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Project Book
Version 6.0
Revision Information
Index/Contents
1 Supplier Information / Contact information ............................................................... 4
2 Scope of Supply ....................................................................................................... 5
2.1 Automation ......................................................................................................... 7
2.1.1 PLC Equipment .......................................................................................... 7
2.1.2 HMI Equipment .......................................................................................... 8
2.1.3 Networks .................................................................................................. 10
2.1.4 Motion Control and Drives........................................................................ 13
2.1.5 Safety ....................................................................................................... 14
2.2 Control Products............................................................................................... 16
2.2.1 I/O Devices............................................................................................... 16
2.2.2 Other Machine Control Products .............................................................. 17
2.2.3 Network I/O & Devices ............................................................................. 18
2.3 Power Distribution ............................................................................................ 19
2.4 Engineering Services........................................................................................ 20
2.4.1 Program Management ............................................................................. 20
2.4.2 Integration Services ................................................................................. 20
3 Architecture ............................................................................................................ 21
3.1 Assembly Architecture ...................................................................................... 21
3.1.1 Assembly Architecture: Auto and Semi-Auto Stations.............................. 22
3.1.2 Assembly Zone Architecture: Line Layout ................................................ 23
3.1.3 Assembly Distributed Architecture: Line Layout ....................................... 24
3.1.4 Assembly Conveyor Controller: Separate Conv Control / Sta Control..... 25
3.1.5 Assembly Manual Station in Zone Architecture........................................ 26
3.1.6 Assembly Manual Station in Distributed Architecture............................... 27
3.1.7 Hybrid: Example showing three grouped manual stations........................ 28
3.2 Machining Architecture: .................................................................................... 29
3.2.1 Transfer Machine Architecture ................................................................. 30
3.2.2 Flexible Machining Cell Architecture ........................................................ 32
3.3 Architecture for General Machines ................................................................... 35
4 Software Approach................................................................................................. 36
4.1 Logic Structure ................................................................................................. 37
4.1.1 Integrated Diagnostics and HMI paging ................................................... 37
4.1.2 System Reporting..................................................................................... 38
4.1.3 Object Based............................................................................................ 38
4.1.4 Configuration versus Programming.......................................................... 38
4.1.5 Model Management ................................................................................. 39
4.1.6 Alternative approaches (PL7 vs. Unity) .................................................... 39
4.2 Device Interfaces.............................................................................................. 39
4.3 HMI Screens..................................................................................................... 40
4.4 Programming Software ..................................................................................... 40
4.5 Flex Cell Agent Technology.............................................................................. 40
Contact Information:
In many countries including the United States, our products are sold through distributor
channel partners. When more about OEM locations and project specifics are known,
distributor contacts will be identified as well as additional contacts from our other
country organizations.
2 Scope of Supply
This project book is primarily intended to demonstrate the range of automation and
control architectures Schneider typically implements for powertrain manufacturing
operations. This section will serve to explain the large breadth of our potential scope of
supply.
Schneider Electric offers a system that is highly modular and lends itself to open
connectivity with systems and devices from third parties. Our breadth of products can
be divided into the essential subsystems of a controls architecture. This is intended to
provide flexibility and scalability to machine builders while still allowing a great deal of
design standardization for the larger scope of the project. Consider the total system as
follows:
The device and I/O subsystems themselves employ a further level of modularity. This
approach allows for interchangeability of control subsystems as well as devices within
those subsystems to be mixed with other vendor solutions in a way that can easily be
standardized and validated. This allows the use of a standard for a particular subsystem
across varied complete solutions. For example, one could use a common I/O and
device strategy with a variety of PLCs and CNCs.
2.1 Automation
There are three PLC options, depending on the architecture chosen, including the
Premium, M340 and Quantum. Processor capability may determine the architecture
chosen. The Premium range can be programmed with Unity or PL7 software while the
M340 range is programmed with Unity only and the Quantum is programmed with Unity,
Concept or Proworx software.
The M340 will be the primary controller for distributed systems with Premium for more
central systems and stations requiring complex motion control. The Quantum may be
used if process control or PID loops are required. Each system will include Ethernet
Modbus TCP/IP as the primary network with options for additional networks to support
varied device strategies.
The primary HMI used will be the XBTGT family. This is a scalable family with systems
of various sizes all programmed using Vijeo Designer Software. Templates will be
provided per the Chrysler specification with options to support the proposed logic
strategy.
The use of PCs is generally discouraged and requires special approval from Chrysler.
However, PCs still can still provide valuable functionality. Care should be taken to apply
them in ways that allow production to continue while PCs are in maintenance. The
Compact IPC and Smart IPC ranges can provide integrated PC and HMI functionality
using similar templates as developed for the XBTGT and using the same Vijeo Designer
programming software.
As the I/O and device structure can be entirely networked and machine mounted, the
PLC and HMI system can be standardized into integrated panels as well. Below is a
functional view of variations of this offer:
These systems are typically built on our modular “Tego” enclosure offer. This is a line of
customizable enclosure equipment directed to smaller systems.
Schneider also has designs for integrated material handling control systems that can be
adapted to meet many assembly needs: ConveyorPak.
2.1.3 Networks
One of the architecture goals is to make greater use of network I/O and devices while
also reducing the number of networks. The core network for the complete Schneider
Electric system will be Ethernet using Modbus TCP/IP protocol. A second device level
network will be available and shown for most system options to provide modularity and
reduced cost for I/O and devices.
The network strategy is based on using Ethernet as the primary network with ASi or
other network of choice as required to provide a complete and effective installation.
At the machine level, devices and I/O typically rest on a device level network, which,
depending upon the system, will be Ethernet, ASi or other network of choice. Controllers
will rest on the department level Ethernet network. This network will provide machine
interlocking, HMI connection and can serve system data as well. There can be another
segregated Ethernet network for systems if preferred, but it is not technically required.
HMIs and third party devices such as robots, nut-runners, etc. can rest on either the
device network or the department network.
The network strategy is based on using Ethernet as the primary network with ASi as
required to provide a complete and effective installation. However, other networks are
supported to provide a full array of options to support legacy systems or make extensive
use of third party technology. Below is an overview of the various networks and their
capabilities.
Schneider’s line of Connexium Ethernet hardware includes a full range of switch and
cabling equipment to support a variety of industrial Ethernet networks from simple to
highly complex systems. The offer includes:
As for the network masters, the Premium, M340 and Quantum controllers have Ethernet
interfaces as options built in to the CPUs or as a slot module. Services supported by
these networks include: global data, I/O scanning, broadcast with IGMP/GMRP filtering,
time-synch with SNTP/PTP, VLAN, BootP, SNMP, DHCP.
Similarly, CanOpen and ASi master modules are available for all three offers as well as
supporting hardware, power supplies, cabling and devices (see device section and
product list).
The growth in intelligent drive technology has made most applications of PLC motion
modules redundant. In most applications servo drives can be adequately controlled over
a device network with handshake and data exchange over the network, with motion
profiles contained in the drive. Such is the case with Schneider Electric’s Lexium-15 and
Lexium-05 ranges. The servo system can be managed in one of three ways: via direct
bus, through an Automation Island bridge or, where tight axis coordination is required,
via a PLC Sercos card. Schneider has also supported third party interfaces to other
servo controller offers.
The Lexium-05 Servo Drive and Altivar-312 Frequency Drive are based on the same
platform and make a very cost effective system for applications other than machining.
As for the CNC Machining Centers themselves, Schneider Electric accepts that these
will probably be treated as “OEM” systems and intends to pursue an open approach to
supporting CNC solution(s) of choice be they NUM, Indramat, Siemens, Fanuc,
Mitsubishi or other vendor. Our intent is to offer the same I/O and device structure as
the rest of the machining equipment regardless of the controller in use. Simply change
the network interface and keep the I/O and device structure the same.
2.1.5 Safety
Schneider Electric offers a variety of safety approaches to choose from based on the
needs of your system and architecture:
● E-Stop Pushbuttons
● Safety Gate Switches
● Non-contact Safety Switches
● Floor Mats and Foot Switches
● Light Curtains
● Integrated Drive and Servo
Safety
Schneider Electric can also provide power distribution panels with the safety system
integrated.
Below is a functional view of a sample PDP design that incorporates safety functions. It
provides switched power controlled by the safety circuit as well as control power that
can be switched and unswitched. A variation provides only 460V and 110V to a
secondary bus (24V is generated in the plugs – see below)
The power distribution concept incorporates safety at the source. Safety inputs are
brought into a PDP (power distribution panel) via ASi-Safe (alternatively by a classical
safety relay dual channel circuit). The output controlled is the actual power source so no
further consideration of safety is required downstream. The full system is protected to
Category 4.
Schneider offers a variety of I/O possibilities for control systems. The PLC offer provides
for rack I/O as well as remote rack I/O. Several networks are supported with a variety of
I/O in both IP20 and IP67 form factors. The I/O and device structure is shown in the
larger Schneider controls architectures contained in Section 3. The architectures
support three basic approaches for device networking: ASi, Ethernet and using the
“Automation Island” concept. In the latter case, one or more of these “islands” provides
a single point of connection to the control system. That connection is via the network
most ideal for the host controller (Ethernet for Schneider PLC, others to support
different host controllers as well).
The remote I/O offer can work seamlessly with third party controllers on common
industry networks.
The machine control product offer itself extends to the following additional areas:
Sensors
o Mechanical Limit
o Inductive Proximity
o Photo
o Pressure
Relays
o Control
o Protection
Terminal Strips
o Fuse Holders
o Distribution Blocks
Pushbutton, Pilot Lights
Frequency Drives
Motor Control
o Contactors
o Starters
o Motor Circuit Protectors
o Motor Management
System
o Soft starts
Alarm Beacons
o Stack Lights
o Horns
Safety Disconnects
Control Transformers
Transformer Disconnects
Panel Main Disconnects
Power Supplies
Circuit Breakers
o Molded Case
o Compact
o Automatic Switch
Examples of devices other than PLCs and HMIs that can also be connected on the
machine Ethernet network are shown below.
Contact Square D/Schneider Electric for any power distribution needs. Power
distribution is not covered in this document. However, Schneider Electric provides a
complete range of industrial power products and technologies for distributing and
monitoring power. For example, I-Line Busway, Bus225, PowerLogic monitoring
systems, harmonic filtering and power factor correction equipment, and power system
engineering services.
Additionally, the new UL508A and NEC409 regulations may warrant a closer look at
engineered MCCs (motor control centers) and panelboards on the floor level for
machine power distribution.
Network Design: Schneider Electric offers a variety of services and expertise to support
your industrial networking needs.
Plant Systems: Schneider Electric can provide engineering and integration services for
plant systems. This would include andon systems, production monitoring (FIS) systems,
production history, production scheduling, quality, birth history, error proofing, tool
monitoring and more.
3 Architecture
One of the goals of this project book is to provide OEMs with the information and tools
necessary to build a controls architecture that best meets their individual needs.
Depending on the machine or process, the best architecture may change. This sections
presents sample architectures for the following machine types:
Assembly Systems
Transfer Lines
Machining Cells
Gantries
Automation and Simple Machines
Facilities
The assembly system is shown as a unique system because of some of its unique
needs:
For these reasons the approach differs from other parts of the complete Powertrain
manufacturing process. Also, subassembly systems and some simple automation might
use more of the assembly architecture than the machining architecture.
There are numerous possibilities, but examples shown here are for 3 types of
architectures. If these architectures do not suit a specific OEM design, Schneider
Electric will consult with the OEM to customize an architecture that best suits their
needs.
1) Zone Architecture – The line will be broken up into zones and each zone will
have a zone controller which will control the transport, stops, manual stations,
manual back-up stations, and lifts and rotates that are not included in automatic
stations. Each Automatic station will have its own controller.
2) Distributed Architecture – There are no zone controllers. Every manual station,
lift, rotate and automatic station will have its own controller. There may be
additional conveyor controllers to handle sections of conveyor with stops and any
other device not associated with a specific station.
3) Hybrid – The Chrysler specification limits an area system to five stations. Any
combination of equipment from fully distributed to this is acceptable.
SCHNEIDER ELECTRIC Page 21 of 69
CHRYSLER
Project Book Version 6.0
For the purposes of this book, machining architectures shall refer to transfer line
equipment and CNC machining cells. Specific architectures for transfer line stations and
gantries will be shown. Operation level architectures will be shown for transfer lines and
flexible machining cells. As Schneider is not proposing a CNC controller, the latter
architecture will show connectivity to an unnamed CNC controller. The rest of the
system will use PLCs for all control other than the CNC machine tool itself. This
provides for the production critical equipment to be controlled in a familiar fashion, while
allowing the machine tools, whose downtime affects production incrementally, to be
treated as “white appliance” machines. This is not unlike past applications in Crank/Cam
machining. So the following will be shown:
1) Transfer Machine Architecture – For the purpose of this approach, the station
architecture and the transfer architecture are the same with console functionality
available at any station through “virtual console”. Both the station detail and a
machine operation overview are shown.
2) Flexible Machining Cell Architecture – An overall operation overview is shown
as well as a gantry system detail. A potential architecture using similar
technology with an OEM specified CNC is shown for the machine tools
themselves.
For other machines that might appear in the machining department (i.e. washers, test
equipment, conveyors) see the section for “general machines”
Dedicated machining systems such as transfer lines will utilize a network I/O & Device
structure in order to offer consistency across systems. This will be connected over
Ethernet to either the Premium Controller or the M340 Controller. Alternatively, a classic
discrete I/O structure can be supported with either the Premium or M340.
Note that the servo drives can rest directly on the Ethernet network rather than inside
the automation island. Also, for stations requiring interpolation, the drives can rest on a
Sercos network from the PLC rack.
Flexible machining systems can utilize the same network I/O & Device structure
described in the previous section. This can serve a Premium or M340 PLC in many
applications such as Gantries, Conveyors and Washers but can also serve a variety of
controllers including third-party CNC controllers using a variety of network interfaces.
Machines that are not specifically part of the architectures described above can be
accommodated in a similar manner. If a device I/O structure is preferred then machines
in the assembly areas should use ASi in a manner similar to the rest of the assembly
line architecture and those in machining departments should use automation islands
with a network structure similar to the rest of the department.
For the case of some general systems (esp. simple equipment, HVAC and filtration
equipment) a classical discrete I/O approach may be more suitable than using a device
network exclusively. Both the TSX Premium and M340 systems support complete offer
of standard discrete I/O to support this need.
For facilities equipment, OEMs can make use of custom turn-key Square D equipment
from Schneider such as PDPs (power distribution panels) and MCCs (motor control
centers).
4 Software Approach
There are two approaches to software design, traditional ladder logic and structured
programming. Since traditional ladder logic is familiar to all OEMs, only the structured
programming approach will be discussed here. That said, varied approaches may be
considered.
For the structured programming approach, Schneider Electric has developed a set of
software modules that provide necessary control and diagnostic functions for any
application. This document will provide an overview of the tools available, but in-depth
training on this software approach is available on an as-needed basis. Please contact
Schneider Electric for more information.
Standard logical elements integrate these functions with the basic logic. Manual Control,
Auto Control, HMI paging, Machine Interlocking and Diagnostic Reporting are all
together. This prevents machine creep over time where the basic logical control is not
matched by corresponding fault handling. The system cannot stop without a
corresponding fault.
HMI Reporting
The HMI function for discrete control is fully integrated with the logic. No changes are
required to the HMI application to add or modify control functions. Console and zone
control functionality is available at all stations with access controlled (request/accept)
based on a “Virtual Console” implementation
The system fault reporting is “root cause”, that is the fault reported is not the action that
failed to occur but the condition that prevented it. Below is an example map of the
methodology:
As all the diagnostic data is managed in the background in a standard manner, data
required by the system reporting will be available in the same manner from all
machines. This would lead to a significant reduction in the effort to integrate these
systems (fault reporting especially)
With this methodology much of the traditional coding is replaced with copy, paste and
configure efforts. This also means machine modifications can be substantially easier.
The system also supports a common HMI template for all discrete functions. The same
HMI application can be applied on very different machines and templates can be
developed for different HMI hardware. It does not matter what the client HMI is so long
as it runs a proper template.
Schneider Electric has created application software to provide model management for
assembly system in accordance with the specifications set forth by Chrysler. In addition
to the HMI and PLC functionality required to manage the data requirements and drive
the Tag configuration, the system uses the embedded SOAP interface to allow XML
export of the data table. This may provide the ability to tie the data directly to an
external application and/or to edit the values concisely in a spreadsheet. We have
created an Excel spreadsheet template to support this feature. Follow the attached link
to application information and tools: Chrysler Model Management
As the purpose of the Project Book effort from the Chrysler perspective is to allow for
OEM best practices, this system allows for existing software strategies used on
previous programs to continue to be used. By using the Premium controller exclusively,
every aspect of the hardware architectures presented can be realized by using PL7 in
lieu of Unity programming software.
Also, Unity could still be utilized but with a more generic programming approach than
that described above. In fact, PL7 applications can be imported into Unity allowing
OEMs to maintain past programming practices and migrate to the Unity platform. This
also allows OEMs to use their current programming practices and use the more cost
effective M340 controller.
The logic and HMI structure has been adapted to the screen templates developed by
Chrysler AME. Schneider has developed generic HMI screens to support these. They
can be developed as specific templates to support the software strategy described
above. In this case they are true templates, that is, changes in discrete logic actually
affect the required changes to the HMI presentation so no programming of the HMIs is
required.
Unity: This is the common programming software for the Premium and M340
PLC ranges. It also supports the Quantum range and future Schneider offers.
PL7: This platform is also available to program the Premium range. Applications
developed in PL7 can be imported and converted to Unity
Vijeo Designer: This is the programming software for the XBTGT HMIs
Vijeo Citect: This is the programming software for the SCADA system.
Powersuite: VF Drive and Softstart configuration software
Connexview: Ethernet network configuration and diagnostic software
Safety Suite: Safety controller configuration software
ASi Design: ASi design software
Unilink: Servo drive configuration software
TCP-Open: 3rd Party Ethernet protocol configuration utility
Schneider can provide product and services in the form of our Factory Broker system to
implement “Agent Technology” in the flexible machining cells. This provides adaptive
intelligence that increases the utilization of machines in a cell by providing optimized
use of the material handling equipment (gantries and conveyors) serving the cell
machines.
5 Program Components
This section contains a master component list. Each part number in the list contains a
link to catalog pages with further information and detail on that specific product. Also
below are links to general product information and additional resources.
Web Links:
Schneider Electric Home Page
Schneider Electric Products
Schneider Electric Automation and Control Services
Schneider Electric Product Technical Library
Schneider Electric Customer Training Center
CAD Drawings for Schneider Electric Products
Essential Guides:
Automation and Control: The Essential Guide (16.6Mb)
Human/Machine Interfaces: The Essential Guide (773Kb)
Motion Control: The Essential Guide (6.2Mb)
Soft Starters and Variable Speed Drives: The Essential Guide (1.7Mb)
Power Control and Protection: The Essential Guide (3.4Mb)
Machine Safety Preventa: The Essential Guide (4Mb)
Detection: The Essential Guide (3.2Mb)
Control and Signaling Units: The Essential Guide (1.3Mb)
Interfaces and I/O: The Essential Guide (1.8Mb)
Complete Catalogs:
Automation Platform Modicon Premium (30Mb)
Automation Platform Modicon M340 (24Mb)
Automation Platform Modicon Quantum (23Mb)
Twido Programmable Controllers (11Mb)
Human/Machine Interfaces (8Mb)
Global Detection Catalog (123Mb)
Motion Control Catalog (30Mb)
5.2 Networking
5.2.1 Ethernet Hardware
Connexium Switches, Transceivers
TCSESU033FN0 Basic Unmanaged 3-port switch
TCSESU053FN0 Basic Unmanaged 5-port switch
499NES18100 Unmanaged 8-port switch
TCSESU051F0 IP67 switch, 5-port, M12 connections
TCSESM043F23F0 Managed Switch 4-port, 2 plus dual copper uplink
TCSESM083F23F0 Managed Switch 8-port, 6 plus dual copper uplink
TCSESM083F2CU0 Managed Switch 8-port, 6 plus dual fiber uplink
TCSESM103F2LG0 Managed Switch 10-port, 8 plus dual copper uplink, Gigabit
TCSESM103F23G0 Managed Switch 10-port, 8 plus dual fiber uplink, Gigabit
TCSESM163F2CU0 Managed Switch 16-port, 14 plus dual copper/fiber uplink
TCSESM243F2CU0 Managed Switch 24-port, 22 plus dual copper/fiber uplink
499NTR10100 Fiber/Copper Transceiver
Ethernet Cables, CAT5e shielded, RJ45 and M12
490NTW000xxU Ethernet Cat5e
490NTW000xxU Ethernet Cat5e crossover
note: x = 02, 05, 12, 40, 80 which is meters of length
TCSECL1M3MxS2 Ethernet Patch Cable M12 to RJ45
TCSECL1M1MxS2 Ethernet Patch Cable M12 to M12
note: x = 1, 3, 10, 25, 40 which is meters of length
TCSEAAF11F13F00 Ethernet bulkhead adapter RJ45 to M12
5.3 Inputs/Outputs
5.3.1 I/O (Racks and Telefast)
Premium Input and Output Modules
TSXDEY32D2K 32 DI 24Vdc, type 1, 20 way HE10 connector
TSXDEY64D2K 64 DI 24Vdc, type 1, 20 way HE10 connector
TSXDSY32T2K 32 DO 24Vdc, 0.1A, 20 way HE10 connector
TSXDSY64T2K 64 DO 24Vdc, 0.1A, 20 way HE10 connector
TSXDEY16D2 16 DI 24Vdc
TSXDSY16T2 16 DO 24Vdc
TSXDSY08T22 8 DO 24 VDC 2A per poin
TSXDSY08R5A Relay Output Module 8 point protected
TSXBLY01 Terminal Module for TSXDxY16 or TSXDSY08
note: for other I/O such as high speed input and counter modules, see link
Telefast Flex I/O Extensions
ABE7H16R21 16 DI 24Vdc LED (2 rows)
ABE7BV20 Addition common rail for ABE7H16R21
ABE7R16S111 16 DO 2A relay LED, 1 common/8 ch
ABE7S16S2B0 16 DO 24Vdc 0.5A, LED, fault report
ABE7R16S210 16 DO 5A relay, LED, volt free
Cables for Telefast I/O
TSXCDPxx3 HE10 connector to Telefast2 0.25m
note: xx= 05, 10, 20, 30, 50 for 0.5, 1, 3, or 5 meters respectively
Premium Analog Modules
TSXASY410 4 Channel Analog Output
TSXAEY414 Multi-range Analog Input (16 bit)
TSXBLY01 Terminals for TSXAEY414 and TSXASY410
M340 Input and Output Modules
BMXDDI1602 16pt Input Module 24V sink
BMXDDO1602 16pt Output Module 24V
BMXDAO1605 16pt Output Module Relays
BMXDDI3202K 32pt Input Module 24V sink HE10 Connector
BMXDDI6402K 64pt Input Module 24V sink HE10 Connector
BMXDDO3202K 32pt Output Module 24V HE10 Connector
BMXDDO6402K 64pt Output Module 24V HE10 Connector
note: analog, high speed input and counter modules are also available, consult Schneider
5.3.4 Terminals
IEC Terminal Strip Hardware
AB1VV435Ux Screw Terminal 4mm2, 6mm spacing (100 p/pck)
AB1VV635Ux Screw Terminal 6mm2, 8mm spacing(100 p/pck)
AB1VVN1035Ux Screw Terminal 10mm2, 10mm spacing (100 p/pck)
AB1VVN1635Ux Screw Terminal 16mm2, 12mm spacing (100 p/pck)
AB1VVN3535Ux Screw Terminal 35mm2, 16 mm spacing (100 p/pck)
AB1VVN7035Ux Screw Terminal 70mm2, 24mm spacing (100 p/pck)
note: for x blank=grey, BL=blue, GE-orange, RO=red (435/635 only), VE=green (435 only),
BLA=white (435 only), UNO=black (435 only)
AB1ET435U Double Screw Term., 6mm spacing, 2 in 2 out, grey (100)
AB1ET435U2 Double Screw Term., 6mm spacing, 4 wire, black (100)
AB1ET435UTP Double Screw Term., 6mm spacing, Earth, green/yellow (100)
AB1ET435UBRO Double Screw Term., 6mm spacing, 24V LED, red (100)
AB1ET435UBVE Double Screw Term., 6mm spacing, 24V LED, green (100)
note: see catalog for additional numbers: end stops partitions, labels, etc.
5.4 Safety
5.4.1 Safety Relays
Safety Relays General
XPSAV11113T050 Fixed time delay relay 0.5 sec,3 N/O + 3 timed + 3 solid state
XPSAK311144P Safety Relay 3 N/O + 1 N/C + 4 solid state
XPSAR311144P Safety Relay 7 N/O + 2 N/C + 4 solid state
XPSECM5131 Extension modules 4 N/O + 1 N/C + 1 solid state
XPSECP5131 Extension modules 8 N/O + 1 N/C + 1 solid state
XPSBF1132P Safety Relay Two hand control 2 N/O + 2 Solid State
XPSVNE1142P 3 phase zero -speed monitoring relay back EMF
Safety Relays Configurable/Programmable
XPSMP11123P two independent configurable safety functions
5.4.2 Asi Safety
ASi Safe Monitors
ASISAFEMON1 ASi Safety Monitor 1 output group
ASISAFEMON2 ASi Safety Monitor 2 output groups
ASi Safe Input Devices
ASISSLC1 ASi Safe Interface module with one dual channel M12
ASISSLC2 ASi Safe Interface module with two single channel M12
ASISSLLS ASi Safe Interface module with one dual channel ISO
Pending E-Stop box with approved PB and ASi safe interface
5.4.3 Programmable Safety
Safety Controllers
XPSMC16ZC Controller, 8 independent safety outputs, 16 inputs, CanOpen
XPSMC32ZC Controller, 8 independent safety outputs, 32 inputs, CanOpen
note: Profibus (change C to P) and Modbus (no C) are optional uplinks instead of CanOpen
XPSMF4002 Safety Controller with Ethernet safety network
note: EtherSafe remote safety I/O modules are provided in partnership with Hima
5.5 Devices
5.5.1 RF Tag System
Ositrack Tags
XGHB211345 256B Cylindrical 18mm
XGHB221346 256B Tag 26mm x 26mm
XGHB444345 3.4KB Tag 40mm x 40mm
XGHB445345 13.6KB Tag 40mm x 40mm
XGSTP401 Ositrack Handheld Terminal Unit
Ositrack Readers
XGCS4901201 Compact Station 40mm x 40mm, M12 connector
XGCS8901201 Compact Station 80mm x 80mm, M12 connector
TCSMCN1M1Fx Cable for connection between readers and NIMs
note: x = 1, 2, 5 or 10 for length in meters
Ositrack Network Interface Modules
XGSZ33ETH 3-way Ethernet Tap
TCSAMT31FP 3-way Tap CanOpen or Modbus
5.5.2 Servo Motors And Drives
Lexium 15 Servo Drive/Controllers
LXM15LxxxN4 Lexium Drive, low power range (to 6A cont. at 460VAC)
LXM15LxxxN4 Lexium Drive, medium power range (to 20A cont. at 460VAC)
LXM15LxxxN4X Lexium Drive, high power range, (to 70 cont. A at 460VAC)
note: xxx= amp rating, see link
Lexium Network Interface (Sercos, Can, Ethernet, others)
note: CanOpen and integrated controller are standard
AM0ETH001V000 Ethernet Interface Unit
AM0SER001V000 Sercos Interface Unit
Lexium 05 Servo Drive/Controllers (low cost micro drive)
LXM05ADxxN4 Micro Servo/Drive Controller with CanOpen
note: xx=14,22,34,57 for "x.x" kW, BSH Motors only
Lexium Servo Motors
BSHxxxxx22y2A High performance, low inertia servo motors
BDHxxxxx22y2A Standard inertia servo motors
note: xxxx = size and winding (see catalog), y = F for brake or A for no brake
note: xxxx = gearmotors are also available (see catalog)
VW3M5x0xRyyy BSH/BDH Motor Power cable
note: x is connector type, y is length(See catalog)
VW3M8x0xRyyy BSH/BDH Feedback Cable
note: x is connector type, y is length(See catalog)
note: see catalogs for additional accessories
Mechanical Limit
XCKJ161D Limit Switch (2NC + NO) M12, End Plunger
XCKJ167D Limit Switch (2NC + NO) M12, Roller Plunger
XCKJ10511D Limit Switch (2NC + NO) M12, Roller Lever
XCKJ10541D Limit Switch (2NC + NO) M12, Variable Lever
XCKJ10559D Limit Switch (2NC + NO) M12, Rod Lever
9007C54B2D5T Side rotary with M12 connector (single pole)
9007C54FD5T Side plunger with M12 connector (single pole)
9007C54DD5T Top plunger with M12 connector (single pole)
9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)
9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)
9007C54FY140Y35D5T Side plunger, viton seals, epoxy filled with M12 (single pole)
9007C54DY140Y35D5T Top plunger, viton seals, epoxy filled with M12 (single pole)
9007C62B2Y19016 Switch, limit, side rotary with 9-pin (double pole)
9007C62FY19016 Side plunger with 9-pin (double pole)
9007C62DY19016 Top plunger with 9-pin (double pole)
9007C62B2 Y140Y35M9T Side rotary, viton seals, epoxy filled with 9-pin (double pole)
9007C62FY140Y35M9T Side plunger, viton seals, epoxy filled with 9-pin (double pole)
9007C62DY140Y35M9T Top plunger, viton seals, epoxy filled with 9-pin (double pole)
Pressure
XMLFM01D2035 Vacuum -1.16 PSI (-0.08 bar) to -14.5 PSI (-1.0 bar)
XMLF001D2035 Pressure 1.16 PSI (0.08 bar) to 14.5 PSI (1.0 bar)
XMLF002D2035 Pressure 2.9 PSI (0.2 bar) to 36.3 PSI (2.5 bar)
XMLF010D2035 Pressure 12 PSI (0.8 bar) to 145 PSI (10 bar)
XMLF016D2035 Pressure 19 PSI (1.3 bar) to 232 PSI (16 bar)
XMLF025D2035 Pressure 29 PSI (2.0 bar) to 363 PSI (25 bar)
XMLF040D2035 Pressure 46 PSI (3.2 bar) to 580 PSI (40 bar)
XMLF070D2035 Pressure 81 PSI (5.6 bar) to 1015 PSI (70 bar)
XMLF100D2035 Pressure 116 PSI (8.0 bar) to 1450 PSI (100 bar)
XMLF160D2035 Pressure 186 PSI (12.8 bar) to 2320 PSI (160 bar)
XMLF250D2035 Pressure 290 PSI (20 bar) to 3625 PSI (250 bar)
XMLF400D2035 Pressure 464 PSI (32 bar) to 5800 PSI (400 bar)
XMLF600D2035 Pressure 696 PSI (48 bar) to 8700 PSI (600 bar)
Ultrasonic
XX518A3PAM12 18mm ultrasonic tubular body, normally open (0.5-0.5 meters)
XX630A1PCM12 30mm ultrasonic tubular body, normally open (0.1-1.0 meters)
Mounting Brackets
XUZA50 Mounting Bracket (Metal), for use with XUM
XUZA118 Mounting Bracket (Metal), for use with XU 18mm, XUB
XUZA218 Swivel Mounting Bracket (Plastic), for use with XU 18mm, XUB
XUZB2003 3D mounting kit for use with SUB, XU18, SUZC50
XUZM2003 3D mounting kit for use with XUM, SUZC50
XUZK2003 3D mounting kit for use with XUK, XUZC50
XUZX2003 3D mounting kit for with XUX, XUZC50
XUZM2004 Protective 3D mounting kit for XUM
XUZK2004 Protective 3D mounting kit for XUK
XUZX2004 Protective 3D mounting kit for XUX
XUZ2001 M12 stem (75mm), for use with XUZB, XUZM, XUZK, XUZX
XUZ2003 3D mounting base, for use with XUZ2001
Zero Speed Detection
XSAV11373LD Motion detector, range 6-150 pulse/min, 9 sec start-up delay
XSAV12373LD Motion detector, range 120-3000 pulse/min, 9 sec start-up
note: not to be used for safety circuits, use XPS-VN back-emf relay
5.5.9 Cables And Sensor Docks
Sensor Docks
ABE9C1241C23 4 channel splitter M12/M23
ABE9C1281C23 8 channel splitter M12/M23
ABE9XLA10 Marker labels (lot of 12)
FTXCM12B Sealing Plugs for M12 connectors (lot 10)
Molded Cables
XZCP0766Lx Elbowed M8 female, 3 pin, PUR, with PNP LED
XZCP0866Lx Elbowed M8 female, 3 pin, PUR, with NPN LED
XZCP1340Lx Elbowed M12 female, 3 pin, PUR, with 2 PNP LEDs
XZCP1440Lx Elbowed M12 female, 3 pin, PUR, with 2 NPN LEDs
note: for x: 2= 2 meters, 5=5 meters, 10=10 meters
XZCC43FCP40B DIN connector for field cable installation
XSZEDD1020 Extension M12 to M12, PVR, 1 meter
XSZEDD1040 Extension M12 to M12, PVR, 2 meters
XZCR1501040G1 Extension M8 to M12, PVR, 1 meter
XZCR1501040G2 Extension M8 to M12, PVR, 2 meters
XZCR1523062K1 Extension DIN to M12, PVR, 1 meter
XZCR1523062K2 Extension DIN to M12, PVR, 2 meters
note: many more cable and connector types are available
6 Revision Log
Home
6.1 Version 2.0 Revision Detail
3.1 Removed the “Mixed Architecture”
Changed the order of the architecture presentations
Removed presentation of Twido PLC as part of assembly station Home
3.3 Added representation of Twido for simple standalone machines
4.1.2 Removed XBT-N display
Added IPC with note that Chrysler approval is required
6.1 Updated drawing of standard PDP
8.1.1 Corrected M340 CPU part numbers
Added more powerful M340 power supply
8.1.3 Removed XBT-N
8.2.1 Corrected switch part numbers
8.4.2 Updated part number for safety controller
8.5.4 Updated part numbers for higher amperage MCPs
8.5.8 Updated ultrasonic sensor part numbers
8.5.10 Updated power supply part numbers
8.6.4 Corrected transformer disconnect part number
6.2 Version 3.0 Revision Detail
2 Removed Home
2.1 Removed
2.2 Moved to new section 2 Scope of Supply
2.3 Removed
2.4 Moved to new section 2.1.3 Networks
3 Architectures moved to new section
3.1 Changed “Anything In Between” to “Hybrid”
3.1.1 Updated graphic
3.1.2 Updated graphic
3.1.4 Updated graphic
3.1.7 Updated graphic and changed to “Hybrid”
3.2.1 Updated graphic
3.2.2 Updated graphic for gantry
3.3 Removed graphic showing Twido for simple machine
4,5,6 Moved to new section 2 Scope of Supply
4.1.1 (now 2.1.1) Removed Twido and added Quantum
4.1.2 (now 2.1.2) Added Factorycast HMI and Citect Scada
4.2 Moved to 2.1.3 and rearranged
5 Moved to 2.2 Control Products and revised
5.2 Moved to 2.1.4 Motion Control and Drives and revised
6 Split into 2.1.5 Safety and 2.3 Power Distribution and revised
New Added section 2.4 System Capabilities
7 Becomes section 4
8 Becomes section 5, added web and product links, corrected links throughout section
8.1.1 (now 5.1.1) Added memory card, removed Twido processor and memory card
8.1.2 (now 5.1.2) Removed Twido modules
New Added 5.1.3 PLC programming software
New Added 5.1.4 PLC programming cables
8.1.3 (now 5.1.5) Removed 5.7” HMIs, added HMI software, added XBTGK keypad HMI
8.2.1 (now 5.2.1) Added several Connexium switches
5.3.3 Updated part numbers for FTB modules for typo, updated typo in ASI67FFP43EY, added ETB
modules and accessories
5.4.1 Updated XPSVNE1142P, removed XPSN3440 standstill monitoring relay due to obsolescence
5.5.2 Corrected typo in Lexium Network Interface modules AM0…
5.5.3 Replaced ATV31 with ATV312 (direct replacement), corrected part number ATV71HU55N4,
added ATV71 Ethernet/IP module, added ATS22 softstart
5.5.4 Updated part numbers LC2D40ABD, LC2D50ABD, LC2D65ABD now with Everlink, updated
GV2AF4 for typo, added Tesys-T motor management system part numbers
5.5.6 Added XVC stack lights.
5.5.8 Updated part number XUB0BPSNM12 due to obsolescence, corrected part number XUZA50
5.5.9 Replaced Elbowed molded cables with new part numbers due to obsolescence