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www.schneider-electric.com
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not
intended as a substitute for and is not to be used for determining suitability or reliability of these
products for specific user applications. It is the duty of any such user or integrator to perform the
appropriate and complete risk analysis, evaluation and testing of the products with respect to the
relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or
subsidiaries shall be responsible or liable for misuse of the information contained herein. If you
have any suggestions for improvements or amendments or have found errors in this publication,
please notify us.
You agree not to reproduce, other than for your own personal, noncommercial use, all or part of
this document on any medium whatsoever without permission of Schneider Electric, given in
writing. You also agree not to establish any hypertext links to this document or its content.
Schneider Electric does not grant any right or license for the personal and noncommercial use of
the document or its content, except for a non-exclusive license to consult it on an "as is" basis, at
your own risk. All other rights are reserved.
All pertinent state, regional, and local safety regulations must be observed when installing and
using this product. For reasons of safety and to help ensure compliance with documented system
data, only the manufacturer should perform repairs to components.
When devices are used for applications with technical safety requirements, the relevant
instructions must be followed.
Failure to use Schneider Electric software or approved software with our hardware products may
result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
© 2018 Schneider Electric. All Rights Reserved.
2 EIO0000001678 02/2018
Table of Contents
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Deliverables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 2 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Architecture Related Safety Information . . . . . . . . . . . . . . . . . . . . . . . 22
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 3 Safety & Safety Requirements . . . . . . . . . . . . . . . . . . . . 27
Safety Evolution Structure for the System User Guides . . . . . . . . . . . 28
Evolution of Legal Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Standard EN ISO 13849-1 Machinery Safety - Safety-Related Parts of
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Standard EN/IEC 62061 Machinery Safety - Safety-Related Parts of
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Selecting the Applicable Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
More Information Regarding Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Functional Safety Measures Implemented in this Architecture . . . . . . 54
Chapter 4 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Electrical Distribution and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 56
PowerPact H-Frame Circuit Breaker - Hardware . . . . . . . . . . . . . . . . 57
Multi-9 C60 (UL 1077) Circuit Breaker - Hardware . . . . . . . . . . . . . . . 59
Multi-9 C60 (UL 489) Circuit Breaker - Hardware . . . . . . . . . . . . . . . . 61
Phaseo Power Supply Universal - Hardware . . . . . . . . . . . . . . . . . . . 62
iEM31xx Energy Meter Series - Hardware . . . . . . . . . . . . . . . . . . . . . 64
4.2 Safety Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Modicon TM3 Safety Module - Hardware . . . . . . . . . . . . . . . . . . . . . . 69
Preventa Detection and Dialog - Hardware . . . . . . . . . . . . . . . . . . . . . 72
4.3 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Magelis HMI STO - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Harmony XB5R ZBRRC Wireless Access Point - Hardware . . . . . . . . 77
Harmony Control and Signaling - Hardware . . . . . . . . . . . . . . . . . . . . 79
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4.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Modicon M221 Modular Logic Controller - Hardware. . . . . . . . . . . . . . 81
Modicon TM3 Modules - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
TM3XTYS4 TeSys Module - Hardware . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ConneXium Ethernet Switch (Unmanaged) - Hardware . . . . . . . . . . . 95
4.6 Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
TeSys D Contactor - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
TeSys GV2 Motor Circuit Breakers - Hardware . . . . . . . . . . . . . . . . . . 100
TeSys U LU2B Motor Starter- Hardware . . . . . . . . . . . . . . . . . . . . . . . 102
TeSys GV2DP - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
TeSys LAD5Cxx Wiring Adapter - Hardware . . . . . . . . . . . . . . . . . . . . 108
Altistart 01 Soft Starter - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Altivar 12 Variable Speed Drive - Hardware . . . . . . . . . . . . . . . . . . . . 113
4.7 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
OsiSense XG Tap-off box - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 118
OsiSense XGCSx90 RFID - Hardware . . . . . . . . . . . . . . . . . . . . . . . . 119
OsiSense Industrial Sensors - Hardware . . . . . . . . . . . . . . . . . . . . . . . 123
Chapter 5 Communication Topology and Wiring Guide . . . . . . . . . . 125
5.1 Introduction to System Communication . . . . . . . . . . . . . . . . . . . . . . . . 126
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Ethernet Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Ethernet Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Modicon M221 Modular Logic Controller - Wiring . . . . . . . . . . . . . . . . 131
Magelis HMI STO - Ethernet Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3 Modbus Serial Line Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Modbus SL Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Modbus SL Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Modicon M221 Modular Logic Controller - Wiring . . . . . . . . . . . . . . . . 138
Chapter 6 Implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2 Access the SoMachine Project Template . . . . . . . . . . . . . . . . . . . . . . 141
Access the SoMachine Project Template . . . . . . . . . . . . . . . . . . . . . . 142
Access the SoMachine Basic Project Template. . . . . . . . . . . . . . . . . . 143
4 EIO0000001678 02/2018
6.3 Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Vijeo-Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Chapter 7 System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1 Setup Controller and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Setup Controller and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2 Setup Other Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Network and Device Parameter Settings. . . . . . . . . . . . . . . . . . . . . . . 167
TeSys U Motor Starter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Altivar 12 Variable Speed Drive - Setup . . . . . . . . . . . . . . . . . . . . . . . 169
Altistart 01 Soft Starter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
OsiSense XGS - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
iEM3110 Energy Meter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Harmony ZBRRC Wireless Receiver - Setup . . . . . . . . . . . . . . . . . . . 177
Chapter 8 Bill of Material (BOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Bill of Material (BOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Glossary ......................................... 185
Index ......................................... 189
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6 EIO0000001678 02/2018
Safety Information
Important Information
NOTICE
Read these instructions carefully, and look at the equipment to become familiar with the device
before trying to install, operate, service, or maintain it. The following special messages may appear
throughout this documentation or on the equipment to warn of potential hazards or to call attention
to information that clarifies or simplifies a procedure.
EIO0000001678 02/2018 7
PLEASE NOTE
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of
the use of this material.
A qualified person is one who has skills and knowledge related to the construction and operation
of electrical equipment and its installation, and has received safety training to recognize and avoid
the hazards involved.
WARNING
UNGUARDED EQUIPMENT
Do not use this software and related automation equipment on equipment which does not have
point-of-operation protection.
Do not reach into machinery during operation.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
This automation equipment and related software is used to control a variety of industrial processes.
The type or model of automation equipment suitable for each application will vary depending on
factors such as the control function required, degree of protection required, production methods,
unusual conditions, government regulations, etc. In some applications, more than one processor
may be required, as when backup redundancy is needed.
Only you, the user, machine builder or system integrator can be aware of all the conditions and
factors present during setup, operation, and maintenance of the machine and, therefore, can
determine the automation equipment and the related safeties and interlocks which can be properly
used. When selecting automation and control equipment and related software for a particular
application, you should refer to the applicable local and national standards and regulations. The
National Safety Council's Accident Prevention Manual (nationally recognized in the United States
of America) also provides much useful information.
In some applications, such as packaging machinery, additional operator protection such as point-
of-operation guarding must be provided. This is necessary if the operator's hands and other parts
of the body are free to enter the pinch points or other hazardous areas and serious injury can occur.
Software products alone cannot protect an operator from injury. For this reason the software
cannot be substituted for or take the place of point-of-operation protection.
Ensure that appropriate safeties and mechanical/electrical interlocks related to point-of-operation
protection have been installed and are operational before placing the equipment into service. All
interlocks and safeties related to point-of-operation protection must be coordinated with the related
automation equipment and software programming.
8 EIO0000001678 02/2018
NOTE: Coordination of safeties and mechanical/electrical interlocks for point-of-operation
protection is outside the scope of the Function Block Library, System User Guide, or other
implementation referenced in this documentation.
WARNING
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.
Before operational tests are performed, remove all blocks or other temporary holding means
used for shipment from all component devices.
Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future references.
Software testing must be done in both simulated and real environments.
Verify that the completed system is free from all short circuits and temporary grounds that are not
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to prevent accidental equipment damage.
Before energizing equipment:
Remove tools, meters, and debris from equipment.
Close the equipment enclosure door.
Remove all temporary grounds from incoming power lines.
Perform all start-up tests recommended by the manufacturer.
EIO0000001678 02/2018 9
OPERATION AND ADJUSTMENTS
The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English
version prevails):
Regardless of the care exercised in the design and manufacture of equipment or in the selection
and ratings of components, there are hazards that can be encountered if such equipment is
improperly operated.
It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. Always use the manufacturer’s instructions as a guide for functional adjustments.
Personnel who have access to these adjustments should be familiar with the equipment
manufacturer’s instructions and the machinery used with the electrical equipment.
Only those operational adjustments actually required by the operator should be accessible to
the operator. Access to other controls should be restricted to prevent unauthorized changes in
operating characteristics.
10 EIO0000001678 02/2018
About the Book
At a Glance
Document Scope
This document describes a generic architecture based on Modicon M221 Logic Controller.
This document is intended to provide a quick introduction to the described system.
It is not intended to replace any specific product documentation, nor any of your own design
documentation. On the contrary, it offers additional information to the product documentation for
installing, configuring, and implementing the system.
The architecture described in this document is not a specific product in the normal commercial
sense. It describes an example of how Schneider Electric and third-party components may be
integrated to fulfill an industrial application.
A detailed functional description or the specification for a specific user application is not part of this
document. Nevertheless, the document outlines some typical applications where the system could
be implemented.
Your specific application requirements may be different and will require additional and/or different
components. In this case, you will have to adapt the information provided in this document to your
particular needs. To do so, you will need to consult the specific product documentation of the
components that you are substituting in this architecture.
Pay particular attention in conforming to any safety information, different electrical requirements,
and normative standards that would apply to your adaptation.
There are some major components in the architecture described in this document that cannot be
substituted without completely invalidating the architecture, descriptions, instructions, wiring
diagrams, and compatibility between the various software and hardware components specified
herein.
Be aware of the consequences of component substitution in the architecture described in this
document as substitutions may impair the compatibility and interoperability of software and
hardware.
Validity Note
This document has been updated for the release of TM3TI4D Add-on for SoMachine V4.3.
This document has been updated for the release of SoMachine Basic V1.6 SP1.
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Related Documents
12 EIO0000001678 02/2018
Title of Documentation Reference Number
Osisense XG, Radio Frequency Identification System, Catalog 9006CT0902
Detection for automation solutions OsiSense MKTED210041EN
The essential guide of Detection DIA4ED2041203EN
Transparent Ready, User Guide 31006929
Modbus Serial Line, Planning and Installation Guide 33003925
SoMachine Programming Guide EIO0000000067 (ENG)
You can download these technical publications and other technical information from our website
at https://www.schneider-electric.com/en/download
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
Disconnect all power from all equipment including connected devices prior to removing any
covers or doors, or installing or removing any accessories, hardware, cables, or wires except
under the specific conditions specified in the appropriate hardware guide for this equipment.
Always use a properly rated voltage sensing device to confirm the power is off where and when
indicated.
Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a
proper ground connection exists before applying power to the unit.
Use only the specified voltage when operating this equipment and any associated products.
Failure to follow these instructions will result in death or serious injury.
This equipment has been designed to operate outside of any hazardous location. Only install this
equipment in zones known to be free of a hazardous atmosphere.
DANGER
POTENTIAL FOR EXPLOSION
Install and use this equipment in non-hazardous locations only.
Failure to follow these instructions will result in death or serious injury.
EIO0000001678 02/2018 13
WARNING
LOSS OF CONTROL
The designer of any control scheme must consider the potential failure modes of control paths
and, for certain critical control functions, provide a means to achieve a safe state during and
after a path failure. Examples of critical control functions are emergency stop and overtravel
stop, power outage and restart.
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
Observe all accident prevention regulations and local safety guidelines.1
Each implementation of this equipment must be individually and thoroughly tested for proper
operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
1For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the
Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest
edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of
Adjustable-Speed Drive Systems" or their equivalent governing your particular location.
WARNING
UNINTENDED EQUIPMENT OPERATION
Only use software approved by Schneider Electric for use with this equipment.
Update your application program every time you change the physical hardware configuration.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Standard Description
EN 61131-2:2007 Programmable controllers, part 2: Equipment requirements and tests.
ISO 13849-1:2008 Safety of machinery: Safety related parts of control systems.
General principles for design.
14 EIO0000001678 02/2018
Standard Description
EN 61496-1:2013 Safety of machinery: Electro-sensitive protective equipment.
Part 1: General requirements and tests.
ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk
reduction
EN 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
EN 1088:2008 Safety of machinery - Interlocking devices associated with guards - Principles
ISO 14119:2013 for design and selection
ISO 13850:2006 Safety of machinery - Emergency stop - Principles for design
EN/IEC 62061:2005 Safety of machinery - Functional safety of safety-related electrical, electronic,
and electronic programmable control systems
IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-
related systems: General requirements.
IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety-
related systems: Requirements for electrical/electronic/programmable
electronic safety-related systems.
IEC 61508-3:2010 Functional safety of electrical/electronic/programmable electronic safety-
related systems: Software requirements.
IEC 61784-3:2008 Digital data communication for measurement and control: Functional safety
field buses.
2006/42/EC Machinery Directive
2014/30/EU Electromagnetic Compatibility Directive
2014/35/EU Low Voltage Directive
In addition, terms used in the present document may tangentially be used as they are derived from
other standards such as:
Standard Description
IEC 60034 series Rotating electrical machines
IEC 61800 series Adjustable speed electrical power drive systems
IEC 61158 series Digital data communications for measurement and control – Fieldbus for use in
industrial control systems
Finally, the term zone of operation may be used in conjunction with the description of specific
hazards, and is defined as it is for a hazard zone or danger zone in the Machinery Directive
(2006/42/EC) and ISO 12100:2010.
NOTE: The aforementioned standards may or may not apply to the specific products cited in the
present documentation. For more information concerning the individual standards applicable to the
products described herein, see the characteristics tables for those product references.
EIO0000001678 02/2018 15
16 EIO0000001678 02/2018
Compact Modbus SL Logic Controller M221 Book
General Information
EIO0000001678 02/2018
Chapter 1
General Information
General Information
EIO0000001678 02/2018 17
General Information
Introduction
Overview
With Tested Validated Documented Architectures (TVDAs), Schneider Electric provides complete
controlling system proposals applicable for a wide range of applications.
TVDAs are meant to help you to
quickly find cost efficient controlling solutions,
optimize the system implementation time,
gain a competitive advantage and optimize overall costs for your machine.
With detailed component lists, wiring diagrams, commissioning guides, controller, and HMI
applications the effort to assemble and setup the system becomes significantly reduced.
For a high level of reliability and robustness each TVDA is subjected to extensive system
validation. Specific performance requirements as well as installation constraints are considered in
the system design.
TVDAs provide a high level of openness for adaptations. With a clear separated project template
structure and dedicated functions embedded in SoMachine and SoMachine Basic, required
modifications can be realized quickly.
WARNING
UNINTENDED EQUIPMENT OPERATION
Thoroughly read and understand any and all device manuals for the characteristics and
properties of the devices employed before attempting to modify parameters that may alter those
characteristics and properties.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
18 EIO0000001678 02/2018
General Information
Deliverables
HMI Application
The HMI application is a ready-to-use interface that can:
Control the main functionalities of the system
Indicate the system status
Visualize the system errors that are detected
Wiring Diagram
The wiring diagrams provide detailed guidance on the system wiring, and are reusable as a base
to generate final technical documentation of the controlling system.
The wiring diagrams are provided for download on the Schneider Electric web page
www.schneider-electric.com and are available in the following file formats:
EPLAN Electric P8 V2.4 project archive
*.pdf (generated with EPLAN)
*.dwg (generated with EPLAN)
EIO0000001678 02/2018 19
General Information
20 EIO0000001678 02/2018
Compact Modbus SL Logic Controller M221 Book
System Architecture
EIO0000001678 02/2018
Chapter 2
System Architecture
System Architecture
EIO0000001678 02/2018 21
System Architecture
Remote Devices
Remote control operating devices may lead to unintended equipment operation by:
incorrect operation
insufficient view on the machine during operation
unintentional manipulation
Care must be taken and provisions made for use of this product as a control device to avoid
inadvertent consequences of commanded machine operation, state changes, or alteration of data
memory or machine operating parameters.
WARNING
UNINTENDED EQUIPMENT OPERATION
Place operator devices of the control system near the machine or in a place where you have
full view of the machine.
Protect operator commands against unauthorized access.
If remote control is a necessary design aspect of the application, ensure that there is a local,
competent, and qualified observer present when operating from a remote location.
Configure and install the Run/Stop input, if so equipped, or, other external means within the
application, so that local control over the starting or stopping of the device can be maintained
regardless of the remote commands sent to it.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Wireless Devices
Data transmission between wireless devices can be influenced by environmental conditions.
Especially for portable devices, such as wireless and batteryless push-buttons, the quality of the
wireless communication is changing depending on the position of the device to the receiver.
WARNING
LOSS OF CONTROL
Do not use wireless equipment as the only means of control for critical control functions such
as motor start/stop or power disconnect.
Provide separate or redundant control paths for critical control functions.
Provide a means to achieve a safe state during and after a path failure for critical control
functions such as emergency stop and overtravel stop.
Improve the reliability of the wireless network by the use of repeater(s).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
22 EIO0000001678 02/2018
System Architecture
Communication
Fieldbusses or network communication may lead to loss of control by:
Communication disturbance by external influences (for example wiring or EMC)
Delay during communication
Interruption of communication
Inaccurate communication
WARNING
LOSS OF CONTROL
The designer of any control scheme must consider the potential failure modes of control paths
and, for certain critical control functions, provide a means to achieve a safe state during and
after a path failure. Examples of critical control functions are emergency stop and overtravel
stop, power outage and restart.
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
Observe all accident prevention regulations and local safety guidelines.1
Each implementation of this equipment must be individually and thoroughly tested for proper
operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
1
For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the
Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest
edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of
Adjustable-Speed Drive Systems" or their equivalent governing your particular location.
EIO0000001678 02/2018 23
System Architecture
System Architecture
Overview
The architecture is arranged into the optimized performance class and is distinguished by the
following characteristics:
Modicon M221 Logic Controller (book format)
Magelis HMI STO touch panel
Energy metering
Modbus serial line communication
Ethernet connectivity
Application of machine functional safety
Wireless and batteryless operator push-buttons
24 digital inputs
24 digital outputs
2 analog inputs
2 TM3XTYS4 expansion modules for connection with up to 8 TeSys motor starters
The following devices are linked to Modbus serial line and are controlled and monitored by the
controller:
Altivar 12 variable speed drive
3 RFID compact smart antennas
The architecture implements 5 motor starters which are linked to the TM3XTYS4 expansion
modules on the controller. The control and monitoring of the motor starters is realized with the
controller via hardwired signals.
2 TeSys D motor starter combinations
1 TeSys D motor starter combination and Altistart soft starter
2 TeSys U motor starter controller
24 EIO0000001678 02/2018
System Architecture
Layout
EIO0000001678 02/2018 25
System Architecture
26 EIO0000001678 02/2018
Compact Modbus SL Logic Controller M221 Book
Safety & Safety Requirements
EIO0000001678 02/2018
Chapter 3
Safety & Safety Requirements
EIO0000001678 02/2018 27
Safety & Safety Requirements
Overview
1. Evolution of legal framework (see page 29)
2. Risk assessment (see page 32)
3. Functional safety standards overview (see page 36)
4. Standard EN ISO 13849-1 machinery safety (see page 37)
5. Standard EN/IEC 62061 machinery safety (see page 44)
6. Selecting the applicable standard (see page 51)
7. Where to get more information regarding safety (see page 52)
a. Safety guide
b. Sistema
c. Sistema library
8. Concept used on specific TVDA
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Safety & Safety Requirements
EC Directive
Legal instrument to harmonize the legislation of the European member states
Defines the essential health and safety requirements (EHSRs).
Transposed into national law (act, decree, order, regulations).
Standard
A standard is a technical specification approved by a recognized standardization body for repeated
or continuous application, with which compliance is not compulsory.
Harmonized Standard
A standard becomes harmonized when published throughout the member states.
Presumption of Conformity
When a product conforms to a harmonized European standard, the reference to which has been
published in the official journal of the European Union for a specific directive, and which covers
one or more of the essential safety requirements, the product is presumed to comply with those
essential safety requirements of the directive.
In many cases European standards (ENs) are technically similar to international (IEC or ISO)
standards. However only European standards include a list of which EHSRs are covered, so
only European standards can confer a presumption of conformity.
A, B and C Standards
When a type C standard deviates from one or more provisions dealt with by a type A standard or
by a type B standard, the type C standard takes precedence. EN ISO 12100 is type A standards.
European standards for the machinery safety form the following structure:
Type A standards
Basic safety standards giving basic concepts, principles for design, and
general aspects that can be applied to all machinery.
Type B standards
Generic safety standards dealing with one safety aspect or one type of
safeguard that can be used across a wide range of machinery:
Type B1 standards on particular safety aspects (for example, safety
distances, surface temperature, noise)
Type B2 standards on safeguards (for example, two-hand controls,
interlocking devices, pressure sensitive devices, guards)
Type C standards
Machine safety standards dealing with detailed safety requirements for a
particular machine or group of machines.
Manufacturers' Responsibilities
Manufacturers placing machines on the market within the European Economic Area (EEA) must
comply with the requirements of the machinery directive. Note that "placing on the market" includes
an organization supplying a machine to itself, that is, building or modifying machines for its own
use, or importing machines into the EEA.
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Safety & Safety Requirements
Users' Responsibilities
Users of machines need to ensure that newly purchased machines are CE marked, and
accompanied by a declaration of conformity to the machinery directive. Machines must be used in
accordance with the manufacturer's instructions.
Existing machines taken into service before the machinery directive came into force do not need
to comply, although they need to comply with the regulations resulting from the use of work
equipment directive and be safe and fit for purpose.
Modification of machines can be considered as manufacture of a new machine, even if for use in-
house, and the company modifying a machine needs to be aware that it might need to issue a
declaration of conformity and CE marking.
EIO0000001678 02/2018 31
Safety & Safety Requirements
Risk Assessment
European Legislation
Machines are sources of potential risk and the machinery directive requires a risk assessment to
ensure that any potential risk is reduced to less than the acceptable risk.
Standard EN/ISO 12100 defines risk as follows: risk is the severity multiplied by the possibility of
occurrence. It defines an iterative process for achieving machine safety, which states that the risks
for each potential hazard can be determined in 4 stages.
1. Risk assessment
2. Determination of machine limits
3. Identification of the potential hazard
4. Risk evaluation
This method provides the basis for the requisite risk reduction.
Risk Assessment
Risk assessment consists of a series of logic steps which make it possible to analyze and evaluate
machinery-related risks systematically.
Risk assessment is followed, whenever necessary, by a reduction of the risk.
This definition taken from standard EN/ISO 12100 is based on an iterative process represented in
the diagram opposite.
Definition of risk
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Safety & Safety Requirements
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Safety & Safety Requirements
The risk is a function of the severity of the harm and the probability that this harm will occur. The
severity of the harm takes into account:
The severity of injuries (slight, serious, death)
The extent of the harm (number of persons)
Risk Evaluation
Based on the risk assessment, the designer has to define the safety-related control system. To
achieve that, the designer will choose one of the 2 standards appropriate to the application:
either standard EN ISO 13849-1, which defines performance levels (PL)
or standard EN/IEC 62061, which defines safety integrity level (SIL)
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Safety & Safety Requirements
Risk Reduction
The process of risk reduction for dangerous events starts by:
intrinsic prevention (inherently safe design)
definition of the appropriate protective means (guards, carters, fix fences, ...)
personnel training
If the selected preventive measure depends on a safety-related control system, the designer has
to perform an iterative process for the design of the safety relative control system. The first stage
is to define the necessary safety-related control functions:
either through the choice of components
or by adapting the control system architecture. Redundancy (double circuit components), for
example, significantly increases the reliability of the solution
Once the limits of available technologies have been reached; it will not be possible to further
reduce the rate of dangerous failures. To achieve the required level of safety, it will be necessary
to use a diagnostic system that allows dangerous failures to be detected.
EIO0000001678 02/2018 35
Safety & Safety Requirements
Overview
The functional safety standards are intended to encourage designers to focus more on the
functions that are necessary to reduce each individual risk, and on the performance required for
each function, rather than simply relying on particular components. These standards make it
possible to achieve greater levels of safety throughout the life of a machine.
Under the previous standard, EN 954-1, categories (B, 1, 2, 3 and 4) dictated how a safety-
related electrical control circuit must behave under fault conditions. Designers can follow either
EN ISO 13849-1 or EN/IEC 62061 to demonstrate conformity with the machinery directive.
These 2 standards consider not only whether a fault will occur, but also how likely it is to occur.
This means that there is a quantifiable, probabilistic element in compliance: machine builders
must be able to determine whether their safety circuit meets the required safety integrity level
(SIL) or performance level (PL). Panel builders and designers should be aware that
manufacturers of the components used in safety circuits (such as safety detection components,
safety logic solvers, and output devices like contactors) must provide detailed data on their
products.
36 EIO0000001678 02/2018
Safety & Safety Requirements
Overview
Standard EN ISO 13849-1 is an evolution of standard EN 954-1.
Process
The risk assessment leads to decisions on risk reduction measures.
It defines a 6-stage design process:
1. Selection of the essential safety functions that SRP/CS must perform. For each safety function,
specify the required characteristics.
2. Determine the required performance level (PLr).
3. Design and technical creation of safety functions: identify the parts that perform the safety
function.
4. Evaluate the performance level PL for each safety-related part.
5. Check that the performance level PL achieved is greater than or equal to the required level
(PLr).
6. Check that all requirements are satisfied.
The above 6 stages will be illustrated taking as an example a safety function where a severe injury
can be caused by a horizontal movement on a machine not stopping where an operator maybe
exposed to this dangerous situation. The machine is sometimes accessed by production workers
and monitored during operation.
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Safety & Safety Requirements
For the example: a serious injury S2 can be caused by being exposed near the machine as if there
is no safe guarding to ensure that the movement will stop the horizontal movement with a load may
continue until collision.
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Safety & Safety Requirements
After considering the severity of the injury investigate the frequency and/or duration of the possible
entry to the dangerous area. Here you define the frequency of exposure to the hazard is low F1
(occasional presence).
The last step is based upon the possibility to avoid the hazard and limiting the harm. To evaluate
this, take into consideration that it is possible to avoid the harm as the visibility around the
dangerous machine is monitored by the operator and in this case there is a possibility to avoid the
harm under certain conditions so define it as P1.
The result of the estimation gives a required performance level PLr = c.
EIO0000001678 02/2018 39
Safety & Safety Requirements
Im Interconnecting means
C Cross monitoring
I, I1, I2 Input device, for example sensor
L, L1, L2 Logic
m Monitoring
O, O1, O2 Output device, for example main contactor
TE Test equipment
OTE Output of TE
Index Range
Low 3 years ≤ MTTFd < 10 years
Medium 10 years ≤ MTTFd < 30 years
High 30 years ≤ MTTFd < 100 years
A MTTFd of less than 3 years should never be found, because this would mean that after 1 year in
operation, 30% of all those components in use would have failed to a dangerous state. The
maximum value is limited to 100 years because devices dealing with a significant risk should not
depend on the reliability of a single component. Additional measures such as redundancy and tests
are required.
Diagnostic coverage (DC)
This term is expressed as a percentage and quantifies the ability to diagnose a dangerous failure.
For example, in the event of welding of a N/C contact in a relay, the state of the N/O contact could
incorrectly indicate the opening of the circuit, unless the relay has mechanically linked N/O and N/C
contacts, when the fault can be detected.
40 EIO0000001678 02/2018
Safety & Safety Requirements
Denotation Range
Nil DC < 60%
Low 60% ≤ DC <90%
Medium 90% ≤ DC < 99%
High 99% ≤ DC
The relationship between categories, DC and MTTFd of each channel and PL.
Using the above chart you can now select the most appropriate architecture, the required
diagnostic coverage as well as ensure the products selected have the right MTTFd values.
As the example requires PL=c the chart states as a minimum a category 1 architecture with a
diagnostic coverage of 0 (Nil) and a MTTFd of high is required.
It is possible to use architectures with higher categories to solve the safety function needs.
You start with determining the architecture required to solve the function. Use the following
category 1 architecture:
EIO0000001678 02/2018 41
Safety & Safety Requirements
Knowing the architecture it is now possible to select the most appropriate products. Using the offer
catalogs you define the products as illustrated below.
The selection of the right products may take several iterations as it is only possible to ensure that
the right products are selected after calculations have been made.
Stage 4 - Evaluate the Performance Level (PL) for Each Safety-Related Part
Typically the data needed for the calculation of the performance level is being provided by the
components supplier.
For safety processing devices the MTTFd, DC and performance level values are provided.
For other non-safety components such as contactors, limit switches, and so on, which wear
primary as a result of their mechanical actuation, B10d values are provided by the supplier in some
cases. When the B10d values are not available, the annex C from the 13849-1 standard can be
used.
To estimate the performance level of a safety function, the condition is that the MTTFd, the DC,
and the category from each component are known. The procedure to follow:
Calculation of MTTFd and DC of the complete system
Analysis of the category
42 EIO0000001678 02/2018
Safety & Safety Requirements
In this case, the machine operates for 220 days per year, 8 hours per day with a cycle of 90 s
N = 220 x 8 x (3600 / 90) = 70,400 operations/year
MTTFd = B10d / (0.1 x N)
EIO0000001678 02/2018 43
Safety & Safety Requirements
Overview
This standard is specific to the machine sector according to EN/IEC 61508. It gives rules for the
integration of subsystems designed in accordance with EN/ISO 13849. It does not specify the
operating requirements of non-electrical control components in machines (for example: hydraulic,
pneumatic).
The decisive advantage of this approach is that of being able to offer a failure calculation method
that incorporates all the parameters that can affect the reliability of electrical systems, whatever the
technology used.
The method consists of assigning a SIL to each function, taking into account the following
parameters:
1. The probability of a dangerous failure of the components (PFHd)
2. The type of architecture; with or without redundancy, with or without diagnostic device making
it possible to avoid some of the dangerous failures
3. Common cause failures (power cuts, overvoltage, loss of communication network, and so on)
(CCF)
4. The probability of a dangerous transmission error where digital communication is used
5. Electromagnetic interference (EMC)
44 EIO0000001678 02/2018
Safety & Safety Requirements
Process
Designing a system is split into 5 stages after having drawn up the functional safety plan:
1. Based on the safety requirements specification (SRS), assign a safety integrity level (SIL) and
identify the basic structure of the safety-related electrical control system (SRECS), describe
each related function (SRCF)
2. Break down each function into a function block structure (FB)
3. List the safety requirements for each function block and assign the function blocks to the
subsystems within the architecture
4. Select the components for each subsystem
5. Design the diagnostic function and check that the specified safety integrity level (SIL) is
achieved
EIO0000001678 02/2018 45
Safety & Safety Requirements
Stage 1 - Assign a Safety Integrity Level (SIL) and Identify the Structure of the SRECS
Based on the risk assessment performed in accordance with standard EN/ISO 12100, estimation
of the required SIL is performed for each hazardous phenomenon and is broken down into
parameters, see illustration below.
Severity Se
The severity of injuries or damage to health can be estimated by taking into account reversible
injuries, irreversible injuries, and death.
Consequence Severity Se
Irreversible: death, loss of an eye or an arm 4
Irreversible: shattered limb, loss of a finger 3
Reversible: requires the attention of a medical practitioner 2
Reversible: requires first aid 1
46 EIO0000001678 02/2018
Safety & Safety Requirements
Therefore a class CI = 5 + 2 + 3 = 10
EIO0000001678 02/2018 47
Safety & Safety Requirements
A level of SIL 2 must be achieved by the safety-related electrical control systems (SRECS) on the
machine.
Stage 2 - Break down Each Function into a Function Block Structure (FB)
A function block (FB) is the result of a detailed breakdown of a safety-related function. The function
block structure gives an initial concept of the SRECS architecture. The safety requirements of each
block are deduced from the specification of the safety requirements of the system's function.
Stage 3 - List the Safety Requirements for Each Function Block and Assign the Function Blocks to the
Subsystems
Each function block is assigned to a subsystem in the SRECS architecture. A failure of any
subsystem will lead to the failure of the safety-related control function.
More than one function block may be assigned to each subsystem. Each subsystem may include
subsystem elements and, if necessary, diagnostic functions in order to ensure that anomalies can
be detected and the appropriate action taken.
These diagnostic functions (D) are considered as separate functions; they may be performed
within the subsystem, by another internal or external subsystem.
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Safety & Safety Requirements
EIO0000001678 02/2018 49
Safety & Safety Requirements
For each of the 4 logical architectures A to D presented above, there is a different formula to
calculate the PFHd. The calculation method is complex and will not be presented here (see
EN/IEC 62061 for the formula and the parameters taken into account).
50 EIO0000001678 02/2018
Safety & Safety Requirements
Overview
In order to be able to select the applicable standard, a common table in both standards gives
indications which are summarized below:
Relationship between the performance level (PL) and the safety integrity level (SIL):
EIO0000001678 02/2018 51
Safety & Safety Requirements
Overview
To know more about the relevant regulations, take a look to the safety guide:
http://www.schneider-electric.com/download/ww/en/details/10101698-Machine-safety-
guide/?reference=DIA4ED1100102EN
Sistema
For support in creating the safety-related calculations in accordance to EN ISO 13849-1, refer to
the free software as well as the related Schneider Electric Sistema offer library.
Sistema:
http://www.dguv.de/bgia/en/pra/softwa/sistema/index.jsp
Sistema library:
http://www2.schneider-electric.com/documents/original-equipment-manufacturers/SCHNEIDER-
ELECTRIC-SAFETY-EN_2012_09.zip
52 EIO0000001678 02/2018
Safety & Safety Requirements
EIO0000001678 02/2018 53
Safety & Safety Requirements
Overview
Within the described architecture, the safety function emergency stop is applied what is described
in this section.
NOTE: The safety function proposed in this architecture does not provide a preferred safety chain
solution for your machine. This is a proposal how a safety function could be realized.
WARNING
UNINTENDED EQUIPMENT OPERATION
Ensure that a risk assessment is conducted and respected according to EN/ISO 12100 during
the design of your machine.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Emergency Stop
In this TVDA, the safety function emergency stop is applied to disconnect the main power supply
of all drives.
This safety architecture is conforming to category 4 EN ISO 13849-1:2008 and is using the stop
category 0 in accordance with the standard IEC/EN 60204-1.
The architecture achieves a performance level (PL) of e and a safety integrity level (SIL) of 3.
Used devices
Device Description
Input 2 channel emergency stop button Harmony XAL K
Logic TM3 safety module TM3SAF5R
Output 2 redundant contactors with feedback loop LC1D
54 EIO0000001678 02/2018
Compact Modbus SL Logic Controller M221 Book
Hardware
EIO0000001678 02/2018
Chapter 4
Hardware
Hardware
Overview
This chapter provides general information about the hardware.
EIO0000001678 02/2018 55
Hardware
Section 4.1
Electrical Distribution and Monitoring
56 EIO0000001678 02/2018
Hardware
Front View
PowerPact H-Frame circuit breaker (15...150 A)
Description
The PowerPact multistandard circuit breakers are designed to help protect electrical systems from
damage caused by overloads and short circuits.
Multistandard circuit breakers are available with either thermal-magnetic or Micrologic electronic
trip units. Multistandard circuit breakers with thermal-magnetic trip units contain individual thermal
(overload) and immediate (short circuit) sensing elements in each pole.
PowerPact multistandard circuit breakers offer high performance and a wide range of
interchangeable trip units to protect most applications. Electronic trip units provide highly accurate
protection with wide setting ranges and can integrate measurement, metering, and communication
functions. They can be combined with the front display module (FDM121) to provide functions
similar to a power meter.
Industry-leading multistandard-compliant circuit breakers provide unrivalled reliability for heavy-
duty applications. Common catalog numbers, standardized ratings, and a full range of field-
installable accessories make product selection, installation, and maintenance easier than ever.
EIO0000001678 02/2018 57
Hardware
58 EIO0000001678 02/2018
Hardware
Front View
Multi-9 C60 (UL 1077) miniature supplementary protectors
Description
The Multi-9 supplementary protector line from Schneider Electric is a modular system of
supplementary protectors, accessories, and installation equipment that makes up the most
complete product offering in its class.
These UL 1077 recognized supplementary protectors provide overcurrent protection in
applications where branch circuit protection is either already provided or is not required.
0.5...63 A at 480Y/277 Vac
Up to 10 k AIR
1-, 2-, 3-, and 4-pole versions
Common tripping of all poles
B-curve 3...5 in. (76.2...127 mm), C-curve 7...10 in.(177.8...254 mm), D-curve 10...14 in.
(254...355.6 mm)
Current limiting capability is standard
Full line of accessories
Only 0.71 in. (18 mm) width per pole
Flush, surface, or DIN rail mountable
UL 1077, IEC 60947-2, and CE marked
EIO0000001678 02/2018 59
Hardware
60 EIO0000001678 02/2018
Hardware
Front View
Multi-9 C60 (UL 489) miniature circuit breakers
Description
The Multi-9 C60 (UL 489) miniature circuit breaker is a UL 489 version of the Schneider Electric
Multi-9 C60 family of DIN rail mountable circuit protection devices.
UL 489 devices provide branch circuit protection while UL 1077 supplementary protectors do not.
Designed to meet global applications and code requirements, the UL listed Multi-9 breakers are
the first product to carry UL 489, IEC 947-2, and CSA C22.2 ratings as well as the CE mark.
The Multi-9 breaker family features an extensive array of accessories.
1-, 2-, and 3-pole configurations
17 UL 489 ratings 0.5 A...35 A
2 trip curves available: C curve (7...10 times handle rating); D curve (10...14 times handle
rating)
Small size: less than 19.05 mm (0.75 in.) wide per pole
Interrupting ratings 10K AIR standard
System voltages include 120/240 Vac and 240 Vac; also DC ratings of 60 Vdc (1P) and 125 Vdc
(2P)
Ring terminals available (with finger-safe option)
Padlock attachments for locking in the "OFF" position only
Common tripping of all poles
Variety of accessories including shunt trip, auxiliary switch, and under-voltage release. Same
accessories can be used on both UL 1077 and UL 489 devices.
Mounting base for 12...60 poles.
For more information, refer to Multi 9 System, Catalog, 0860CT0201.
EIO0000001678 02/2018 61
Hardware
Front View
Phaseo ABL8RPS24100 power supply
Description
The Phaseo electronic switch mode power supply is designed to provide the DC voltage necessary
for the controller and automation system equipment control circuits.
Conforming to IEC standards and UL, CSA, TÜV and C-Tick certified, they are suitable for
industrial use.
The ABL8RPS/8WPS range of Phaseo power supplies covers power ratings 72...960 W in 24 Vdc
and adapts to most power distribution systems used throughout the world. The same power supply
can thus be connected phase to neutral or phase to phase for line supplies ranging 100...500 Vac
nominal.
Local or remote diagnostic functions
Current limiting or stop in event of an overload
Function modules to ensure continuity of service
Power reserve for absorbing the transient current peaks
62 EIO0000001678 02/2018
Hardware
Wiring
Connection overview ABL8RPS24100
EIO0000001678 02/2018 63
Hardware
Front View
The graphic shows the front view of the energy meter iEM3110:
Description
The Acti 9 iEM3100 Energy Meter series offers a cost-attractive, competitive range of DIN rail-
mounted energy meters ideal for subbilling and cost allocation applications. Combined with
communication systems such as Smart Link, the Acti 9 iEM3100 series makes it easy to integrate
electrical distribution measurements into your facility management systems. The Acti 9 iEM3100
series contains 8 versions of energy meter (for example, iEM3110 and iEM3150) to satisfy basic
to advanced applications for buildings and industry, data centers, and networks, infrastructure, and
so on.
Graphical display for easy viewing
Self-powered meters
Direct measurement up to 63 A
Onboard Modbus, LON, M-Bus or BACnet communication
Commissioning safely with ease
Compact size
64 EIO0000001678 02/2018
Hardware
Standards and certifications IEC 61557-12, IEC 61036, IEC 61010, IEC 62053-21/22 class 1
and 0.5S, IEC 62053-23, EN50470-3
Current (max) 63 A
Models iEM3100, iEM3110, iEM3115, iEM3135, iEM3150, iEM3155,
iEM3165, iEM3175
Functions (depending on the model Active energy measurement
Electrical measurements such as I, V, P, and so on.
Alarm
Digital output for pulse
MID (legal metrology certification)
For more information, refer to iEM3100 series / iEM3200 series, Energy Meters, User Manual,
DOCA0005EN.
Wiring
The graphic shows the wiring on three-phase systems for direct measurement of iEM31••
EIO0000001678 02/2018 65
Hardware
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Hardware
EIO0000001678 02/2018 67
Hardware
Section 4.2
Safety Modules
Safety Modules
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Hardware
Front View
Modicon TM3 safety module
Description
The Modicon TM3 modular I/O system provides flexible and scalable configuration of expansions
by direct connection with M221, M241, and M251 controllers. Characterized by easy wiring and
maintenance, this modular I/O system offers a wide variety of modules that enables you to meet
your desired configuration for reduced costs and simplification.
The Modicon TM3 modular I/O system contains a range of TM3 safety modules. These Modicon
TM3 safety modules contain inputs and relay outputs to manage one safety function at a time. The
safety function is realized in the module itself and the monitor and control functions are processed
by the controller via the TM3 I/O bus.
There are several types of Modicon TM3 safety modules supporting multiple functions. The
achievable Performance Level (PL) according to EN/ISO 13849-1:2008 reaches from PL d up to
PL e and is dependent on the selected module type and the application.
The module used in the described architecture is the TM3SAF5R. The main characteristics are
described in the table below.
Max. Performance Level Category 4, PL "e" according to EN/ISO 13849-1: 2008, SIL 3 according to
(PL) / Safety Integrity Level IEC/EN 61508-1:2010
(SIL)
Safety function 2 channel operation with cross circuit detection either with monitored or non-
monitored start
Standards and CE
certifications For more information on the standards and certifications, refer to the Modicon
TM3 Safety Modules, Hardware Guide.
Power supply 24 Vdc (-15...+20 %)
Power consumption 3.6 W (power supply), 0.2 W (TM3 I/O bus)
EIO0000001678 02/2018 69
Hardware
Components
Modicon TM3 safety module with removable screw or spring terminal block
For more information, refer to Modicon TM3 Safety Modules, Hardware Guide, EIO0000001831.
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Hardware
Wiring
Wiring example of emergency stop connection to a TM3SAF5R• module
EIO0000001678 02/2018 71
Hardware
Front View
Preventa product range
Description
Schneider Electric is the provider of the safety chain covering the safety functionality and scalability
for your machine. Preventa offers an extensive range of safety-related products, compliant with
international standards, designed to provide protection for personnel and equipment.
For more information, refer to Preventa solutions for efficient machine safety - catalogue,
MKTED2140201EN.
Complementary safety-related products like light curtains, emergency stop rope pull switches or
switches are offered by Telemecanique Sensors; brand of Schneider Electric.
Telemecanique Sensors proposes a number of ranges of safety-related products:
Discover this offer on the website: http://www.tesensors.com/global
Access to the catalog by product at this URL:
http://www.tesensors.com/global/en/product/catalog/
72 EIO0000001678 02/2018
Hardware
Section 4.3
HMI
HMI
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Hardware
Front View
Magelis HMI STO product range
Description
Magelis HMI STO touch screen small panels offer you ease of use and efficiency, while boasting
high-end features and capabilities in a small package. The HMI STO product has capabilities more
typical of larger products, including data management, remote access, and multiplex connectivity
to major controllers and control products, as well as other products.
3.4" monochrome touch screen, available with 2 different types of backlighting:
Green, orange, red
White, pink, red
Standards and EN, IEC, UL 508, ISA 12,12,CSA, Marine Bridge & Deck, Gost
certifications
Power supply 24 Vdc with removable connector
Degree of protection Front panel: IP 65
Rear panel: IP 20
74 EIO0000001678 02/2018
Hardware
Memory Application: 16 Mb
Backup: 128 Kb
For more information, refer to Magelis Small Panels HMI STO, User Manual, EIO0000000239.
Wiring
Rear
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A Display: displays user created screens and D Ethernet interface: connects an Ethernet
remote equipment variables. cable (from the host/controller) to the unit.
B Touch panel: performs screen change E Mini-B USB port connector: connects the
operations and sends data to the host data transfer PC cable to the unit (USB2
(controller). port).
C Power input terminal block: connects the F Standard A USB port connector: connects
power input and ground wires to the unit. the data transfer cable or memory stick to the
unit (USB1 port).
Power plug
+ 24 Vdc
- 0 Vdc
FG Grounded terminal connected to the unit chassis
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Front View
Harmony ZBRRC receiver
Description
Harmony XB5R wireless and batteryless push buttons are used for remote control with an access
point. This allows more flexibility and simplicity in the installation.
The control is realized via radio transmission. Each transmitter is equipped with a generator that
converts the mechanical energy produced by pressing the push button into electrical energy.
A radio-coded message with a unique ID code will be sent in a single pulse to one or more
receivers. These receivers can be located several tens of meters away.
The access point processes the received radio frequency inputs and provides them via 4 transistor
outputs as a 24 Vdc signal.
Wireless and batteryless push-button technology reduces the wiring and hence the cost of
installation. They have a wide range of industrial and building applications such as:
packing lines
automatic doors in logistic centers
automobile industries
bag filling in cement industries
office lighting for efficient usage of the power
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Hardware
For more information, refer to Harmony XB5R, Expert Instruction Sheet, EIO0000000812 (EN).
Wiring
Wiring example Harmony XBRRC
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Front View
Harmony product range
Description
Schneider Electric offers a comprehensive range for control and signaling in industrial and
commercial applications. All aspects of control and signaling needs are catered for including pilot
devices such as push-buttons, indicator lamps, selector switches, and joysticks for standard hole
cutouts.
For more information, refer to Control and signaling components, MKTED208031EN.
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Section 4.4
Controller
Controller
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Front View
Modicon logic controller TM221M16TG
Description
The Modicon M221 Logic Controller has various powerful features and can service a wide range
of applications. Software configuration, programming, and commissioning are accomplished with
the SoMachine Basic software described in the SoMachine Basic Operating Guide.
The SoMachine Basic software supports the following IEC 61131-3 programming languages:
IL: Instruction list
LD: Ladder diagram
Grafcet (List)
The following communication functions, depending on the model, are supported by the controllers:
Ethernet
USB programming
Serial line
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The following embedded I/O types are available, depending on the controller reference:
Regular inputs
Fast inputs associated with counters
Regular transistor outputs
Fast transistor outputs (PWM/PLS/PTO/FREQGEN)
Regular relay outputs
Analog inputs
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TM221M32TK2 12 regular inputs3 14 regular transistor 2 analog inputs 2 serial line ports
4 fast inputs (HSC)4 outputs 0...10 V 1 USB mini-B programming
2 fast transistor outputs port
(PWM/PLS/PTO)5
TM221ME32TK2 12 regular inputs3 14 regular transistor 2 analog inputs 1 serial line port
4 fast inputs (HSC)4 outputs 0...10 V 1 USB mini-B programming
2 fast transistor outputs port
(PWM/PLS/PTO)5 1 Ethernet port
1 With removable spring terminal blocks.
2 With HE10 (MIL 20) connectors.
3 The regular inputs have a maximum frequency of 5 kHz.
4 The fast inputs (max. 100 kHz) can be used either as regular inputs or as fast inputs for counting or event
functions.
5 The fast transistor outputs (max. 100 kHz) can be used as regular transistor outputs, or for PWM, PLS or PTO
functions, or reflex outputs for HSC.
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Physical Description
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* Type T fuse
(1) The V+ terminals are connected internally.
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Front View
Modicon TM3 Modules
Description
The Modicon TM3 modular I/O system provides flexible and scalable configuration of expansions
by direct connection with M221, M241, and M251 controllers. Characterized by easy wiring and
maintenance, this modular I/O system offers a wide variety of modules that enables you to meet
your desired configuration for reduced costs and simplification.
Flexible and scalable I/O configuration:
Local or remote expansion via the local TM3 expansion bus on M221, M241, and M251
controllers.
Wide range of I/O expansion modules:
Digital I/O modules
Analog I/O modules
Expert I/O modules
Safety I/O modules
Transmitter and receiver modules
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Hardware
Standards and IEC/EN 61131-2 ed. 3 2007, UL 508, CSA 22.2 No. 142, CE
certifications
Power supply 24 Vdc or 120 Vac*
* only TM3DI8A
Degree of protection IP 20
Dimensions One assembled integral module (W x H x D):
21.4…42.9 x 94.5…95 x 81.3…88.1 mm (0.84…1.69 x 3.72…3.74 x
3.2…3.47 in.)
For more information, refer to Modicon TM3, Expansion Modules Configuration, Programming
Guide, EIO0000001402.
Wiring
Wiring example TM3DM8R
* Type T fuse
(1) The COM0 and COM1 terminals are not connected internally.
(2) To improve the life time of the contacts, and to protect from potential inductive load damage, you must
connect a free wheeling diode in parallel to each inductive DC load or an RC snubber in parallel of each
inductive AC load.
A Sink wiring (positive logic)
B Source wiring (negative logic)
C Source wiring (positive logic)
D Sink wiring (negative logic)
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Front View
Description
The TM3XTYS4 I/O expansion module connects the controller to the parallel wiring system of
TeSys. This I/O expansion module provides the status and command information for each TeSys
motor starter via an RJ45 connector. One TM3XTYS4 module can manage up to 4 TeSys motor
starters, reverse or forward, whatever they are TeSys D or TeSys U or mix.
The TM3XTYS4 module is compatible with:
TeSys U system equipped with the LUFC00 parallel wiring module
GV and TeSys D system equipped with the LAD5C•• wiring adapter
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Physical Overview
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Pin Assignment
RJ45 connector
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not connect wires to unused terminals and/or terminals indicated as “No Connection (N.C.)”.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
CAUTION
INCOMPATIBLE EQUIPMENT
Use the RJ45 connector only for the link with devices which are compatible with the TeSys RJ45
connection system.
Failure to follow these instructions can result in injury or equipment damage.
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* Type T fuse
24 Vdc Is dedicated to outputs power supply
24 Vdc Aux Is dedicated to inputs power supply
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Section 4.5
Communication
Communication
Front View
5-port TCSESU053FN0 Ethernet switch (unmanaged)
Description
The ConneXium unmanaged Ethernet switch range offers you a smart and flexible way to integrate
Ethernet solutions into your operation, from the device level to the control network and to your
corporate network.
Unmanaged devices are those which there is no possibility to configure or control any of the
parameters of the devices. They support Ethernet 10 Mbit/s and Fast Ethernet 100 Mbit/s.
Furthermore the switch modules support switched Ethernet networks in accordance with IEEE
standard 802.3 or 802.3u using copper and fiber optic technology.
All switches are mounted on a standard DIN rail.
Multi-address capability
Storage and rerouting of received data
Data packets with VLAN tags are transmitted unchanged (IEEE 802.1 Q)
Automatic negotiation of 10/100 Mbit/s and duplex mode
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Hardware
For more information, refer to ConneXium Ethernet Switches, TCSESU0••F•N0, Quick Reference
Guide, 31007950.
Wiring
TCSESU053FN0 connector overview
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Section 4.6
Motor Control
Motor Control
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Front View
TeSys D-LC1D contactor
Description
TeSys D-LC1D contactors are designed for all power switching, control applications, and
integration into control systems.
They conform to standard IEC 60947-4-1, for utilization categories AC6b, as well as to UL/CSA
standards.
This product constitutes a ready-to-use solution and offers you quick simple setup.
TeSys D contactors can be used to create motor starters for any type of application.
AC, DC, and low-consumption DC control circuit
All types of starter: reversing or non-reversing, star/delta, by auto-transformer, and so on.
Various connectors: spring terminal, EverLink terminal block, screw clamp, ring-type
connection, faston connector
Easy and simple direct mounting between contactor and circuit breaker, according to EverLink
terminal block (40...65 A)
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Wiring
TeSys D09…150 3-pole contactors wiring diagram
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Front View
TeSys GV2 P motor circuit breaker
Description
The large TeSys motor circuit-breakers range GV2, GV3 and GV7 is categorized according to their
level of performance and functions. Due to its diverse characteristics, only the GV2 P is presented
and integrated into the TVDA.
The TeSys GV2 P motor circuit-breakers are three-pole thermal-magnetic circuit-breakers
designed for the control and protection of motors.
The motor protection is provided by the thermal-magnetic elements incorporated in the industrial
motor circuit-breaker.
The magnetic elements (short-circuit protection) have a non-adjustable tripping threshold, which is
equal to 13 times the maximum setting current of the thermal trips.
The thermal elements (overload protection) include automatic compensation for ambient
temperature variations. The addition of an under voltage trip allows the circuit-breaker to be de-
energized in the event of an under voltage condition.
Motor and personnel protection
Live parts are protected from direct finger contact
Compact size
Easy to install: screw mounting or clip-on mounting
Control by rotary knob
Connection by screw clamps
Standards and IEC 60947-1, 60947-2, 60947-4-1, EN 60204, UL508, CSA C 22.2 n° 14-05,
certifications NF C 63-650, 63-120, 79-130, VDE 0113, 0660, UL*, CSA, PTB, EZU, GOST,
TSE, DNV, LROS, GL, BV, RINA, CCC, ATEX
Wiring
TeSys GV2 P contactors wiring diagram
Front View
TeSys U LU2B•• motor starter
Description
The TeSys U starter-controller is a Direct On Line (D.O.L.) starter which performs the following
functions:
Protection and control of single-phase or three-phase motors:
isolation and breaking function
overload and short-circuit protection
thermal overload protection
power switching
These functions can be added by selecting control units and function modules which clip into the
power base. This late customization is also possible after power and control circuit wiring has been
completed.
From design through to operation, TeSys U offers advantages and simplifies the selection of
components in comparison with a traditional solution.
The braking, isolation, and contactor functions are incorporated in a single block. Therefore,
there are fewer references to be ordered and selection is easy because a single reference
covers most needs up to 15 kW.
The control unit has a wide setting range. It can operate on a DC or an AC supply.
The compact components in the TeSys U range are mounted on a single rail, optimizing the
amount of space required in enclosures. As power wiring between the circuit-breaker and contactor
is not needed, TeSys U reduces installation times.
Setting-up accessories simplify or eliminate wiring between components, and allow easy selection
and ordering.
With a capacity of up to 32 A/15 kW, TeSys U consists of:
One 45 mm (1.77 in.) power base: two ratings, reversing or non-reversing, circuit-breaker
function, and built-in interference suppression
One clip-on control unit:
Standard CU: protection against overloads and short-circuits
Expandable CU: additional alarm and error differentiation
Multifunction CU: real-time control of motor load, local or remote diagnostics and parameter
setting
One clip-on automation control module: Modbus SL RS-485 2-wire, CANopen, AS-Interface,
PROFIBUS DP, Ethernet, DeviceNet, Fipio, Interbus S via Advantys STB module or a simple
parallel link
Two optional 45 mm (1.77 in.) power functions: limiter-isolator and changeover relay
Standards and IEC/EN 60947-6-2, CSA C22-2 N°14, Type E, UL508 type E: with phase barrier
certifications LU9SP0, UL, CSA, CCC, Gost, ASEFA, ABS, BV, DNV, GL, LROS, ATEX
Power range 0…15 kW at 400 V
Rated insulation voltage Conforming to IEC/EN 60947-1, overvoltage category III: 690 V
Conforming to UL508, CSA C22-2 n°14: 600 V
Dimensions W x H x D: LUB: 45 x 154 (224*) x 135 mm (1.77 x 6.1 (8.8*) x 5.3 in.)
*LU2B (reversible)
Options Four different control units
Error signaling modules
Communication modules
Auxiliary contact modules
Load level modules
Reverser block
Plug-in terminal blocks
Control circuit pre-wiring system
Components
TeSys U - non-reversing
TeSys U - reversing
A Reverser block
B Plug-in terminal blocks
C Control circuit pre-wiring system
Wiring
TeSys U - reversing
Front View
TeSys GV2DP
Description
The Schneider Electric TeSys product range offers a wide range of pre-assembled automatic
motor starter combinations with a power rate of up to 15 kW at 400/415 Vac. Motor starter
combinations with higher power ratings are available for customer assembly.
The product range of the TeSys GV2D•••••• motor starter combinations offers you a quick and
simple selection and product compatibility. The TeSys D contactor, when combined with the
TeSys GV2 motor circuit-breaker, provides a compact motor starter solution.
Range description
Direct On Line (D.O.L.) or reversing starters, 45 mm (1.77 in), and 90 mm (3.54 in) wide
respectively
Motor circuit-breaker with control via push-buttons (GV2ME) or selector switch (GV2P)
Circuit-breaker with built-in overload protection
Type 1 or type 2 coordination
Breaking capacity up to 130 kA
Enclosure for thermal-magnetic circuit breakers TeSys GV2ME
Wiring
Front View
Description
The TeSys LAD5C•• wiring adapter makes the TeSys motor starter combinations with screw-clamp
terminals compatible to the RJ45 connection system.
The RJ45 connection system offers a quick and easy connection to the TM3 I/O expansion module
TM3XTYS4.
All the control and command terminals of the motor starter combination are individually connected
to the adapter with pre-shaped pins. The upstream liaison with the TM3XYS4 module is carried out
with a simple RJ45 preformed cable.
4 types of the wiring adapter are available:
Notes:
GV2AF3 combination block is required for GV2 circuit breaker/contactor assembling.
GVAE20 auxiliary contact block must be assembled on GV2 and GV3 circuit breaker before
LAD5C••
Depth of the motor starter assemblies is increased by 15 mm (0.59 in), height is increased by
22 mm (0.87 in).
For more information, refer to LAD5C Instruction Sheet, HRB8873800
Electrical Schematics
Front View
Altistart 01
Description
The Altistart 01 soft starter enhances starting performance by providing a smooth and controlled
start for asynchronous motors, while providing torque surge suppression during both the starting
and stopping operation. This highly functional mini soft starter can help to decrease your
maintenance work and production downtime by helping to prevent the mechanical shocks that
create wear and tear on your motor and machinery.
Reduce mechanical stress on drive-train components
Ensure smooth acceleration of conveyors
Suppress water hammer on pumping applications
Eliminate belt slippage on fan loads
Minimize voltage sags on the distribution system
Standards and certifications UL, CSA, C-Tick, CCC, B44.1-96/ASME A14.5 for starter wired to the motor
delta terminal
Power range ATS 01N1••: 0,37...11 KW
ATS 01N2••: 0.75...75 kW
Degree of protection IP 20
Wiring
Wiring example power supply and motor
Directly applying line voltage to the Altistart soft starter will result in passing one of the three phases
of power to the motor, even in the case where there is no control power to the soft starter.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
Always use a contactor (-KM1) to remove all power from the motor when using the soft starter of
type ATS01N1••••.
Failure to follow these instructions will result in death or serious injury.
Front View
Altivar 12 variable speed drive
Description
The Altivar 12 drive is a frequency inverter for 200…240 V three-phase asynchronous motors
rated from 0.18 kW to 4 kW.
The Altivar 12 drive is robust, compact, and easy to install. Its integrated functions are suitable for
the requirements of applications involving simple industrial machines for example, packaging
machines, pumps, compressors, fans.
Small: easily integrated in any machine
Easy communication with all other machine components via integrated universal Modbus serial
link.
Low noise level
Product factory set for most applications
Numerous application-specific functions
Standards and IEC 61800-5-1; IEC 61800-3 (environments 1 and 2, categories C1 to C3, cat.
certifications C1 with option for ATV 212); UL, CSA, C-Tick, NOM, GOST
Power range 0.18…4 kW
Voltage range Single-phase 100…120 V (0.18 to 0.75 kW)
Single-phase 200…240 V (0.18 to 2.2 kW)
Three-phase 200…240 V (0.18 to 4 kW)
Degree of protection IP 20
EMC filter Integrated: ATV12•••M2 and ATV312H••N4
Optional: ATV12•••F1; ATV12•••M3
For more information, refer to Altivar 12, Variable speed drives for asynchronous motors, User
manual, BBV28581.
Wiring
Altivar 12 connector overview
1 Power terminals
2 Control terminals
3 RJ45 communication port
Item Description
1 R1 relay contacts, for remote indication of the drive status.
2 Internal +24 Vdc. If an external source is used (+30 Vdc maximum), connect the 0 V of the source to
the COM terminal, and do not use the +24 Vdc terminal on the drive.
3 Reference potentiometer SZ1RV1202 (2.2 kΩ) or similar (10 kΩ maximum).
4 Optional braking module VW3A7005.
5 Optional braking resistor VW3A7••• or other acceptable resistor. See the possible resistor values in
the catalog.
NOTE:
Use transient voltage surge suppressors for all inductive circuits near the drive or coupled to the
same circuit (relays, contactors, solenoid valves, and so on).
The ground terminal (green screw) is located on the opposite side in comparison with its position
on the ATV 12 (see wiring trap label).
Section 4.7
Detection
Detection
Front View
OsiSense XG tap-off box
Description
The OsiSense TCSAMT31FP tap-off box enables XGCS smart antennas to be connected to
Modbus SL communication bus.
The TCSAMT31FP box is fitted with M12 connectors. It is used to connect the power supply, the
communication bus (Modbus SL) and 1 to 3 XGCS smart antennas (up to 15 smart antennas, by
daisy-chaining). It consists of a sealed metal enclosure.
For more information, refer to :
Osisense XG, Radio Frequency Identification System, Catalog, 9006CT0902
RFID OsiSense XG, Compact Stations, W916556690111
Components
Front View
OsiSense XGCS•90
Description
The OsiSense XG smart antennas with RS-485 serial port combine a compact design and
remarkable features to provide elevated performances in read/write operations on 13.56 MHz
RFID tags.
OsiSense XG compact smart antennas integrate functions which simplify communication between
tags, smart antennas, and controllers (automation platform, PC, and so on).
Embedded functions are activated by standard requests to read/write words, sent by the PLC:
Reset: The RFID part of the smart antenna is reinitialized and assumes its factory default
configuration.
Init: The smart antenna is reinitialized and operates as it would after being switched back on
(address unchanged, RFID parameters deleted).
Sleep mode: Transmission of the electromagnetic field of the smart antenna is only activated
upon receipt of a read or write instruction. This mode reduces the power consumption of the
smart antenna and helps to prevent interference when the smart antennas are in close proximity
to each other.
Auto read/write: This mode enables the smart antenna to execute up to 10 read or write
instructions on a tag automatically (without PLC command) as soon as the RFID tag enters the
dialogue zone.
Standards and UL, FCC part 15, CE, ETS 300330-1/2, EN 301489-1/3
certifications
Power supply 24 Vdc PELV
Power consumption < 60 mA
Nominal sensing distance XGCS4901201: 10...70 mm (0.39...2.76 in) depending on associated tag
XGCS8901201: 20...100 mm (0.78...3.94 in) depending on associated tag
Type of associated tag Standardized ISO 15693 and ISO 14443 tags, automatic detection of the tag
type
RFID frequency 13.56 MHz
Communication Interface: RS-485, Modbus RTU and Uni-Telway
Connection: A single male 5-pin shielded M12 connector for connection to
the communication network and power supply
Temperature Operation: -25...+70 °C (-13...+158 °F)
Storage: -40...+85 °C (-13...+158 °F)
Degree of protection IP 65 according to IEC 60529
Dimensions W x H x D:
XGCS4901201: 40 x 40 x 15 mm (1.56 x 1.56 x 0.59 in)
XGCS84901201: 80 x 80 x 26 mm (3.15 x 3.15 x 1.01 in)
Components
Wiring
Example of a Modbus network
Connector Wiring
The stations are equipped with a single male M12 A-coded connector for the power supply and
communication bus.
The communication bus wires are shielded separately from the power supply cables to avoid
disturbances carried by the power supply causing interference on the communication wires.
For the connection between the station and the TSCAM31FP tap-off box, use the preformed
cordset TCSMCN1M1F••.
The TCSMCN1M1F•• cordset is a shielded cable, with 5-way male/female A-coding M12
connectors for Modbus RS-485 connection between one TCSAMT31FP tap-off box and an
XGCS•90 station (or to another tap-off box).
Front View
OsiSense industrial sensors product range
Description
Under the Telemecanique Sensors brand, the latest innovations in the field of sensors for industrial
detection operations are offered.
The OsiSense product range consists of safety and limit switches, pressure control sensors,
ultrasonic sensors, inductive and capacitive proximity sensors, and so on.
For more information, refer to Detection for automation solutions OsiSense, MKTED210041EN.
Chapter 5
Communication Topology and Wiring Guide
Section 5.1
Introduction to System Communication
Introduction
Overview
The TVDA (Tested Validated Documented Architecture) includes 2 different communication
networks.
Ethernet
The Ethernet network is used for the communication between the Modicon M221 Logic
Controller and the Magelis panel HMI STO. Both devices are connected via an Ethernet switch.
The communication is based on the Modbus TCP protocol.
In addition, a PC can be connected to the Ethernet network for downloading and online
monitoring of the application.
Modbus SL
The Modbus SL RS-485 2-wire network is used for the communication between the
Modicon M221 Logic controller (master), the Altivar 12 (slave), and the OsiSense RFID
antennas (slave).
Section 5.2
Ethernet Network
Ethernet Network
Ethernet Topology
#... IP address
Ethernet Wiring
Overview Ethernet
Wiring Accessories
Switch
M12 connector (D- M12 pin Signal Description RJ45 pin RJ45 connector
Coded)
1 TD+ Transmit data + 1
2 RD+ Received data + 3
3 TD- transmit data - 2
4 RD- Received data - 6
- - No connection 4
- - No connection 5
- - No connection 7
- - No connection 8
Ethernet Port
The TM221•E••• controllers are equipped with an Ethernet communication port.
Ethernet port on the controller
Characteristic Description
Standard Modbus TCP/IP
Connector type RJ45
Driver 10 M half duplex (auto negotiation)
100 M full duplex (auto negotiation)
For more information, refer to Modicon M221 Logic Controller, Hardware Guide, EIO0000001384.
Pin Assignment
RJ45 Ethernet connector
Pin Signal
1 TD+
2 TD-
3 RD+
4 N.C.
5 N.C.
6 RD-
7 N.C.
8 N.C.
Ethernet Port
The HMI STO 53• comes equipped with an IEEE802.3 compliant Ethernet interface (1). This
Ethernet port 10BASE-T/100BASE-TX is used either for application download or Ethernet
communication.
For more information, refer to Magelis Small Panels HMI STO, User Manual, EIO0000000239.
Section 5.3
Modbus Serial Line Network
Modbus SL Topology
Modbus SL Wiring
Modbus SL Overview
For more information, refer to Modbus Serial Line, Planning and Installation Guide, 33003925.
Cable
Modbus SL Port
For more information, refer to Modicon M221 Logic Controller, Hardware Guide, EIO0000001384.
Pin Assignment
For this architecture, the port is configured as an RS-485.
Pins for RS-485 and RS-232
Chapter 6
Implementation
Implementation
Section 6.1
Software Requirements
Software Requirements
Software Requirements
SoMachine
The project template of the described architecture is part of SoMachine V4.3 or later.
The SoMachine project includes the SoMachine Basic application for the M221 controller and the
Vijeo-Designer application for the Magelis HMI panel.
The following components must be installed together with SoMachine V4.3:
SoMachine components
Logic Builder
SoMachine Basic V1.6 SP1
Vijeo-Designer
Gateway
Controllers
M221
Repository
Optimized repository
Documentation
Tested, Validated and Documented Architectures (TVDA)
The SoMachine Configuration Manager, which is part of the SoMachine installation, allows you to
verify the current installation. In addition you can add, remove, or update components of your
SoMachine installation.
SoMachine Basic
The project template of the described architecture is part of SoMachine Basic V1.6 SP1 or later.
The SoMachine Basic project includes the application for the M221 controller.
The Vijeo-Designer application for the Magelis HMI panel is provided as a separate file of type
*.vdz (Vijeo-Designer export file) and is also part of the SoMachine Basic V1.6 SP1 software.
For using the project template the following software must be installed on your PC:
SoMachine Basic V1.6 SP1 or later
Vijeo-Designer V6.2 SP4.1 or later
Section 6.2
Access the SoMachine Project Template
Overview
The SoMachine project related to the described architecture is available in terms of a project
template.
It is tested and validated and comprises the SoMachine Basic application with program code and
device configurations for the M221 controller and the Vijeo-Designer project for the defined Magelis
panel in this architecture.
You can use the project template as basis for your own application.
Procedure
You can access the project template as described below.
Overview
The SoMachine Basic project related to the described architecture is available in terms of a project
template.
It is tested and validated and comprises the SoMachine Basic application with all program code
and device configurations for the M221 controller.
The Vijeo-Designer project for the defined Magelis panel in this architecture is available in terms
of a Vijeo-Designer export file (*.vdz) and can be opened with the appropriate Vijeo-Designer
version.
Procedure
You can access the project template as described below.
For opening a project-related file, select the example project in the template browser and click
Open Folder. Then the folder which contains the example projects opens in the Windows Explorer.
From here, you can open the desired file by double-click.
Section 6.3
Project
Project
Controller
Overview
The controller in this architecture is the TM221ME16T, which is assigned to the category of
optimized logic controllers of Schneider Electric.
The mandatory settings for the controller are described below.
All parameter values depicted in this document relate to the template project and the test
equipment used during development.
Ethernet
The Ethernet network in this architecture is used for the communication between the HMI and the
M221 controller. The data exchange is realized via Modbus TCP with the HMI as client (master)
and the M221 controller as server (slave).
In addition, the network provides the possibility for a remote connection with the controller and the
HMI.
Perform the Ethernet configuration of the controller in the Configuration window of the SoMachine
Basic application. When selecting the node ETH1 in the Hardware tree, the associated
configuration editor opens.
The Ethernet settings for the controller are:
Fixed IP address
IP address: 172.20.10.167
Subnet mask: 255.255.0.0
Security settings
Enable the check box labeled Modbus server enabled
Additional settings for the Modbus TCP communication can be performed in the Modbus TCP
configuration editor. When selecting the Modbus TCP node in the Hardware tree, the associated
configuration editor opens.
To help to prevent unauthorized access to the application data, the IP address of the Modbus
master can be set. Therefore, the parameter IP Master Address is set with the IP address of the
HMI device in this application.
For all other parameters, the default settings have been kept.
For more information about the Ethernet settings, refer to the document Modicon M221 Logic
Controller, Programming Guide, EIO0000001360.
Serial Line
The serial line in this architecture is used for the communication between the controller, the RFID
smart antennas, and the Altivar 12.
The serial line configuration for the M221 controllers Modbus SL interface are as follows:
Physical settings:
Device: No Device
Baud rate: 19200
Parity: even
Data bits: 8
Stop bits: 1
Physical medium: Modbus SL RS-485 2-wire
Protocol settings
Protocol: Modbus RTU
Addressing: Master
Response time (x100 ms): 10
Time between frames (ms): 10
For more information about the serial line configuration, refer to the document Modicon M221 Logic
Controller, Programming Guide, EIO0000001360.
HMI
Overview
The HMI in this architecture is a Magelis panel of type HMI STO.
The mandatory settings for the HMI device are described below.
All parameter values depicted in this document relate to the template project and the test
equipment used during development.
Ethernet
The Ethernet network in this architecture is used for the communication between the HMI and the
M221 controller. The data exchange is realized via Modbus TCP with the HMI as client (master)
and the M221 controller as server (slave).
In addition, the network provides the possibility for a remote connection with the controller and the
HMI.
Perform the Ethernet configuration of the HMI device in the Vijeo-Designer application as
described in the table:
I/O Manager
Vijeo-Designer uses driver to enable communications with equipment without you having to write
complex communication programs.
To establish a Modbus TCP communication, the Modbus TCP/IP driver and the M221 controller
(Modbus equipment) must be configured in the Vijeo-Designer application as described in the
table:
For more information, refer to Magelis XBT G/XBT GT, Modbus TCP/IP driver description in the
Vijeo-Designer online help.
Variable Editor
Upon configuring the communication between the HMI and the M221 controller, the variables for
the data exchange need to be configured in the Variable Editor of Vijeo-Designer.
An example on how to configure such a variable is described in the following table.
The variable which shall be exchanged between the HMI and the M221 controller is of type BOOL
and has the address %M1 in the SoMachine Basic application:
8 Click the OK button in the Modbus TCP/IP The address field is filled with %M1.
dialog box.
9 Click the OK button in the New Variable dialog The variable is created. During runtime, the
box. variable is linked to the memory address %M1 of
the M221 controller assuming an Ethernet
connection is established.
Startup Options
Due to the use of the Alarm Summary object in the HMI application, the Time Management option
is required and has been enabled automatically. The used HMI panel does not provide an internal
battery to back up the RTC of the panel, thereby on startup the Date and Time configuration is
displayed. To avoid this, the Auto Start option has been enabled. This setting became applicable
because in this application, the RTC of the HMI is synchronized on each startup with the RTC of
the M221 controller. In addition, the HMI application provides a page for the date and time
adjustment.
Devices
Overview
In this chapter, all devices configured within the SoMachine Basic project are described.
For more information, refer to Modicon TM3 Safety Modules, Hardware Guide, EIO0000001831.
For more information about the TM3 configuration, refer to the documents:
Modicon M241 Logic Controller, Programming Guide, EIO0000001432 (ENG)
Modicon TM3, Expansion Modules Configuration, Programming Guide, EIO0000001402
These motor control functions have a standardized interface via configured memory objects in the
application and can be clearly identified by their symbol names. These memory objects are
assigned to inputs and outputs and/or are processed from the HMI via Modbus TCP.
TeSys U
The architecture implements 2 motor starter controllers of type TeSys U which are controlled via
hardwired signals.
The devices themselves are not configured in the application only the variables to control, and to
monitor each motor starter, are assigned to physical inputs and outputs of the configuration.
The inputs and outputs for each TeSys U device are provided via an RJ45 connector on a
TM3XTSYS4 expansion module.
Module_4 X4 is connected to the TeSys U non-reversing (motor 4)
Module_5 X1 is connected to the TeSys U reversing (motor 5)
For the control and monitoring of each TeSys U device, two separate POUs are created in the
application.
These motor control functions have a standardized interface via configured memory objects in the
application and can be clearly identified by their symbol names. These memory objects are
assigned to inputs and outputs and/or are processed from the HMI via Modbus TCP.
Application
Task Configuration
The M221 modular logic controller supports the following task types:
Master Task
Periodic Task
Event Task
The Master Task represents the main task of the application program. It is obligatory and is created
by default. In this application, all POUs are associated to the Master Task.
The configuration of the Master Task in this application is:
Scan mode: Periodic
Period: 10 ms
When a logic controller is in periodic scan mode, the logic controller waits until the configured scan
time has elapsed before starting a new scan. Every scan is therefore the same duration.
Free POUs
In SoMachine Basic you can configure Free POUs which can be assigned to the Periodic Task or
which can be called as a subroutine in the program code.
In this application, three Free POUs are created which are called under certain conditions with a
subroutine call (SRi) in the POUs under the Master Task. To these belong:
Get DateAndTime
This program reads and converts the Real Time Clock (RTC) of the controller for display on the
HMI.
Set DateAndTime
This program sets the RTC of the controller from the HMI.
Initialization
This program is called after a cold-restart of the controller. The program code initializes the
application with the default values.
Timers
The M221 controller supports up to 255 software objects of type Timer. Each timer needs to be
configured in the application. In the Programming workspace in the Tools tab of the programming
tree, select the node Timers under Software Objects. The window Timer properties is displayed
that allows you to view and to configure all available timers.
In this application, the following timers have been configured covering different tasks.
Communication Objects
The M221 controller supports different communication objects to manage the Modbus
communication with Modbus slaves which are linked to the SL or the Ethernet interface of the
controller. Each communication object needs to be configured in the application. In the
Programming workspace in the Tools tab of the programming tree, select the node for the
respective type under Communication Objects. Depending on the selected node, the associated
property window is displayed that allows you to view and to configure the available communication
function blocks.
The table lists the communication function blocks used in this application
For more information about the Communication Objects, refer to the document SoMachine Basic
Generic Functions, Library Guide, EIO0000001474 (ENG).
Program Code
The program code is divided into several POUs (Program Organization Units). Each POU is called
separately within the associated task.
For each device in this architecture, a separate POU is created which contains the program code
with control and monitoring functions for the respective device. Which POU is related to which
device can be easily detected by the name of the POU.
The following POUs are created in this application:
Motor 1 - TeSysD 1D
Motor 2 - TeSysD 1D
Motor 3 - TeSysD 2D
Motor 4 - TeSysU 1D
Motor 5 - TeSysU 2D
Motor 6&7 - ATV MBSL
RFID Station 1
RFID Station 2
RFID Station 3
Energy
In addition to the POUs for the devices, further POUs are created for general functions of the
application. These are:
Preprocessing
Initialization of the application.
Pulse generator for the blink function of indicators.
System
Processing of summary information about the devices.
Date and time handling of the RTC of the controller.
Vijeo-Designer
Overview
The HMI application is created with the configuration software Vijeo-Designer, which is integrated
in SoMachine.
In case you are using SoMachine Basic only, the Vijeo-Designer software must be installed
separately.
This architecture implements a Magelis HMI panel of type HMI STO.
The application is executed on this panel and provides extensive monitoring and control functions
of the architecture.
Start Page
The start page provides general information about the state of the architecture.
State of the safety function
Device state
Modbus communication state
General operator mode
General alarm reset
Alarm Page
The alarm page provides detailed alarm messages sorted by time of occurrence.
Energy Page
The energy page provides information about the energy consumption of the architecture. In
addition, the energy counter can be reset and the elapsed time since the last reset is displayed.
Device Pages
The device pages provide monitor and control functions for each device:
Motor 1
Motor 2
Motor 3
Motor 4
Motor 5
Motor 6/7
RFID 1
RFID 2
RFID 3
Wireless Push Buttons
Chapter 7
System Setup
System Setup
Overview
This chapter describes the steps necessary to set the architecture in operational mode. It is not
intended to replace any specific product documentations or manuals.
The setup procedure depicted in this document is relevant only for the proposed architecture.
Before using any device in this application, perform the following steps:
Thoroughly read this manual and the respective related documents before running this
application.
Install the drives according to their usage and configure the connected motors.
Thoroughly verify your installation.
Set up the communication parameters of the devices.
WARNING
LOSS OF CONTROL
The designer of any control scheme must consider the potential failure modes of control paths
and, for certain critical control functions, provide a means to achieve a safe state during and
after a path failure. Examples of critical control functions are emergency stop and overtravel
stop, power outage and restart.
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
Observe all accident prevention regulations and local safety guidelines.1
Each implementation of this equipment must be individually and thoroughly tested for proper
operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
1For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the
Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest
edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of
Adjustable-Speed Drive Systems" or their equivalent governing your particular location.
Section 7.1
Setup Controller and HMI
Overview
You must download the applications from the PC to the controller and to the HMI to run the
applications.
There are several options to perform the application download:
Via an USB cable (linked to the integrated mini USB port on the devices)
Via an SD card (plugged into the SD card slot on the front of the M221 controller)
With an USB key (linked to the integrated USB port on the HMI)
Via an Ethernet connection (linked to the Ethernet network)
By using a USB connection or an Ethernet connection between controller and PC, additional
features like monitoring of the application in online mode are available.
NOTE: SoMachine Basic and the associated Vijeo-Designer configuration software are required
on the PC. Both software tools either can be installed separately or they can be installed together
with the installation of SoMachine.
Using the established USB connection between PC and M221 controller, proceed as follows to
download the SoMachine Basic application.
For more information, refer to the SoMachine Basic operating guide (see SoMachine Basic,
Operating Guide).
NOTE: The firmware version of the controller has to correspond with the firmware version of the
controller in the SoMachine Basic project. If the versions of the devices mismatch, you have to
upgrade the version of the controller. The procedure to update the firmware of the controller is
described in the SoMachine Basic operating guide (see SoMachine Basic, Operating Guide) and
in the M221 logic controller programming guide (see Modicon M221, Logic Controller,
Programming Guide).
Using the established USB connection between PC and HMI, proceed as follows to download the
Vijeo-Designer application.
Section 7.2
Setup Other Devices
Overview
This section describes the steps required to initialize and configure the different devices required
to attain the described system function.
The following devices are configured by using the local control panel on the device itself:
Altivar 12
iEM3110 energy meter
NOTE: If a device has already been configured for some other use, re-establish the factory
settings. Instructions on how to do this can be found in the respective documentation.
NOTE: Be sure that the controller is in a STOP state before parameterizing the drives.
WARNING
UNINTENDED EQUIPMENT OPERATION
Never assume that your controller is in a certain controller state before commanding a change
of state, configuring your controller options, uploading a program, or modifying the physical
configuration of the controller and its connected equipment.
Before performing any of these operations, consider the effect on all connected equipment.
Before acting on a controller, always positively confirm the controller state by viewing its LEDs,
confirming the condition of the Run/Stop input (if so configured) and/or the Run/Stop switch (if
so equipped), verifying the presence of output forcing, and reviewing the controller status
information via SoMachine Basic.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Overview
The thermal protection of the motor is set by the rotary switch on the front of the control unit
LUCA05BL. The set value has to be appropriate for the connected motor.
Overview
To operate the Altivar 12 via Modbus serial line, the communication parameters have to be set for
the drive. In addition to this, it is mandatory to set the parameter of the connected motor in the drive.
Further configuration settings are dependent on your application and on the installation.
There are several options to configure the drive:
By the local HMI on the front of the drive
By a remote display terminal*
By the software SoMove lite installed on a PC*
WARNING
UNINTENDED EQUIPMENT OPERATION
Verify that both wiring and mounting are correct before you start to configure the drive.
Verify that an unintentional start of the connected motor will not endanger personnel or
equipment in any way.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
If necessary, disconnect the motor from the drive to prevent an unintentional motor start.
For more information, refer to :
Altivar 12, Variable speed drives for asynchronous motors, User manual BBV28581.
Altivar 12 Variable speed drives for asynchronous motors, Modbus Communication Manual,
BBV28590.
Settings
The following steps to set up the drive are based on the configuration by the local HMI on the front
of the drive.
4 Configure the parameter [Reference The drive is operated via Modbus. The parameter
Channel 1] under the menu: (FULL) -> [Reference Channel 1] is set to Modbus
(CtL-) -> (Fr1). (Mdb).
5 Configure the ramp parameters under the menu: In most cases, the factory settings can be maintained
(FULL) -> (FUn-) -> (rPt-): for a quick start. But nevertheless, you have to verify
[Acceleration] (ACC) the values.
[Deceleration] (dEC)
6 Configure the speed limit parameters under the In most cases, the factory settings can be maintained
menu: (FULL) -> (FUn-) -> (SPL-): for a quick start. But nevertheless, you have to verify
[Low Speed] (LSP) the values.
[High Speed] (HSP)
7 Configure the [Motor thermal current] Refer to the motor rating plate. Values have to be
under the menu: (FULL) -> (Flt-) -> (tHt- adjusted if the factory settings differ from your
) -> (itH). application.
8 Configure the communication parameters under The communication parameters in this example are
the menu: (FULL) -> (COM-): set as follows:
[Modbus Address] (Add) [Modbus Address] = 1
[Modbus baud rate] (tbr) [Modbus baud rate] = 19.2
[Modbus format] (tFO) [Modbus format] = 8E1
[Modbus time out] (ttO) [Modbus time out] = 2 seconds
WARNING
UNINTENDED EQUIPMENT OPERATION
After any configuration changes or adjustments, power cycle the drive (power removal followed
by power reapplied).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
CAUTION
INOPERABLE EQUIPMENT
Set the start time to a level that can be reached even if the motor is operating with maximum load
conditions.
Failure to follow these instructions can result in injury or equipment damage.
Initial voltage
The initial voltage applied to the motor (the level at which the voltage ramp begins) can be adjusted
by a potentiometer on the front of the ATS01N1 soft starter.
The initial voltage level can be adjusted from approximately 30 to 80% of the AC line voltage level.
See the diagram above for more details.
Since the resultant motor torque varies in proportion to the square of the applied voltage, the scale
on the front of the soft start is calibrated from A to E rather than from 30 to 80%, with A being the
lowest level and E being the highest level. A lower setting reduces motor torque during starting.
Set this level to the minimum required that will result in motor rotation immediately after a start
command.
Settings
For more information, refer to Altistart 01, Soft Starts for Single-Phase and Three-Phase
Asynchronous Motors, 45A01SS.
Overview
Each time the station is powered up, it automatically detects the format and network speed. The
stations are supplied configured at network address 1. Before use, it is essential to configure the
network address of each station.
Stations can be addressed in 2 ways:
Using the XGS ZCNF01 configuration badge (supplied with the station)
Via the network (Modbus or Uni-Telway write command)
Configuration Badge
The addressing procedure is described on the back of the configuration badge:
Overview
The energy meter features a sophisticated and intuitive human machine interface (HMI) with
signaling LEDs, a graphic display, and contextual menu buttons for accessing the information
required to operate the energy meter and modify parameter settings. The navigation menu allows
displaying, configuring, and resetting parameters.
The graphic shows the general display:
1 Configuration mode
2 Values / parameters
3 Unit
4 Cancelation
5 Confirmation
6 Selection
7 Date and time (except for iEM3100 / iEM3200 )
8 Tariff used (iEM3115 / iEM3155 / iEM3215 / iEM3255)
9 Functions / measurements
In addition to this system user guide the product manual for the iEM3110 energy meter has to be
read carefully.
For more information, refer to iEM3100 series / iEM3200 series, Energy Meters, User Manual,
DOCA0005EN.
Basic Configuration
Before starting the configuration of the energy meter, verify that the installation is correct.
NOTE: Further configurations can be done depending on your application needs. For more
information, refer to iEM3100 series / iEM3200 series, Energy Meters, User Manual,
DOCA0005EN.
Overview
Use the integrated push-buttons on the receiver module to configure the Harmony ZBRRC
wireless receiver.
Settings
Before you work with the devices, the receiver module has to be connected to the power supply
and the wireless push button has to be in reach of the receiver module.
Release the key when only the Q1 indicator lamp on the device
starts flashing green.
2 Select the output for teaching
or unteaching:
Press the arrow key to
switch between output 1, 2,
3, or 4.
For more information, refer to Harmony XB5R, Expert Instruction Sheet, EIO0000000812 (EN).
Chapter 8
Bill of Material (BOM)
Overview
In this chapter, a Bill of Materials (BOM) for the main components of the architecture is provided.
Components and component combinations of the protection system of this architecture are marked
with additional information about the conformity to standards IEC and UL. Those which are marked
as UL can be considered as a multistandard solution. Nonetheless, you must consider and respect
the local standards and codes, as well as the electrical and environmental conditions, where the
system is installed and operated. For more information on this topic, refer to the associated product
manuals and on the Schneider Electric webpage.
Regardless of the industrial application of a control panel, its protection systems and devices must
comply with applicable international standards:
IEC 60-204 safety of machinery
UL 508A industrial control panel
Components and component combinations that meet multiple standards are equally important to
design and size for ensuring that control panels meet legal requirements across international
markets.
WARNING
REGULATORY INCOMPATIBILITY
Ensure that all equipment applied and systems designed comply with all applicable local,
regional, and national regulations and standards.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Main Switch
Energy meter
Emergency Stop
Automation Components
Magelis HMI
Sensors
Ethernet Wiring
Modbus SL Wiring
Software Tools
Glossary
C
CANopen
An open industry-standard communication protocol and device profile specification (EN 50325-4).
CSA
(Canadian standards association) The Canadian standard for industrial electronic equipment in
hazardous environments.
CW/CCW
ClockWise / Counter ClockWise
E
Ethernet
A physical and data link layer technology for LANs, also known as IEEE 802.3.
expansion bus
An electronic communication bus between expansion I/O modules and a controller.
H
HMI
(human machine interface) An operator interface (usually graphical) for human control over
industrial equipment.
I
I/O
(input/output)
IEEE 802.3
A collection of IEEE standards defining the physical layer, and the media access control sublayer
of the data link layer, of wired Ethernet.
IL
(instruction list) A program written in the language that is composed of a series of text-based
instructions executed sequentially by the controller. Each instruction includes a line number, an
instruction code, and an operand (refer to IEC 61131-3).
IP 20
(ingress protection) The protection classification according to IEC 60529 offered by an enclosure,
shown by the letter IP and 2 digits. The first digit indicates 2 factors: helping protect persons and
for equipment. The second digit indicates helping protect against water. IP 20 devices help protect
against electric contact of objects larger than 12.5 mm, but not against water.
L
LD
(ladder diagram) A graphical representation of the instructions of a controller program with symbols
for contacts, coils, and blocks in a series of rungs executed sequentially by a controller (refer to
IEC 61131-3).
M
Magelis
The commercial name for Schneider Electric's range of HMI terminals.
Modbus
The protocol that allows communications between many devices connected to the same network.
Modbus SL
(Modbus serial line The implementation of the protocol over a RS-232 or RS-485 serial connection.
P
Profibus DP
(Profibus decentralized peripheral) An open bus system uses an electrical network based on a
shielded 2-wire line or an optical network based on a fiber-optic cable. DP transmission allows for
high-speed, cyclic exchange of data between the controller CPU and the distributed I/O devices.
R
RJ45
A standard type of 8-pin connector for network cables defined for Ethernet.
RS-232
A standard type of serial communication bus, based on 3 wires (also known as EIA RS-232C or
V.24).
RS-485
A standard type of serial communication bus, based on 2 wires (also known as EIA RS-485).
T
TCP
(transmission control protocol) A connection-based transport layer protocol that provides a
simultaneous bi-directional transmission of data. TCP is part of the TCP/IP protocol suite.
terminal block
(terminal block) The component that mounts in an electronic module and provides electrical
connections between the controller and the field devices.
TVDA
(tested validated documented architectures) Control system proposals based on
Schneider Electric components.TVDAs cover a wide range of machine types and consider
machine performance requirements, installation constraints, and target costs. To optimize the
implementation effort, each TVDA comes with a detailed component list, wiring diagrams, and
commissioning guide, as well as controller and HMI applications to control components of the
system.
Index
M
M221 book Modbus SL
SUG, 11
TVDA, 11
S
setup devices
TVDA, 161
SUG (system user guide)
M221 book Modbus SL, 11
system setup
TVDA, 161
system user guide (SUG)
M221 book Modbus SL, 11
T
template
TVDA, 139
TVDA
communication, 125
hardware, 55
implementation, 139
M221 book Modbus SL, 11
safety requirements, 27
setup devices, 161
template, 139
wiring, 125
TVDA Compact Modbus SL M221 book
bill of material (BOM), 179
TVDA Modbus SL M221 book
system architecture, 24