IFM AL4043 Operating instructions

Operating instructions

Remote I/O module 16 DI

ModbusTCP

IP65 / IP66 / IP67 / IP69K

AL4043

11489160 / 0104 / 2023

GB

AL4043 Remote I/O module 16 DI

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Contents

1 Preliminary note ............................................................. 4

1.1 Legal and copyright information ............................................ 4

1.2 Symbols used.......................................................... 4

1.3 Warnings used ......................................................... 4

1.4 Safety symbol on the device............................................... 4

1.5 Change history......................................................... 5

2 Safety instructions............................................................ 6

2.1 Cyber security.......................................................... 6

3 Intended use................................................................ 7

4 Function ................................................................... 8

4.1 Visual indication ........................................................ 8

4.2 Parameter setting....................................................... 8

4.3 Inputs................................................................ 8

4.3.1 Sensor supply...................................................... 8

4.4 Digital input filters....................................................... 8

4.4.1 Debouncing........................................................ 9

4.4.2 Stretching......................................................... 9

4.4.3 Inverting .......................................................... 10

4.4.4 Filter combination................................................... 10

4.5 Counter............................................................... 10

4.5.1 Counter mode CTU.................................................. 10

4.5.2 Counter mode CTD.................................................. 11

4.5.3 Counter mode CTUD ................................................ 11

4.5.4 Counter mode CTDIR................................................ 12

4.6 Modbus TCP........................................................... 12

5 Installation.................................................................. 14

5.1 Overview.............................................................. 14

5.2 Install device........................................................... 14

6 Electrical connection.......................................................... 15

6.1 Overview.............................................................. 15

6.2 General wiring information ................................................ 15

6.2.1 Connection technology............................................... 15

6.3 Ethernet .............................................................. 16

6.4 Process connections..................................................... 16

6.5 Voltage supply ......................................................... 16

6.5.1 Derating behaviour.................................................. 17

7 Operating and display elements................................................. 18

7.1 LEDs................................................................. 18

7.1.1 Status............................................................ 18

7.1.2 Ethernet .......................................................... 19

7.1.3 Voltage supply ..................................................... 19

7.1.4 Process connections................................................. 19

8 Set-up..................................................................... 20

9 Settings.................................................................... 21

9.1 Parameter setting software................................................ 21

9.1.1 Supported parameter setting software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

9.1.2 Getting started ..................................................... 21

9.1.3 Fieldbus: Configuring a ModbusTCP interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9.1.4 Fieldbus: Reading the connection status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9.1.5 Ports: Setting the arrangement of the digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9.1.6 Ports: Configuring input filters.......................................... 24

9.1.7 Ports: Reading digital input data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9.1.8 Counter: Configuring counter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9.1.9 Counter: Reading counter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9.1.10 Counter: Controlling counter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9.1.11 Gateway: Reading identification information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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9.1.12 Gateway: Reading status and diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . 27

9.1.13 Gateway: Setting the application tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

9.1.14 Firmware: Reading the firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.1.15 Firmware: Resetting the device......................................... 28

9.1.16 Firmware: Restarting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.2 IoT-Core Visualizer...................................................... 29

9.2.1 Starting the ifm IoT Core Visualizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.2.2 Searching elements of the IoT Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9.2.3 Configuring the device ............................................... 31

9.2.3.1 Configuring a ModbusTCP interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

9.2.3.2 Configuring input filters.......................................... 32

9.2.3.3 Configuring counter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.2.3.4 Setting the arrangement of the digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.2.3.5 Reading device information....................................... 35

9.2.3.6 Reading the firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2.3.7 Setting the application tag........................................ 35

9.2.4 Accessing process data .............................................. 36

9.2.4.1 Reading digital input data........................................ 36

9.2.4.2 Reading counter values ......................................... 37

9.2.4.3 Controlling counter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9.2.4.4 Reading status and diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9.2.5 Update firmware.................................................... 38

9.3 ModbusTCP........................................................... 39

9.3.1 Integrating a device into a Modbus TCP project . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.3.1.1 Example: Integrating a device into a CODESYS project . . . . . . . . . . . . . . . . . 39

9.3.2 Device-specific notes ................................................ 40

9.3.2.1 Rules for accessing the Modbus register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.3.2.2 Supported function codes........................................ 40

9.3.2.3 Exception codes............................................... 40

9.3.3 Configuring the device ............................................... 41

9.3.4 Configuring digital inputs.............................................. 41

9.3.5 Configuring counter modules .......................................... 41

9.3.6 Reading process data................................................ 41

9.3.7 Controlling counter modules........................................... 42

9.3.8 Controlling the device................................................ 42

9.3.9 Reading diagnostic data.............................................. 42

9.3.10 Reading identification information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

10 Maintenance, repair and disposal................................................ 44

10.1 Cleaning.............................................................. 44

10.2 Update firmware........................................................ 44

11 Appendix................................................................... 45

11.1 ModbusTCP ........................................................... 45

11.1.1 Register .......................................................... 45

11.1.1.1 Input data (0 - 34).............................................. 45

11.1.1.2 Port Configuration - Digital Inputs (100 - 163) . . . . . . . . . . . . . . . . . . . . . . . . . 47

11.1.1.3 Port Configuration - Counter (200 - 271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11.1.1.4 Port Output - Counter (300 - 355) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

11.1.1.5 Block Configuration (400 - 408). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11.1.1.6 Byte Swap (500)............................................... 54

11.1.1.7 Connection Timeout (510)........................................ 55

11.1.1.8 DI Channel Mapping (550) ....................................... 56

11.1.1.9 System Command (600)......................................... 57

11.1.1.10 Diagnostic Data (2000 - 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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1 Preliminary note

You will find instructions, technical data, approvals and further information using the QR code on the

unit / packaging or at documentation.ifm.com.

1.1 Legal and copyright information

used without the consent of ifm electronic gmbh.

All product names, pictures, companies or other brands used on our pages are the property of the

respective rights owners.

1.2 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

1.3 Warnings used

ATTENTION

Warning of damage to property

CAUTION

Warning of personal injury

wSlight reversible injuries may result.

WARNING

Warning of serious personal injury

wDeath or serious irreversible injuries may result.

1.4 Safety symbol on the device

Safety symbol on the device:

uAdhere to the operating instructions for the safe operation of the unit.

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1.5 Change history

Issue Subject Date

00 New creation of the document 11 / 2022

01 • Corrected: Chapter DI Channel Mapping (550) (Ò/56) 04 / 2023

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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 (Ò 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 Cyber security

ATTENTION

Operating the machine in an unprotected network environment

wUnauthorised read or write access to data is possible.

wUnauthorised manipulation of the device function is possible.

uCheck and restrict access options to the device.

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3 Intended use

The device may only be used for the following purposes:

• Gateway between digital sensors and a higher-level control system

The device is designed for use without a control cabinet in the food industry.

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4 Function

4.1 Visual indication

The device displays the following indications:

• Status and error indication of the gateway and the system

• Status and activity indication of the Ethernet connection

• Status display of the voltage supply

• Status, error and short circuit/overload indication of the sensor ports

4.2 Parameter setting

The device can be configured using the following options:

• Parameter setting software

– ifmmoneo

– ifm moneo|configure SA

• ifm IoT Core

– IoT-Core Visualizer

• ModbusTCP

– Projection software

4.3 Inputs

The device has 8 ports. Each port has 2 digital inputs.

4.3.1 Sensor supply

The device has a total of 8 sensor supplies (1 sensor supply per port).

4.4 Digital input filters

The device pre-processes the digital input signals. The filter result is forwarded as a process value.

The following filters can be applied to the input signals in the sequence specified.

1. Debouncing

2. Stretching

3. Inverting

Digital input Debouncing Stretching Inverting

Counter input

Process data

Filter module

Each filter can be configured separately.

The device detects signals of a length of min. 0.23 ms. Shorter signals are not detected.

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Periodic signals are only detected reliably if the signal period is at least twice as long as the

cycle time.

4.4.1 Debouncing

The filter suppresses noise signals. The filter provides the input signals at the filter output with a delay

(debounce time). All signals shorter than the set debounce time are ignored by the filter.

Time diagram debounce filter:

2

11 11

0

1

0

1

0

1

t

Process data

Filter output

Filter input

1: Debounce time

2: Cycle time

4.4.2 Stretching

The filter stretches short input pulses. Level changes that occur during a stretching period are ignored.

The filter is configured via the following parameters:

• Hold time: pulse duration to which short pulses are to be stretched. Pulses that are present for a

longer time than the hold time are not stretched.

• Hold level: signal level to be stretched (HIGH or LOW)

Time diagram stretch filter (status HIGH):

2

1 1 1

0

1

0

1

0

1

t

Process data

Filter output

Filter input

1: Hold time

2: Cycle time

Time diagram stretch filter (status LOW):

2

1 1 1

0

1

0

1

0

1

t

Filter input

Filter output

Process data

1: Hold time

2: Cycle time

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4.4.3 Inverting

The filter inverts signals.

4.4.4 Filter combination

The filters can be combined.

Example: All 3 filters are activated

Time diagram:

0

1

0

1

0

1

0

1

0

1

t

1

Digital input

Filter Debounce

Filter Hold

Filter Inverter

Process data

Digitaleingang

Filter Entprellen

Filter Halten

Filter Invertieren

Prozessdaten

1: Cycle time

4.5 Counter

The device features one counter module per port.

A counter module consists of 2 separate counters:

• Main counter: The main counter counts the rising edges of the filtered digital input signals. The

main counter has a value range that is defined by a threshold value. If the value range of the main

counter is exceeded or not reached, an overflow or underflow signal is sent to the batch counter.

• Batch counter: The batch counter counts the overflow or underflow signals of the main counter.

Filter module pin 4

Filter module pin 2

Count input

Count input/

control input

Main counter

Batch counter

Process data

Counter module

A counter module can be operated in different operating modes. The following operating modes are

available.

4.5.1 Counter mode CTU

In CTU (Count Up) mode, the counter module operates as an up counter with overflow detection and

overflow counter.

Behaviour:

• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The

main counter has a threshold value CT. The batch counter has a threshold value CTb.

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• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is

incremented (m = m+1).

• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).

Due to the overflow detection, the value of the batch counter is incremented (b = b+1).

• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).

CTb

CT

0

t

Main Counter

Batch Counter

4.5.2 Counter mode CTD

In CTD (Count Down) mode, the counter module operates as a down counter with underflow detection

and underflow counting.

Behaviour:

• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The

main counter has a threshold value CT. The batch counter has a threshold value CTb.

• The first time a positive edge is detected at pin 4, the value of the main counter is set to the

threshold value CT-1 (m = CT-1). At the same time, the value of the batch counter is set to the

threshold value CTb-1 (b = CTb-1).

• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is

decremented (m = m-1).

• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due

to the underflow detection, the value of the batch counter is decremented (b = b-1).

• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).

CTb

CT

0

t

Main Counter

Batch Counter

4.5.3 Counter mode CTUD

In CTUD (Count Up Down) mode, the counter operates as a simultaneous up and down counter with

overflow and underflow detection.

Behaviour:

• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The

main counter has a threshold value CT. The batch counter has a threshold value CTb.

• If the counter module detects a positive edge at pin 4 of the port, the value of the main counter is

incremented (m = m+1).

• If the counter module detects a positive edge at pin 2 of the port, the value of the main counter is

decremented (m = m-1).

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• If the counter module simultaneously detects a positive edge at pin 4 and pin 2 of the port, the

counter value of the main counter does not change.

• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).

Due to the overflow detection, the value of the batch counter is incremented (b = b+1).

• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due

to the underflow detection, the value of the batch counter is decremented (b = b-1).

• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).

• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).

CTb

CT

0

t

Main Counter

Batch Counter

4.5.4 Counter mode CTDIR

In CTDIR (Count Direction) mode, the counter module operates either as an up counter with overflow

detection or as a down counter with underflow detection. The counting direction can be set.

Behaviour:

• The initial value of the main counter is m = 0. The initial value of the batch counter is b = 0. The

main counter has a threshold value CT. The batch counter has a threshold value CTb.

• The user can determine the counting direction. The counter module initially operates as an up

counter with overflow detection.

• If the counter module detects a positive edge at pin 4 of the port and the counting direction of the

port is set to “up”, the value of the main counter is incremented (m = m+1).

• If the main counter reaches the threshold value CT (m = CT), the counter value is reset (m = 0).

Due to the overflow detection, the value of the batch counter is incremented (b = b+1).

• If the batch counter reaches the threshold value CTb (b = CTb), the counter value is reset (b = 0).

• If the counter module detects a positive edge at pin 4 of the port and the counting direction at pin 2

of the port is set to “down”, the value of the main counter is decremented (m = m-1).

• If the main counter falls below 0, the counter value is reset to the threshold value (m = CT-1). Due

to the underflow detection, the value of the batch counter is decremented (b = b-1).

• If the batch counter falls below 0, the counter value is reset to the threshold value (b = CTb-1).

CTb

CT

0

t

Main Counter

Batch Counter

4.6 Modbus TCP

The device offers the following Modbus TCP functions:

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• Device profile: Modbus TCP Server (message mode)

• 2-port switch for access to Modbus TCP interface (X21 / X22)

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5 Installation

5.1 Overview

2

1

1: Upper mounting lug

2: Lower mounting lugs lug

5.2 Install device

uDisconnect the power of the machine before installation.

uUse a flat mounting surface for installation.

uPlease observe the maximum tightening torque.

Fasten the device onto the mounting surface using 2 M5 mounting screws and washers (tightening

torque: 1.8Nm).

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6 Electrical connection

6.1 Overview

X22

X02

X04

X06

X08X07

X05

X03

X01

X31

X21

X21: Ethernet 1 (ModbusTCP)

X22: Ethernet 2 (ModbusTCP)

X31: Power IN

X01: process connection 1 (sensor)

X02: process connection 2 (sensor)

X03: process connection 3 (sensor)

X04: process connection 4 (sensor)

X05: process connection 5 (sensor)

X06: process connection 6 (sensor)

X07: process connection 7 (sensor)

X08: process connection 8 (sensor)

6.2 General wiring information

The device must be connected by a qualified electrician.

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

The device is only suitable for operation using SELV/PELV voltages.

This device contains components that may be damaged or destroyed by electrostatic discharge

(ESD).

uPlease observe the required precautions against electrostatic discharge!

The circuits are insulated from each other and from touchable surfaces of the device with basic

insulation according to EN61010-1.

The communication interfaces are insulated from each other and from touchable surfaces of the

device with basic insulation according to EN61010-1.

6.2.1 Connection technology

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.

uUse connectors with gold-plated contacts.

uDuring installation, place the connectors vertically so that the coupling nut will not damage the

thread.

uObserve the coding of the connectors during installation.

uCover unused connections with protective covers. Tightening torque: 1.3 ± 0.1Nm

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6.3 Ethernet

The device is connected to the ModbusTCP network via the Ethernet ports X21 / X22 (e.g.

ModbusTCP control, additional ModbusTCP device). In addition, the device can be connected to an IT

network via the Ethernet ports. The user can access functions of the ifm IoT Core via the IT network

(parameter setting software, IoT Core Visualizer).

uConnect the device to the ModbusTCP network via a free Ethernet port.

uOptional: Connect the device to the IT network via a free Ethernet port.

uFor connection, use an M12 connector (with at least protection rating: IP65 / IP66 / IP67 / IP69K).

uTighten the cable plug using 1.3 ± 0.1Nm.

Wiring:

1 2

34

5

1: TX+

2: RX+

3: TX-

4: RX-

5: not used

6.4 Process connections

The sensors are connected to the device via the process connections.

The total current supply of the ports X01...X08 is limited to 3.6 A.

The ports feature short-circuit/ overload detection.

uConnect the sensors to ports X01...X08.

uFor connection, use M12 connectors (with at least protection rating: IP65 / IP66 / IP67 / IP69K;

max. cable length: 30m).

uTighten the cable plug using 1.3 ± 0.1Nm.

Wiring:

3

1 2

4

5

1: sensor supply L+ (US)

2: digital output 2 (DI2)

3: sensor supply L- (US)

4: digital output 1 (DI1)

5: functional earth (FE)

6.5 Voltage supply

The device is connected to the supply voltage US via the power IN port.

The US supply voltage supplies the device and the sensors connected to the ports X01...X08 with

voltage.

Port X31 has overvoltage protection (US).

Port X31 has reverse polarity protection (US).

Port X31 has an inrush current limitation.

uDisconnect power.

uConnect the device via port X31 to 24VDC (20…30V SELV/PELV).

uFor connection, use an L-coded M12 connector (with at least protection rating: IP65 / IP66 / IP67 /

IP69K).

uTighten the cable sockets according to the torque specifications indicated by the cable

manufacturer. Maximum permissible tightening torque: 0.8Nm

uObserve the derating behaviour of the device (Ò Derating behaviour/17).

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Wiring:

43

2 1

1: +24VDC (US)

2: not used

3: GND (US)

4: not used

6.5.1 Derating behaviour

The current IUS available at ports X01...X08 depends on the ambient temperature of the device.

-40 -30 -20 -10 0 10 20 30 40 50 60 70

1

2

3

4

2000 m

3000 m

4000 m

Current [A]

Temperature [°C]

0.5

1.5

2.5

3.5

1

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7 Operating and display elements

7.1 LEDs

2 3

4

5

8

1

4

5

6

66

6

7

77

7

1: status: RDY

2: status: ERR

3: status: RUN

4: Modbus TCP: LNK

5: Modbus TCP: ACT

6: Process connection: DI1

7: Process connection: DI2

8: Voltage supply: US

7.1.1 Status

LED Description Colour State Description

RDY Gateway status - Off Not active or reboots

Green Flashes 3s (1Hz) DCP signalling service initiated via fieldbus

Flashes (5Hz) Error

Flashes (200ms

on, 800ms off)

Firmware update running

On OK

red On Error during firmware update (e.g. firmware not compatible)

ERR Error indication red Off No error

Flashes (10Hz) Boot error

flashes (200 ms

on, 200 ms off,

200 ms on, 1000

ms off)

Watchdog error (Modbus TCP or process data)

flashes (200ms

on, 1000ms off)

local error

Flashes (2.5Hz) invalid configuration

On Communication error

RUN Modbus TCP state

(state machine)

Green Off not ready

Flashes (1Hz) ready, but not yet configured

Flashes (5Hz) waiting for connection

On connection established

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7.1.2 Ethernet

LED Description Colour State Description

LNK Status of the connection Green Off No Ethernet connection

On Ethernet connection established

ACT Status of the data transmis-

sion

Yellow Off No data transmission

flashes Data transmission

7.1.3 Voltage supply

LED Description Colour State Description

US Voltage supply sta-

tus

- Off No supply voltage is applied or the applied supply voltage is

too low

Green On Supply voltage applied

red On Overvoltage, undervoltage, short circuit at sensor supply

7.1.4 Process connections

LED Description Colour State Description

DI1 Digital input signal

level (pin 4)

Yellow Off Digital input - pin 4: LOW

On Digital input - pin 4: HIGH

DI2 Digital input signal

level (pin 2)

Yellow Off Digital input - pin 2: LOW

On Digital input - pin 2: HIGH

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8 Set-up

uInstall the unit correctly.

uEstablish a correct electrical connection with the device.

wOnce connected to the supply voltage, the unit will start.

wThe LEDs show status and error conditions.

wThe unit is ready for operation.

wThe device can be configured.

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IFM AL4043 Operating instructions

IFM AL4043 Operating instructions

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