asi-d.ppt - Phoenix Contact

Installation guide
Tips and Tricks
Tips and Tricks
AS-Interface General Features 4
Selecting the Cable
Cable Routing
Power Supply
Network Configuration
Address Allocation for Slaves
Installation and Connection
Project Checklist
Tips and Tricks
Sign-Off Checklist 30
Additional Information
AS-Interface General Features
AS-Interface General Features
o It is important to install only certified products.
a Worldwide Standard
o Products that pass the strict evaluation by an authorized agency
are identified by the AS-Interface certification symbol (shadow logo).
Europe EN 50295 (since 2008, EN 62026-2)
Worldwide IEC 62026-2
AS-Interface Key Features
AS-Interface General Features
o Transmission of data and power on the same cable
o AS-Interface is a potential-free system, symmetrical with respect to ground. Even in industrial environments it offers a high degree of noise immunity without the need
for any additional measures such as a shielded cable.
o Master / Slave communication process
o Up to 62 slaves on a single AS-Interface network
o Cycle time ≤ 5 ms
o Protection class IP20 to IP69K, depending on housing style
o It is important to not affect the ground symmetry of the system.
o It is possible to use a shielded cable for AS-Interface, but this may have a negative effect on the total network length.
o Standard and safety communications on the same AS-Interface cable
o Maximum network length of 100 m without any topology restrictions
• Up to 500 m using repeaters
• Optional, manufacturer specific network extension solutions are available. Here
it is important to comply with manufacturer‘s specifications and data sheets.
Selecting the Cable
Selecting the Cable
We recommend the use of the yellow flat cable
o Note: The yellow flat cable needs to be protected from UV radiation.
o Two-conductor mechanically coded flat cable
• Not twisted • Not shielded
• Not terminated
o Mechanically coded cable prevents reverse polarity installation.
o Piercing technology allows simple and fast installation without tools.
o For currents >2A the voltage drop along the cable must be checked.
o Data and power over one cable
• 240 W maximum output power (30VDC, 8A)
o Different cable jacket materials are available
• Rubber
o Different colors for different applications
• Yellow: AS-Interface• Black: Auxiliary power 24V
Dimensions AS-Interface cable
Diagram of piercing technology
Selecting the Cable
Cable Routing
If the standard AS-Interface cable cannot be used:
o The yellow AS-Interface cable should be used whenever possible.
• Brown lead for ASI +
• Blue lead for ASI -
o Almost any standard round cable can be used.
o Two-conductor cable with a conductor diameter between 0.5 mm2 and 2.5 mm2
o In this case, the power requirements and the voltage drop must be checked!
o It is necessary to check for correct polarity at all times.
o Avoid unfavorable non-ground symmetrical cable routing over longer distances.
o The attainable network length might be reduced if cables are used that do not
conform to the specification.
o Even though communication through the AS-Interface cable is insensitive
to electro magnetic interferences, it needs to be routed separately from
the power cable – even in a cabinet.
Cable Routing
o We recommend using a separate cable for every AS-Interface network. AS-Interface cables should not be routed together with other AS-Interface cables or other power circuits using a single multi-conductor cable.
o If a single leaded cable is used (for instance in a cabinet) the two separate leads
should be routed together and twisted if possible.
Cable Installation,
EMC considerations
o EMC protection through protection diodes, varistors, or RC filters must be used for
all switched inductive loads, such as master control relays and relay coils, valves,
breakers etc., if this is not already integrated in the products.
Please check the manufacturer‘s instructions.
o If frequency inverters are installed, the use of network filters, output filters
and shielded motor cables are recommended.
• Observe installation guidelines in the manufacturer‘s instructions.
• Cable shields between filters, frequency inverters, and motors need to be
connected directly to the system ground at both ends, using a sufficient
cross section (min. 4 mm2).
o Keep the distance to potential sources of interferences (i.e. frequency inverters and
their cables) as large as possible.
Power Supply
o This recommendation is based on Specification 3.o Rev.1.
o Use only AS-Interface power supplies (PELV).
• PELV = Protective Extra Low Voltage
o All AS-Interface Masters are backward compatible.
o If masters designed according to a specification prior to 3.o are installed,
the use of some functions could be limited (for instance diagnostics).
o AS-Interface slaves with the profiles S-7.5.5, S-7.A.5, S-B.A.5, S-7.A.7, S-7.A.A,
S-7.A.8, S-7.A.9 and S-6.0 require a master with profile M4
(first defined in AS-interface Specification 3.o).
o The PE-connector on the AS-Interface
power supply (protective earth) must
be grounded (if available).
o The ground on the AS-i-network
(GND, Ground, Shield) must be
connected to the system ground.
o Neither AS-i - nor AS-i + must be
o Output voltage AS-i: 29.5 to 31.6 V DC
o AS-Interface power supplies deliver
up to 8A (model specific).
o The voltage drop between power
supply and network nodes must not
exceed 3V. If necessary, the power
supply should be installed as close
as possible to the largest consumer.
power supply
with data
Network Configuration
Network Configuration
o One AS-Interface segment including all drop lines must not be longer than 100 m.
o Extension using a repeater
o For network extension please note the following:
o Extension using a repeater:
• An additional 100 m of AS-i cable can be connected after every repeater.
However, no more than 2 repeaters can be installed between a slave and
the master (max. 2 repeaters daisy-chained).
• In each segment, a galvanically separated AS-Interface power supply
must be installed.
• Hence, the maximum possible distance between two slaves in an AS-Interface network is 500 m, if the master is positioned accordingly
(see picture on the next page).
o Centered grouping: Extension with a repeater up to 500 m
Address Allocation for Slaves
Address Allocation for Slaves
o For AS-Interface 31 slave addresses are available.
o Before start-up of the system all slaves must be addressed.
o There is a difference between standard address allocation and extended address
allocation. The address allocation mode of a slave is set by the manufacturer.
o In general, at the time of delivery, slaves have address 0.
o For standard address allocations, each slave utilizes a full address (1 -31).
o For extended address allocation each address can be used by 2 slaves.
(1A - 31A, 1B - 31B)
o Each address can only be allocated once.
• Double address allocation of the slaves is not permitted.
o Address allocation can be conducted electronically or by using an addressing device.
o Example: Address 3 can be used by:
• One standard slave with address 3 or
• One extended slave with address 3A or
• One extended slave with address 3B or
• Two extended slaves with addresses 3A and 3B
Installation and Connection
o Connecting modules to AS-Interface networks
• Numerous different module concepts are available from the various
• It is necessary to follow the manufacture’s installation guidelines.
Installation and Connection,
I/O Supply
o Whenever possible, sensors and actuators should be supplied directly by
the slave‘s inputs or outputs, respectively.
o This cable should be kept separate from the power cable and as short as possible.
• Slave modules should be installed as close as possible to sensors and actuators.
o Ground-free sensors/actuators: Grounding of peripheral devices, galvanically
connected with AS-i potential, is not permitted according to specification.
It must be avoided to maintain a high degree of interference immunity.
oIf the sensor/actuator has a ground connection that is galvanically isolated
from the AS-Interface network, it must be connected to the system ground.
M 12 Connection
Project Checklist
o Allocation of M12-plug connections on AS-i Slaves (here: bushing).
How many inputs and outputs are needed?
• The number of inputs and outputs determines the number
of AS-Interface networks.
How much power is required for the peripheral devices?
• The total power demand of the required modules determines the size of the
AS-Interface power supply. Since power supplies cannot be wired in parallel, the size of the installed power supply must be chosen according the power consumption. If the AS-Interface network is segmented using repeaters,
the power for each segment is supplied separately and the entire network
can transmit considerably more power.
Are special cables needed?
• In general, a combination of flat and round cables is possible. Environmental
influences must be considered when choosing a suitable cable material.
Project Checklist
Project Checklist
Is the address allocation correct?
• To maintain installation clarity it is suggested to maintain a list that clearly
identifies each slave with its assigned address.
• In some cases, the master may not recognize double address allocations as error.
In general, this process occurs automatically, but can also
be performed manually using the control software.
Which modules use which addresses?
• It is imperative to carefully mark those modules or slaves that already received
an address.
When are modules installed?
• Whenever the above rules have been observed. The cable can be installed
How will the slaves be recognized?
• First, it is necessary to check if the master recognized all of his slaves.
Subsequently, the program can be started in safe mode and in the control
system (RUN).
How can the system be tested?
• Input/output tests are performed as usual in the PLC. This means, the sensors
are locally activated and verified in the PLC.
How to configure the system?
• The configuration is simply read by registering the AS-Interface profile of each
slave into the master.
How can the system be activated?
• Optionally, the operating software can be programmed as usual or the existing software can be used. If the existing software is to be used, it may be necessary
to adjust the symbolic assignment of the addresses.
Tips and Tricks
Tips and Tricks
How to check if ground faults exist on the AS-Interface network?
• By using a ground fault detection device, available as a separate component
as well as integrated in the master and/or power supply.
• In general, it is suggested to install a ground fault detection as part of the AS-i networks. The installation of a ground fault detection is mandatory for systems controlling dangerous motion (IEC / EN 60204).
What else can be done to achieve a higher noise immunity?
• The connection “Shield“ on the AS-i power supply must be connected directly
and with good HF characteristics to the machine ground of the system.
This does not present grounding for safety reasons but a functional ground to
operate the AS-i cable symmetrically against the ground. If a shielded cable is
used, the cable shield must be connected to this point (and only here).
• Good symmetry should also be maintained towards other electrical noise sources (drives, welding equipment, etc.). The cables connecting active I/O modules and sensors or actuators, respectively, should be limited to a maximum of 2m.
• Whenever the possibility for high electrostatic charge exists (for instance
polishing machines, die cast machines, or when wrapping/unwrapping
plastic foils) it may be necessary to employ additional protective measures,
for instance discharge brushes.
Tips and Tricks
Tips and Tricks
Can the AS-i cable be routed parallel to power cables?
• Even if the communication via the AS-Interface is insensitive to noise, it should
still be routed separately from power cables – even in a cabinet.
• Maximum possible distances to potential interference sources (such as frequency inverters) should be maintained.
• Each AS-Interface network should have its own cable, i.e. AS-Interface cables
should not be routed with other cables using a multi-conductor cable.
• However, if single conductors are needed (for instance in cabinets) conductor
pairs must be routed in parallel. Standard single-lead cables must be routed
together or twisted.
Considerations when using a 8A-AS-i power supply
If more than the typically normal 2A will be transferred through the AS-i network,
the following limitations need to be considered when designing the network:
• The voltage drop along the AS-i network increases. Guideline: If 2A are
transmitted using 100 m cable with a diameter of 1.5 mm2, the resulting
voltage drop is about 5V. • The piercing contacts are designed for certain maximum constant amperage, below 8A. It is very important to refer to the manufacturer‘s data sheets.
Sign-Off Checklist
Sign-Off Checklist
o The installation was done according to the installation guidelines of the
different manufacturers.
o The Ground/PE/Shield connection of the AS-i power supplies is connected to the
system ground to maintain symmetry.
o The segment length is equal to or shorter than 100 m. Segment length is
the sum of all “drop lines“ in a segment.
o A distance larger than 50cm has been maintained between AS-i networks or sensor network and strong interferences sources such as: welding robots, switched power supplies and frequency inverters.
o The connection to the slave farthest from the master runs through no more
than two repeaters.
o If network extension is accomplished using manufacturer specific products,
the manufacturer‘s data sheets and information must be observed.
o A distance of at least 10 to 20 cm has been maintained between AS-i networks
or sensor networks and medium interference sources such as controls with
inductive loads or low power emission supplies.
o Wherever possible use the yellow profile AS-Interface cable, otherwise use a twisted two-conductor 2 x 1.5 mm2 cable.
o The current carrying capacity of connection T‘s or terminal connectors has been
checked (see manufacturer‘s data sheet).
o How to apply the bus configuration to the AS-i master?
• In the master by pushing a key
• In the control system through the hardware configuration
• In the control system through the user application
Sign-Off Checklist
Sign-Off Checklist
o How are slaves connected to the network documented
(type, address, and identification data)?
• Drawing of the electrical layout
• Manually inserted in a table
• Printed table based on the hardware configuration
• Printed table with data read by the AS-i master
o Is the maximum power consumption of the AS-i network smaller than the maximum current supplied by the AS-i power supply?
o How is the network topology documented?
The documentation must show the topology such as: line, tree, star, drop lines, etc.,
and the segmentation with the actually used cable length of AS-i network.
AS-i power supplies, slaves with their corresponding address, and repeaters,
if used, should be included.
• Drawing of the electrical layout
• Graphically • Not at all
o The value of the AS-i voltage at the end of each segment (the point farthest away
from the AS-i power supply) should be determined under full load. The measurement
point M must be shown in the network topology. This value must be determined for
all segments.
• The AS-i voltage between AS-i + and AS-i must be between U+/- = 26.5 and 31.6 V.
o If used, the 24V auxiliary power must be checked similarly.
o Theoretical maximum current load: the current requirement can be calculated by
referring to the data sheets of the used components.
Sign-Off Checklist
Product Overview
o The current load on the AS-i power supply, measured with a clamp meter under full
load conditions, must be compared to the maximum permissible current load of the
power supply. This value must be determined for all segments. It is recommended
that this maximum load does not exceed 90% of the power supply capacity.
1. AS-i Masters / Gateways / Links / Scanner
o Using analyzer devices or diagnostic functions in the master, the number of faulty
telegrams during operation can be determined. At least 100,000 telegrams need
to be evaluated (about 9 minutes for 31 slaves).
• The three slaves with the largest number of errors should be recorded during
system sign-off.
• According to the AS-Interface specification, the admissible error rate must be
below 0.1%.
Error rate = (faulty telegrams*100)/number of telegrams
AS-i 3.0 PROFIBUS Gateways
AS-i 3.0 EtherNet/IP
+ Modbus TCP Gateways
AS-i 3.0 PROFINET Gateways
AS-i 3.0 EtherCAT Gateways
o The diagnostic results must be documented (for instance by reading and interpreting
the flags in the AS-i masters).
AS-i 3.0 Master for
Allen-Bradley ControlLogix
AS-i 3.0 Master for
Allen-Bradley CompactLogix/
AS-i 3.0 CANopen Gateways
AS-i 3.0 DeviceNet Gateways
AS-i 3.0 PROFIBUS Gateways
(Basic Master)
2. Software
3. AS-i Analog Modules: 4 ... 20mA, 0 ... 10V, Pt100, Thermocouple Type J/K
AS-i Control Tools:
Configuration and
AS-i Diagnostics Software
AS-i 3.0 Analog Modules,
IP20, 2 channels
AS-i Analog Modules (M12)
2 channels, IP65
AS-i Safety Monitor
Configuration Software
AS-i Analog Modules,
IP20, 4 channels
AS-i Analog Modules (M12),
4 channels, IP65
AS-i Analog Modules 1E/1A
(M12), IP65
4. OEM Modules / AS-i Special Slaves*
AS-i Analog Modules (PG), IP65
AS-i 2E/2A AB Modules
AS-i 1E/1A AB Modules
AS-i 8E/8A Modules
AS-i 16E/16A Modules
AS-i Balance Controller, IP65
AS-i 4E/4A Modules, AS-i 8E Modules, AS-i 6A AB Modules,
AS-i 4E/3A AB Modules, AS-i 4E/4A OEM Modules,
AS-i OEM Slaves with serial interface
AS-i OEM Power Supply
AS-i OEM Analog Modules
4 ... 20mA
0 ... 10V
* customer-specific
orders are welcome!
5. Specialities
7. Power Supplies
AS-i-4E/4A Modules
AS-i-8E Modules
AS-i-8A Modules
AS-i-4E/4A Relay Modules
AS-i-4E/3A Relay Modules
AS-i Counter Modules
AS-i/AS-i Coupler
AS-i Power Supply, 1,8 A
AS-i Power Supply, 4A/8A
Power Supply for AS-i Master,
AS-i Power Extender
AS-i Wide Range Power
Supply, 8A
AS-i Module for
Power Decoupling
6. Network Extensions / Diagnostics
AS-i Advanced Repeater
with Bus Termination
AS-i High Power Repeater
AS-i Advanced Repeater,
AS-i Bus Termination
AS-i Diagnostic Tuner
AS-i Analyser
Additional Information
8. Safety: up to 16 release circuits (OSSDs)
Gateways with
integrated Safety
AS-i 3.0 EtherNet/IP
AS-i 3.0 EtherCATGateways*
AS-i 3.0 Gateways
AS-i 3.0 Gateways
Data sheets and manufacturer‘s guidelines
AS-i Safety Input Modules,
AS-i Safety Output Modules
AS-i Safety In-/Output Modules
*with integrated Safety Monitor
AS-i Safety Monitor,
Generation II,
16 OSSDs
Information about further
products can be found at
AS-i Safety Monitor,
Generation I,
AS-i Safety Input Modules
(M12), IP67
These recommendations were made according to specification 3.0 Rev.1.
None of the contributors can be held responsible for the appearance of any
inaccurate information or recommendations.
Safety technology is not part of these installation recommendations.
Data sheets and manufacturer‘s information must be strictly observed!
1 monitor configuration for
2 AS-i networks
16 independent release circuits
All safety relevant data can be
requested locally at the monitor
Diagnostics in plain text on the device
Memory cards for storage of
Available with integrated gateway
Modbus TCP or EtherNet/IP
Also obtainable as PROFIsafe via
Bihl+Wiedemann GmbH - Floßwörthstraße 41 - 68199 Mannheim, Germany - Phone: +49 (0)621 339 96-0 - Fax: +49 (0)621 339 22-39
eMail: [email protected] -