules actuators can also be supplied via this cable. If a
higher output current or emergency stop switch-off is required,
actuators are supplied via a second black flat cable with a
separate 24 V auxiliary voltage.

Basic system structure
The minimum configuration of an AS-i system consists of the
master, an AS-i power supply and the slaves. If needed, the
user can also connect safety monitors, repeaters, earth fault
monitors or other diagnostic tools to the AS-i network.













Reduced cost:
reduced wiring complexity
for faster
installation and fewer
error sources



Technology for Mining Industry

32 Version 1.3 / April 2014



AS-Interface Gateways
Type Description Order no.

SmartLink DP AS-i gateway / Profibus DP 1 AS-i master with M4 profile Full master functions Graphic display
Housing materials: aluminium / steel sheet galvanised
AC1375

SmartLink DP AS-i gateway / Profibus DP 2 AS-i master with M4 profile Full master functions Graphic display
Housing materials: aluminium / steel sheet galvanised
AC1376

AS-i Ethernet / IP Controller E 1 AS-i master with M4 profile Ethernet configuration interface Full master functions
Graphic display Housing materials: aluminium / steel sheet galvanised
AC1327

AS-i Ethernet / IP Controller E 2 AS-i master with M4 profile Ethernet configuration interface Full master functions
Graphic display Housing materials: aluminium / steel sheet galvanised
AC1337
AS-Interface Components
Type Description Order no.

AS-i flat cable reverse polarity protection due to special shape material: TPE for use in isolation displacement
connector technology for FC lower parts and compact modules 100 m
E74200

AS-i flat cable reverse polarity protection due to special shape material: TPE for use in isolation displacement
connector technology for FC lower parts and compact modules 500 m
E74203

FC splitter AS-i voltage and external auxiliary voltage via the M12 socket Housing materials: Metal parts: stainless steel
316L / 1.4404 / Blanks: FPM / O-ring: EPDM
E70354

AS-i repeater Extension of the AS-i network by another 100 m One additional AS-i power supply necessary combicon
connection Housing materials: PA 6.6
AC2225

Passive AS-i bus termination Extension of the cable to a maximum of 200 m without additional repeater Improvement of
the signal quality Monitoring of the supply voltage by means of LEDs
AC1147

Active AS-i switching cabinet module 4 digital inputs / 4 digital outputs String mounting possible Addressing socket
Version 2.11 Combicon connection Housing materials: PA
AC2251

Active AS-i ClassicLine module 2 digital outputs / 2 digital inputs Version 2.11 and 3.0 with extended addressing mode
Addressing socket Three orientations of the flat cable are possible Output supply via AS-i Sockets M12 x 1
Housing materials: PA
AC5224

Active AS-i ClassicLine module 2 analogue inputs 4...20 mA For the connection of 2-wire and 3-wire sensors Version
2.11 and 3.0 Addressing socket Three orientations of the flat cable are possible Sockets M12 x 1 Housing materials:
PA
AC5222


Technology for Mining Industry



Version 1.3 / April 2014 33


AS-Interface Safety at Work
Type Description Order no.

AS-i safety monitor Extended functionality 2-channel Performance Level e to EN ISO 13849-1, IEC 61508 / SIL 3
Configuration and setup by configuration software ASIMON Screw terminal
AC004S

AS-i safety monitor 2 safe semi-conductor outputs SIL 3 to EN 62061, IEC 61508 / SIL 3 and EN ISO 13849 - 1 / PL e
Chip card to save the configuration data Configuration and setup by configuration software ASIMON V3 G2 USB 2.0
interface Chip card and Combicon screw terminals supplied with the device
AC041S

Safe contact expander without delay Screw terminal 2 independent channels 4 contact blocks (NO) per channel 1
feedback circuit (NC) per channel Mounting on DIN rail
E7053S

Safe AS-i input module AS-i version 2.11 for connection of mechanical /electrical contacts Sockets M12 x 1 Housing
materials: PBT Complies with the requirements: ISO 13849-1 PL e and SIL 3 to EN62061 / IEC 61508
AC505S

AS-i safety PCB connection of mechanical contact and LED components complies with the requirements: ISO 13849-1
PL e and SIL 3 to EN62061 / IEC 61508
E7015S

Safe illuminated E-STOP operating unit with integrated AS-i connection Connector M12 x 1 AS-i interface via AS-i flat
cable IP 67 fool-proof E-STOP to EN ISO 13850 Pull to reset interchangeable button inserts
AC012S

Software ASIMON V3 G2 configuration, set-up and diagnostics of the AS-i safety monitor E7050S

USB interface cable for the connection of the safety monitor AC041S to the PC cable length 1.8 m E7051S

Western connector RJ 45 8 poles / D-Sub socket 9 poles for the connection of the safety monitor AC004S to the PC
cable length 2.5 m
E7001S
Power supplies
Type Description Order no.

2,8A AS-i power supplies Output voltage: 29.5...31.6 V DC single phase Nominal voltage: 100...120 AC / 200...240
AC , 10 %, automatic range selection Efficiency typ. 88 %
AC1256

8A AS-i power supplies Output voltage: 29.5...31.6 V DC single phase Nominal voltage: 100...120 AC / 200...240 AC ,
10 %, automatic range selection Efficiency typ. 89,4 %
AC1258

24 V DC / 5A power supplies Output voltage: 24...28 DC, adjustable, output voltage to SELV/PELV single phase
Nominal voltage: 100...120 AC / 200...240 AC , 10 %, automatic range selection Efficiency typ. 89,4 %
DN4012

24 V DC / 10A power supplies Output voltage: 24...28 DC, adjustable, output voltage to SELV/PELV single phase
Nominal voltage: 100...120 AC / 200...240 AC , 10 %, automatic range selection Efficiency typ. 91 %
DN4013


Technology for Mining Industry

34 Version 1.3 / April 2014

Third-generation communicator








The bus at a glance
The new ifm gateways are the fast connection from
AS-i to Profibus or Profinet. Thanks to a colour display
and web interface, the status of all AS-i slaves is
recognizable at a single glance.
The quick set-up menu and intuitive handling facilitate
installation and diagnosis. In addition, the web
interface allows full remote access.

Three types of voltage supply
The flexible voltage supply ensures a low-cost
integration into your application. The units can be
operated via AS-I power supplies, DC power supplies,
or a combination of both. It is also allowed to supply
several AS-i networks via a single power supply.
AS-i gateways with ultra short
transfer times

Colour display for clear diagnosis
and set-up

AS-i double address recognition,
integrated earth fault monitor

Certified EtherNet/IP interface with
2 ports

Profinet switch with 2 ports and
certification according to
Conformance Class B

Profibus DP interface with certified
DPV0 and DPV1 functionality



Technology for Mining Industry



Version 1.3 / April 2014 35

Third-generation communicator

Advantages and customer benefits
Communication interfaces:
EtherNet/IP:
Certified EtherNet /IP functionality
Ethernet switch with 2 integrated ports
Profinet:
Profinet Class B
Profinet switch with 2 integrated ports
Profibus:
Profibus DPV0 and DPV1 functionality
AS-Interface:
1 and 2 AS-i masters pursuant to M4
profile
Configuration interface:
Ethernet with integrated web interface
Connections:
AS-i and auxiliary supply: plug-in terminals
(supplied with the unit)
EtherNet/IP and Profinet 2 x RJ45
Profibus D-Sub 9
Configuration interface RJ45
Visualisation:
1.8" colour display
LEDs for unit and fieldbus status
Housing:
Robust metal housing:
aluminium powder-coated; steel sheet galvanised
Ambient temperature:
Operating temperature 0...60 C
Storage temperature -20...70 C

Functions
Pluggable data decoupling
Via the optional data decoupling AC1250, the
gateway and the connected AS-i slaves can be
powered by one power supply. A single voltage
source can hereby supply several gateways and
their AS-i networks.
Power supplies with a voltage of 30 V (DC or AS-
i) allow any possible AS-i structure at full cable
length.
The use of a 24 V power supply offers the
advantage of AS-i power24: For AS-i networks of
up to 50 m the introduction of the bus system AS-
Interface will become even more cost-efficient.
Transfer of AS-i data
PLC user programs of existing plant can be
changed to the new AS-i gateways of the third
generation without any changes to the I /O
addresses.
The products
Type Description Order no.

AS-i Profinet gateway
1 AS-i master with M4 profile
AC1401
AS-i Profinet gateway
2 AS-i masters with M4 profile
AC1402

AS-i Profibus gateway
1 AS-i master with M4 profile
AC1411
AS-i Profibus gateway
2 AS-i masters with M4 profile
AC1412

AS-i Ethernet/IP gateway
1 AS-i master with M4 profile
AC1421
AS-i Ethernet/IP gateway
2 AS-i masters with M4 profile
AC1422

AS-i data decoupling, can be mounted on AS-i
gateway
AC1250
AC1401 / AC1402 / AC1411 / AC1412
AC1421 / AC1422

AC1250

Dimensions


Technology for Mining Industry

36 Version 1.3 / April 2014

Connection Technology








ecolink M12 for demanding applications
Most applications require special solutions. Only
high-quality materials, assured production processes
and faultless assembly lead to success in the long
run. The integrated end stop protects the O-ring
against destruction caused by overtightening the nut.
No tools needed for installation and removal.
The asymmetrically acting vibration protection holds
the nut tight in its position, guaranteeing optimum and
permanent sealing.
High-quality materials especially suited to the
application and intensive monitoring during and after
production guarantee maximum quality standards.

ecolink
a new dimension in connection technology.





Connection technology meets the
M12 standard (EN 61076)

Optimum sealing even when
fastened by hand

The mechanical end stops the
O-ring being destroyed

Nut secured against shock and
vibration due to saw tooth
vibration protection


Technology for Mining Industry



Version 1.3 / April 2014 37


Jumper cables, 3-wire
Type Description Order no.
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 0,3 m PUR cable 3 x 0.34 mm
EVC040

Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 0,6 m PUR cable 3 x 0.34 mm
EVC041
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 1 m PUR cable 3 x 0.34 mm
EVC042
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 2 m PUR cable 3 x 0.34 mm
EVC043
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 5 m PUR cable 3 x 0.34 mm
EVC044
Jumper cables, 4-wire
Type Description Order no.
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 0,3 m PUR cable 4 x 0.34 mm
EVC010

Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 0,6 m PUR cable 4 x 0.34 mm
EVC011
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 1 m PUR cable 4 x 0.34 mm
EVC012
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 2 m PUR cable 4 x 0.34 mm
EVC013
Jumper M12 straight / straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 5 m PUR cable 4 x 0.34 mm
EVC014
Connectors
Type Description Order no.

Cable plug M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 2 m PUR cable 4 x 0.34 mm
EVC076
Cable plug M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 5 m PUR cable 4 x 0.34 mm
EVC077
Cable plug M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP 69k
Ambient temperature: -2590 C 10 m PUR cable 4 x 0.34 mm
EVC078

Cable socket M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP
69k Ambient temperature: -2590 C 2 m PUR cable 4 x 0.34 mm
EVC001
Cable socket M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP
69k Ambient temperature: -2590 C 5 m PUR cable 4 x 0.34 mm
EVC002
Cable socket M12 connector straight free from silicone free from halogen gold-plated contacts IP67 / IP 68 / IP
69k Ambient temperature: -2590 C 10 m PUR cable 4 x 0.34 mm
EVC003


Technology for Mining Industry

38 Version 1.3 / April 2014

Locations in Africa:
ifm electronic (Pty) Ltd - RSA ifm electronic (Pty) Ltd - Namibia
National Tel: 0861 IFM RSA (436 772) Land line: +264 61 300 984
International Tel: +27 12 450 0370/ 0400 Fax to email: +264 88 651 9943
Fax line: +27 12 450 0322/ 1860

[email protected] [email protected]
[email protected] www.ifm.com/na
www.ifm.com/za

Branches Branches
Centurion (HO) Durban Windhoek
Rustenburg Richards Bay
Steelpoort Port Elizabeth
Cape Town Northern Cape
Vaal Triangle
Klerksdorp & Carltonville


Locations in Australia:
ifm efector pty ltd.
PO Box 479
Suite 3, 745 Springvale Road
Mulgrave VIC 3170

Tel. 1300 365 088
Fax 1300 365 070

[email protected]
www.ifmefector.com.au


Locations in Europe:
ifm electronic - France
Siege :
Savoie Technolac BP226
73374 Le Bourget du Lac
Agence commerciale :
Immeuble Uranus
1-3 rue Jean Richepin
93192 NOISY LE GRAND CEDEX
Tl: 0820 22 30 01
Fax: 0820 22 22 04
[email protected]
www.ifm.com/fr
ifm electronic gmbh - Germany
Friedrichstr. 1
45128 Essen

Tel. +49 201 24 22 0
Fax +49 201 24 22 12 00

[email protected]
www.ifm.com/de



ifm electronic ab - Sweden
Drakegatan 6
41250 Gothenburg

Tel. vxel 031-750 23 00
Tel. order 031-750 23 50
Telefax 031-750 23 29
[email protected]
www.ifm.com/se





Locations in South America:
ifm electronic Ltda. - Brazil
Rua Eleonora Cintra, 140
Jardim Analia Franco
03337-000 So Paulo/SP

Tel. +55-11-2672-1730
Fax +55-11-2673-3501

[email protected]
www.ifm.com/br



Technology for Mining Industry



Version 1.3 / April 2014 39









Over 70 locations worldwide
at a glance at www.ifm.com

ifm electronic gmbh
Friedrichstrae 1
45128 Essen
Tel. +49 / 201 / 24 22-0
Fax +49 / 201 / 24 22-1200
E-mail [email protected]




































Overview
ifm product range:


Position sensors


Sensors for
motion control


Industrial imaging


Safety technology


Process sensors


Industrial
communication


Identification systems


Condition monitoring
systems


Systems for
mobile machines


Connection technology


Accessories

Visit our website:
www.ifm.com








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