Compact Modbus SL Logic Controller M221 Book

EIO0000001678 04/2014

Compact Modbus SL
Logic Controller
M221 Book
System User Guide
04/2014
EIO0000001678.00

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.
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Schneider Electric.
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.
© 2014 Schneider Electric. All rights reserved.

2 EIO0000001678 04/2014
 Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
About the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Deliverables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 2 System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Architecture Related Safety Information . . . . . . . . . . . . . . . . . . . . . . . 20
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 3 Safety & Safety Requirements . . . . . . . . . . . . . . . . . . . 25
Safety Evolution Structure for the System User Guides . . . . . . . . . . . 26
Evolution of Legal Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Functional Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Standard EN ISO 13849-1 Machinery Safety - Safety-Related Parts of
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Standard EN/IEC 62061 Machinery Safety - Safety-Related Parts of
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Selecting the Applicable Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
More Information Regarding Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Functional Safety Measures Implemented in this Architecture . . . . . . 53
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Modicon TM3 Embedded Safety Module - Hardware . . . . . . . . . . . . . 68
Preventa Detection and Dialog - Hardware . . . . . . . . . . . . . . . . . . . . . 71
4.3 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Magelis HMI STO - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Harmony XB5R ZBRRC Wireless Access Point - Hardware . . . . . . . . 76
Harmony Control and Signaling - Hardware . . . . . . . . . . . . . . . . . . . . 78

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 4.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Modicon M221 Modular Logic Controller - Hardware. . . . . . . . . . . . . . 80
Modicon TM3 Modules - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
TM3XTYS4 TeSys Module - Hardware . . . . . . . . . . . . . . . . . . . . . . . . 87
4.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ConneXium Ethernet Switch (Unmanaged) - Hardware . . . . . . . . . . . 93
4.6 Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
TeSys D Contactor - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
TeSys GV2 Motor Circuit Breakers - Hardware . . . . . . . . . . . . . . . . . . 98
TeSys U LU2B Motor Starter- Hardware . . . . . . . . . . . . . . . . . . . . . . . 100
TeSys GV2DP - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
TeSys LAD5Cxx Wiring Adapter - Hardware . . . . . . . . . . . . . . . . . . . . 106
Altistart 01 Soft Starter - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Altivar 12 Variable Speed Drive - Hardware . . . . . . . . . . . . . . . . . . . . 112
4.7 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
OsiSense XG Tap-off box - Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 117
OsiSense XGCSx90 RFID - Hardware . . . . . . . . . . . . . . . . . . . . . . . . 118
OsiSense Industrial Sensors - Hardware . . . . . . . . . . . . . . . . . . . . . . . 122
Chapter 5 Communication Topology and Wiring Guide . . . . . . . 123
5.1 Introduction to System Communication . . . . . . . . . . . . . . . . . . . . . . . . 124
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.2 Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Ethernet Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Ethernet Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Modicon M221 Modular Logic Controller - Wiring . . . . . . . . . . . . . . . . 129
Magelis HMI STO - Ethernet Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Modbus Serial Line Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Modbus SL Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Modbus SL Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Modicon M221 Modular Logic Controller - Wiring . . . . . . . . . . . . . . . . 136
Chapter 6 Implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.1 Access the SoMachine Project Template . . . . . . . . . . . . . . . . . . . . . . 138
Access the SoMachine Project Template . . . . . . . . . . . . . . . . . . . . . . 139
Access the SoMachine Basic Project Template. . . . . . . . . . . . . . . . . . 140
6.2 Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

4 EIO0000001678 04/2014
 6.3 Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Vijeo-Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Chapter 7 System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.1 Setup Controller and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Setup Controller and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 Setup Other Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Network and Device Parameter Settings. . . . . . . . . . . . . . . . . . . . . . . 161
TeSys U Motor Starter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Altivar 12 Variable Speed Drive - Setup . . . . . . . . . . . . . . . . . . . . . . . 163
Altistart 01 Soft Starter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OsiSense XGS - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
iEM3110 Energy Meter - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Harmony ZBRRC Wireless Receiver - Setup . . . . . . . . . . . . . . . . . . . 171
Chapter 8 Bill of Material (BOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Bill of Material (BOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Glossary ......................................... 179
Index ......................................... 183

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6 EIO0000001678 04/2014
 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, 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 04/2014 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.

BEFORE YOU BEGIN

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of
effective point-of-operation guarding on a machine can result in serious injury to the operator of
that machine.

WARNING
UNGUARDED EQUIPMENT
z Do not use this software and related automation equipment on equipment which does not have
point-of-operation protection.
z 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.

8 EIO0000001678 04/2014
 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.
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.

START-UP AND TEST

Before using electrical control and automation equipment for regular operation after installation,
the system should be given a start-up test by qualified personnel to verify correct operation of the
equipment. It is important that arrangements for such a check be made and that enough time is
allowed to perform complete and satisfactory testing.

CAUTION
EQUIPMENT OPERATION HAZARD
z Verify that all installation and set up procedures have been completed.
z Before operational tests are performed, remove all blocks or other temporary holding means
used for shipment from all component devices.
z Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in 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:
z Remove tools, meters, and debris from equipment.
z Close the equipment enclosure door.
z Remove all temporary grounds from incoming power lines.
z Perform all start-up tests recommended by the manufacturer.

EIO0000001678 04/2014 9
OPERATION AND ADJUSTMENTS
The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English
version prevails):
z 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.
z 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.
z 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 04/2014
 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 with the release of SoMachine V4.1.
This document has been updated with the release of SoMachine Basic V1.1.

EIO0000001678 04/2014 11
Related Documents

Title of Documentation Reference Number

PowerPact Multistandard, Catalogue LVPED212023EN
The essential guide for power supplies and transformers DIA3ED2070412EN
Multi 9 System, Catalog 0860CT0201
Phaseo power supplies and transformers, Catalogue Pages 14082-EN
iEM3100 series / iEM3200 series, Energy Meters, User Manual DOCA0005EN
Control and protection components MKTED210011EN
LAD5C Instruction Sheet HRB8873800
Preventa, Machine Safety Products MKTED208051EN
The essential guide: Preventa machine safety DIA4ED2041204EN
Magelis Small Panels HMI STO, User Manual EIO0000000239
Magelis XBT G/XBT GT, Modbus TCP/IP driver 35007091
Harmony XB5R, Expert Instruction Sheet EIO0000000812 (EN)
Control and signaling components MKTED208031EN
Modicon M221 Logic Controller, Hardware Guide EIO0000001384
Modicon M221 Logic Controller, Programming Guide EIO0000001360
Modicon M241 Logic Controller, Programming Guide EIO0000001432 (ENG)
Modicon TM3, Expansion Modules Configuration, Programming EIO0000001402
Guide
Modicon TM3, Digital I/O Modules, Hardware Guide EIO0000001408
Modicon TM3, Expert I/O Modules, Hardware Guide EIO0000001420
Control and protection components MKTED210011EN
TeSys U, Starter-controllers, Catalogue DIA1ED2081003EN
The essential guide, TeSys for power control & protection DIA1ED2040401EN
Altistart 01, Soft Starts for Single-Phase and Three-Phase 45A01SS
Asynchronous Motors
Characteristics, Soft starters for asynchronous motors Altistart 01 60541-EN
Reduce mechanical stress on your machines DIA2ED1121204EN
Instruction Sheet ATS01N1...FT 1624685
Altivar 12, Variable speed drives for asynchronous motors, User BBV28581
manual
Altivar 12 Variable speed drives for asynchronous motors, Modbus BBV28590
Communication Manual
RFID OsiSense XG, Compact Stations 9006CT1101

12 EIO0000001678 04/2014
 Title of Documentation Reference Number
ConneXium Ethernet Switches, TCSESU0••F•N0, Quick Reference 31007950
Guide
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 www.schneider-electric.com.

Product Related Information

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
z 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.
z Always use a properly rated voltage sensing device to confirm the power is off where and when
indicated.
z Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a
proper ground connection exists before applying power to the unit.
z 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 04/2014 13
 WARNING
LOSS OF CONTROL
z 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.
z Separate or redundant control paths must be provided for critical control functions.
z System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
z Observe all accident prevention regulations and local safety guidelines.1
z 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
z Only use software approved by Schneider Electric for use with this equipment.
z 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.

14 EIO0000001678 04/2014
 Compact Modbus SL Logic Controller M221 Book
General Information
EIO0000001678 04/2014

General Information

Chapter 1
General Information

What Is in This Chapter?

This chapter contains the following topics:
Topic Page
Introduction 16
Deliverables 17

EIO0000001678 04/2014 15
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
z quickly find cost efficient controlling solutions,
z optimize the system implementation time,
z 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. Full functional tests are performed on real machines to verify that the control system
meets the machine requirements it is recommended for. 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 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.

Special Note
At the time of this writing, not all products documented in the proposed architecture(s) may be
commercially available. Although, the architecture(s) documented herein have been tested and
functionally validated, for some of the products prototypes were used for proof of concept and
general functionality representative of the final products. Nonetheless, there is the possibility that
perhaps certain product characteristics, configuration methods and/or product references may be
subject to change without notice in the commercial versions of those products documented herein.
Finally, for some of the products documented herein, certain agency certifications are pending the
availability of the commercial versions of the products. For more information concerning product
availability, certifications and the latest product characteristics, please contact your local service
representative.

16 EIO0000001678 04/2014
 General Information

Deliverables

SoMachine Project Template

Ready-to-use controller project covers the complete system configuration, with preconfigured
application code to operate field devices to monitor the system status and to handle detected
errors.

HMI Application
Ready-to-use HMI application as interface to
z control the system in its main functionalities,
z indicate the system status,
z visualize the detected system faults.

System User Guide (SUG)

z System documentation with focus on installation, commissioning, and adaptation of the system
z Bill of Material (BOM), including power distribution components
z Detailed installation information for each component
z Guidance on how to commission the complete system
z Introduction of available ranges and key features of each component used within the
architecture
z Guide on how to adapt the system efficiently by making use of dedicated functions provided
within SoMachine software

Wiring Diagram
Detailed guidance on the system wiring, reusable as a base to generate final technical wiring
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:
z EPLAN P8 V2.1 project archive
z *.pdf (generated with EPLAN)
z *.dwg (generated with EPLAN)

EIO0000001678 04/2014 17
General Information

18 EIO0000001678 04/2014
 Compact Modbus SL Logic Controller M221 Book
System Architecture
EIO0000001678 04/2014

System Architecture

Chapter 2
System Architecture

What Is in This Chapter?

This chapter contains the following topics:
Topic Page
Architecture Related Safety Information 20
System Architecture 22

EIO0000001678 04/2014 19
System Architecture

Architecture Related Safety Information

Remote Devices
Remote control operating devices may lead to unintended equipment operation by:
z incorrect operation
z insufficient view on the machine during operation
z unintentional manipulation

The manufacturer or the operating company of the machine must take precautions to avoid
unintentional equipment operation that may be caused by remote control.

WARNING
UNINTENDED EQUIPMENT OPERATION
z Place operator devices of the control system near the machine or in a place where you have
full view of the machine.
z Protect critical operator commands against unauthorized access (for example, by access
control, password protection, or key switch).
z Ensure that unintended equipment operation (for example by remote control) is prohibited at
machine site.
z Configure and install the RUN/STOP input for the application so that local control over the
starting or stopping of the controller can be maintained regardless of the remote commands
sent to any controller.
z 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.
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.

20 EIO0000001678 04/2014
 System Architecture

WARNING
LOSS OF CONTROL
z Do not use wireless equipment as the only means of control for critical control functions such
as motor start/stop or power disconnect.
z Provide separate or redundant control paths for critical control functions.
z 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.
z 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.

Communication
Fieldbusses or network communication may lead to loss of control by:
z Communication disturbance by external influences (for example wiring or EMC)
z Delay during communication
z Interruption of communication
z Inaccurate communication

WARNING
LOSS OF CONTROL
z 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.
z Separate or redundant control paths must be provided for critical control functions.
z System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
z Observe all accident prevention regulations and local safety guidelines.1
z 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 04/2014 21
System Architecture

System Architecture

Overview
The architecture is arranged into the optimized performance class and is distinguished by the
following characteristics:
z Modicon M221 Logic Controller (book format)
z Magelis HMI STO touch panel
z Energy metering
z Modbus serial line communication
z Ethernet connectivity
z Application of machine functional safety
z Wireless and batteryless operator push-buttons
z 24 digital inputs
z 24 digital outputs
z 2 analog inputs
z 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:
z Altivar 12 variable speed drive
z 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.
z 2 TeSys D motor starter combinations
z 1 TeSys D motor starter combination and Altistart soft starter
z 2 TeSys U motor starter controller

22 EIO0000001678 04/2014
 System Architecture

Layout

1 PowerPact H-Frame circuit breaker 13 Harmony wireless push-buttons

2 iEM3110 energy meter 14 Harmony signaling/control devices
3 TeSys D contactor 15 TeSys D motor starter + wiring adapter
4 Multi-9 C60 (UL 1077) circuit breaker 16 TeSys D rev. motor starter + wiring adapter
5 Phaseo power supply 24 Vdc 17 Altistart ATS01N1 soft starter
6 Modicon M221 Logic Controller (book format) 18 TeSys U motor starter
7 TM3 embedded safety module 19 TeSys U rev. motor starter
8 TM3 I/O expansion module 20 Multi-9 C60 (UL 489) circuit breaker
9 Modbus RS-485 hub 21 TeSys GV2P motor circuit breaker
10 Ethernet switch (unmanaged) 22 Altivar 12 variable speed drive
11 Magelis HMI STO touch panel 23 OsiSense sensors and switches
12 Harmony wireless receiver 24 OsiSense XG tap-off box + RFID compact
smart antennas

EIO0000001678 04/2014 23
System Architecture

24 EIO0000001678 04/2014
 Compact Modbus SL Logic Controller M221 Book
Safety & Safety Requirements
EIO0000001678 04/2014

Safety & Safety Requirements

Chapter 3
Safety & Safety Requirements

What Is in This Chapter?

This chapter contains the following topics:
Topic Page
Safety Evolution Structure for the System User Guides 26
Evolution of Legal Framework 27
Risk Assessment 30
Functional Safety Standards 34
Standard EN ISO 13849-1 Machinery Safety - Safety-Related Parts of Control System 35
Standard EN/IEC 62061 Machinery Safety - Safety-Related Parts of Control System 43
Selecting the Applicable Standard 50
More Information Regarding Safety 51
Functional Safety Measures Implemented in this Architecture 53

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Safety & Safety Requirements

Safety Evolution Structure for the System User Guides

Overview
1. Evolution of legal framework (see page 27)
2. Risk assessment (see page 30)
3. Functional safety standards overview (see page 34)
4. Standard EN ISO 13849-1 machinery safety (see page 35)
5. Standard EN/IEC 62061 machinery safety (see page 43)
6. Selecting the applicable standard (see page 50)
7. Where to get more information regarding safety (see page 51)
a. Safety guide
b. Sistema
c. Sistema library
8. Concept used on specific TVDA

26 EIO0000001678 04/2014
 Safety & Safety Requirements

Evolution of Legal Framework

EC Directive
Legal instrument to harmonize the legislation of the European member states
z Defines the essential health and safety requirements (EHSRs).
z 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
z 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.
z 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.

European Directives and Safety Standards

Link between some of the main safety standards and the European directives according with the
sectors of activity.

A list of such standards can be accessed at:

http://www.newapproach.org/Directives/DirectiveList.asp

EIO0000001678 04/2014 27
Safety & Safety Requirements

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:
z Type B1 standards on particular safety aspects (for example, safety
distances, surface temperature, noise)
z 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.

Some examples of these types of standards are:

Name Type Description

EN ISO 12100 A 2010 Safety of machinery - General principles for design - Risk
assessment and risk reduction
EN ISO 13850 B Emergency stop - Principles for design
EN/IEC 62061 B Functional safety of safety-related electrical, electronic, and electronic
programmable control systems
EN ISO 13849-1 B Safety of machinery - safety-related parts of control systems - Part 1
general principles for design
EN 349 B Minimum gaps to avoid crushing of parts of the human body
EN ISO 13857 B Safety of machinery - safety distances to prevent hazard zones being
reached by upper and lower limbs
EN 60204-1 B Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
EN 1088/ISO 14119 B Interlocking devices associated with guards - Principles for design and
selection

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.

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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

Determination of Machine Limits

Risk assessment starts by determining the limits of the machine at all stages of its life cycle:
z Transport, assembly, installation
z Commissioning
z Use
z De-commissioning, dismantling

The use limitations must then be specified:

z Operating modes
z Level of training required
z Space limits (amplitude, movement...)
z Time limits (life cycle, frequency of maintenance...)

Logic steps for risk analysis

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Safety & Safety Requirements

Identification of the Potential Hazard

If a potential hazard exists, a hazardous phenomenon will cause harm if measures are not taken.
All the tasks associated with the life cycle of a machine must be identified, such as:
z Assembly, transport, and installation
z Adjustment, testing
z Learning, programming
z Tool changing
z Feeding, removal of product from the machine
z Starting, stopping
z Emergency stops, restarting after an unexpected stop
z Maintenance, cleaning, and so on.

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:
z The severity of injuries (slight, serious, death)
z The extent of the harm (number of persons)

The probability of the harm occurring takes into account:

z Exposure to the hazard (nature of access, time spent in the hazardous zone, number of persons
exposed, frequency of access)
z The occurrence of a hazardous event (accident history, comparison of risks, ...)
z The possibility of avoiding or limiting the harm (experience, awareness of the risk, ...)

Elements of the risk

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:
z either standard EN ISO 13849-1, which defines performance levels (PL)
z 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:
z intrinsic prevention (inherently safe design)
z definition of the appropriate protective means (guards, carters, fix fences, ...)
z 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:
z either through the choice of components
z 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.

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Safety & Safety Requirements

Functional Safety Standards

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.
z 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.
z 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.

34 EIO0000001678 04/2014
 Safety & Safety Requirements

Standard EN ISO 13849-1 Machinery Safety - Safety-Related Parts of Control

System

Overview
Standard EN ISO 13849-1 is an evolution of standard EN 954-1.

Field of Application of the Standard

This standard gives safety requirements and advice relating to principles for the design and
integration of safety-related parts of control systems (SRP/CS), including software design.
For these parts, it specifies the characteristics, including the performance level, needed to achieve
these safety functions. It applies to the SRP/CS of all types of machine, regardless of the
technology and type of energy used (electric, hydraulic, pneumatic, mechanical, and so on).

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.

Stage 1 - Selection of Safety Functions

The diagram below shows a safety function which consists of several parts:
z The input actuated by opening of the guard (SRP/CSa)
z The control logic, limited in this example to opening or closing of a contactor coil (SRP/CSb)
z The power output that controls the motor (SRP/CSc)
z The connections (Iab, Ibc)

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Safety & Safety Requirements

Representation of the safety function

Stage 2 - Estimation of Required Performance Level (PLr)

Considering the example of the person coming into area where the machine is operating, the risk
is estimated using the risk graph.
The parameters to be considered are:

S: Severity of the injury

z S1: Slight injury, normally reversible
z S2: Serious, normally irreversible, including
death
F: Frequency and/or duration of exposure to the
hazardous phenomenon
z F1: Rare to fairly frequent and/or short duration of
exposure
z F2: Frequent to permanent and/or long duration
of exposure
P: Possibility of avoiding the hazardous phenomena
or limiting the harm
z P1: Possible under certain circumstances
z P2: Virtually impossible

Start Starting point for the evaluation

PLr Required performance level
L Low contribution to risk reduction
H High contribution to risk reduction

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.

36 EIO0000001678 04/2014
 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.

Stage 3 - Design and Creation of the Safety Functions

There is a need to describe the PL (performance level) calculation method.
For a SRP/CS (or a combination of SRP/CS), PL could be estimated with the figure after estimation
of several factors such as:
z Hardware and software system structure (categories)
z Mechanism of failures, diagnostic coverage (DC)
z Components reliability, mean time to dangerous failure (MTTFd)
z Common cause failure (CCF)

Categories (Cat.) and designated architectures

Summarized system behavior in the event of a failure and the principles used to achieve the safety,
for the 5 categories defined.

Category System Behavior Designated Architecture

B A fault can lead to loss of the safety function.
1 As for category B but the probability of this
occurrence is lower than for the category B.

2 A fault can lead to loss of the safety function

between 2 periodic inspections and loss of the
safety function is detected by the control system at
the next test.

3 For a single fault, the safety function is always

ensured. Only some faults will be detected. The
accumulation of undetected faults can lead to loss
of the safety function.

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Safety & Safety Requirements

Category System Behavior Designated Architecture

4 When faults occur, the safety function is always
ensured. Faults will be detected in time to prevent
loss of the safety function.

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

MTTFd (mean time to dangerous failure)

The value of the MTTFd of each channel is given in 3 levels (see table below) and shall be taken
into account for each channel (for example, single channel, each channel of a redundant system)
individually.
Reliability levels of components

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.

38 EIO0000001678 04/2014
 Safety & Safety Requirements

The standard recognizes 4 levels:

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:

Category System Behavior Designated Architecture

1 As for category B but the
probability of this
occurrence is lower than for
the category B.

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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.

Example B10d (Where 10% of the Population MTTFd DC

Fail to Dangerous Failure Mode)
SRP/CSa: Magnetic switch 50000000 1578.28 -
SRP/CSb: XPS AXE safety module - 457 99.99%
SRP/CSc: TeSys contactor 1369863 194 99%

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:
z Calculation of MTTFd and DC of the complete system
z Analysis of the category

For electromechanical products:

z The MTTFd is calculated based on the total number of operations that the product can perform,
using B10d values.

40 EIO0000001678 04/2014
 Safety & Safety Requirements

In this case, the machine operates for 220 days per year, 8 hours per day with a cycle of 90 s
z N = 220 x 8 x (3600 / 90) = 70,400 operations/year
z MTTFd = B10d / (0.1 x N)

For the magnetic switch:

z The MTTFd= 1578 years
For the contactors:
z The MTTFd = (1,369,863) / (0.1) x 70,400 = 194 yearsThe MTTFd for each channel will then be
calculated using the formula:

that is, 284 years

A similar formular is used to calculate the diagnostic capability:

The DC in the example is < 60%, for example nil.

Stage 5 - Checking That Required Performance Level Is Achieved

The result of the above calculations is summarized below:
z An architecture: category 1
z A mean time to failure > 30 years:
high MTTFd >> a diagnostic capability < 60% (nil)
Looking at this table, confirms that PL level c is achieved:

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Safety & Safety Requirements

Stage 6 - Validation of the Required Performance Level

The design of SRP/CS must be validated and must show that the combination of SRP/CS
performing each safety function satisfies all the applicable requirements of EN/ISO 13849.

42 EIO0000001678 04/2014
 Safety & Safety Requirements

Standard EN/IEC 62061 Machinery Safety - Safety-Related Parts of Control

System

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).

Functional Approach to Safety

As with EN/ISO 13849-1, the process using the EN/IEC 62061 starts with analysis of the risks
(EN/ISO 12100) in order to be able to determine the safety requirements.
A particular feature of this standard is that it prompts you to make a functional analysis of the
architecture; then split it into subfunctions and analyze their interactions before deciding on a
hardware solution for them (the SRECS).
A functional safety plan must be drawn up and documented for each design project. It must include
a specification of the safety requirements for the safety functions (SRCF) that is in 2 parts:
z Description of the functions and interfaces, operating modes, function priorities, frequency of
operation, and so on.
z Specification of the safety integrity requirements for each function, expressed in terms of SIL
(safety integrity level).
The structured and documented design process for safety-related electrical control systems
(SRECS):
z The procedures and resources for recording and maintaining appropriate information.
z The process for management and modification of the configuration, taking into account
organization and authorized personnel.
z The verification and validation plan

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)

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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

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 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

Probability of the harm occurring

Each of the 3 parameters Fr, Pr, Av must be estimated separately using the most unfavorable
case. It is strongly recommended that a task analysis model is used in order to ensure that
estimation of the probability of the harm occurring is correctly taken into account.
Frequency and duration of exposure Fr
The level of exposure is linked to the need to access the hazardous zone (normal operation,
maintenance ...) and the type of access (manual feeding, adjustment...). It must then be possible
to estimate the average frequency of exposure and its duration.

Frequency of Dangerous Exposure Fr

≤1 hour 5
> 1 hour...≤ 1 day 4

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Safety & Safety Requirements

Frequency of Dangerous Exposure Fr

>1 day=< 2 weeks 3
2 weeks ≤1 year 2
> 1 year 1

Probability of occurrence of a hazardous event Pr

2 basic concepts must be taken into account:
z The predictability of the dangerous components in the various parts of the machine in its various
operating modes (normal, maintenance, troubleshooting), paying particular attention to
unexpected restarting
z The behavior of the persons interacting with the machine, such as stress, fatigue, inexperience,
and so on.

Probability of Occurrence of a Dangerous Event Pr

Very High 5
Probable 4
Possible 3
Almost impossible 2
Negligible 1

Probability of avoiding or limiting the harm Av

This parameter is linked to the design of the machine. It takes into account the suddenness of the
occurrence of the hazardous event, the nature of the dangerous component (cutting, temperature,
electrical) and the possibility for a person to identify a hazardous phenomenon.

Probability of Avoiding or Limiting the Harm Av

Impossible 5
Almost impossible 3
Probable 1

Assignment of the SIL

Estimation is made with the help of the table below. In the example, the degree of severity is 4
because there is a risk of death; this value is shown in the first column of the table.
All the other parameters must be added together in order to select one of the classes (vertical
columns in the table below), which gives:
z Fr = 5; access between 1 hour and a day
z Pr = 2; low probability of occurrence of the hazardous event (for example, operator monitoring)
z Av = 3; probability of avoiding almost impossible

Therefore a class CI = 5 + 2 + 3 = 10

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 Safety & Safety Requirements

A level of SIL 2 must be achieved by the safety-related electrical control systems (SRECS) on the
machine.

Basic structure of the SRECS

Without going into detail about the hardware components to be used, the system is broken down
into subsystems. In the example, you find the 3 subsystems that will perform the input, processing,
and output functions.
The figure below illustrates this stage, using the terminology given in the standard.

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.

EIO0000001678 04/2014 47
Safety & Safety Requirements

Types of subsystem architectures

Stage 4 - Select the Components for Each Subsystem

As the safety integrity level required in the example mentioned above is SIL 2, each of the
components must achieve this level.Once the targeted SIL is determined, the components
constructing the system from safety-related subsystems (sensor/switch, logic, actuator) have to be
selected. The components must have PFHd (probability of dangerous failure per hour) equal to the
required SIL rating needed.

Stage 5 - Design the Diagnostic Function

The SIL of the subsystem depends not only on the components, but also on the architecture
selected. In EN 62061, a safety integrity requirement is expressed as a target failure value for the
probability of dangerous failure per hour (PFHd) of each safety-related control function (SRCF).
This can be calculated from reliability data for each component or subsystem, and is related to the
SIL as shown in table 3 of the standard.

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 Safety & Safety Requirements

Relationship between SIL and PFHd values

SIL Probability of Dangerous Failures Per Hour (PFHd)

3 ≥10-8<10-7
2 ≥10-7<10-6
1 ≥10-6<10-5

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).

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Safety & Safety Requirements

Selecting the Applicable Standard

Overview
In order to be able to select the applicable standard, a common table in both standards gives
indications which are summarized below:

Technology Used EN ISO 13849-1 EN/IEC 62061

Maximum PL Maximum SIL
Non-electric only, for example, hydraulic e Not covered
Including some electromechanical, example: relays, e (for designated 3
and/or complex electronics architectures only)
Including complex electronics, for example D 3
programmable

Relationship between the performance level (PL) and the safety integrity level (SIL):

PL SIL Probability of Dangerous Failures Per Hour (1/h)

a No correspondence ≥10-5<10-4
b 1 ≥3x10-6<10-5
c 1 ≥10-6<3x10-6
d 2 ≥10-7<10-6
e 3 ≥10-8<10-7

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More Information Regarding Safety

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

Safety Chain Solutions

Schneider Electric offers a library of certified safety chain solutions.
Safety chain solutions provide you with a complete document explaining the concept, the used
cases, the architecture, wiring diagram as well the complete calculation.
Each of the safety chain solutions is certified by TÜV enabling you to reuse the architectures for
your machine and reusing the Sistema calculations as well as the documentation to help certify the
machine to the European legislation.

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Safety & Safety Requirements

To find more information regarding the safety chain solutions:

http://www2.schneider-electric.com/sites/corporate/en/solutions/oem/machine-safety/safety-
selector.page
Using the safety chain solutions provided by Schneider Electric to solve the existing architecture:

Step Action Comment

1 Perform a risk assessment of your A required performance level (PLr) must be specified
machine. for each intended safety function following a risk
assessment in accordance to the standard
EN ISO 12100.
2 Use the Safety Chain Selector* to find By answering the questions the most appropriated
the most appropriated pre-certified architectures will be proposed by the tool.
architecture.
3 Adapt the proposed architecture to meet Select other devices to substitute those in the
the needs of your machine risk proposed architecture by examining the safety
assessment. catalog.
4 Create the Systema file based on the Each architecture, which is provided with the Safety
used architecture within the Systema Chain Selector is available as a template in the
tool. Systema tool.
5 Adapt the template in the Systema tool The safety library within the Systema tool contains
based on the adaptations to the numerous devices with all required parameters for the
architecture and/or substitution of calculation.
devices done in step 3.
6 Adapt the number of machine operations Within the template, default values were set and these
within the Systema file for your machine. have to be adapted in order to match the machine
requirements.
7 Re-evaluate the achieved performance Verify that the attained performance level by the
level. control system is greater than or equal to the required
performance level resulting from the risk assessment
in step 1.
8 Document the relevant changes in the Specific information about the machine, the author,
Systema file. and so on, must be documented.
9 Print the Systema file to be used as part It is necessary to provide the documentation about the
of the machine documentation. risk assessment and the calculation of the machine.
* Safety Chain Selector: http://www2.schneider-electric.com/sites/corporate/en/solutions/oem/machine-
safety/safety-selector.page

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Functional Safety Measures Implemented in this Architecture

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 carried out according to EN ISO 12100 during 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 embedded safety module TM3 SAF5R
Output 2 redundant contactors with feedback loop LC1D

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Safety & Safety Requirements

54 EIO0000001678 04/2014
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Hardware
EIO0000001678 04/2014

Hardware

Chapter 4
Hardware

Overview
This chapter provides general information about the hardware.

What Is in This Chapter?

This chapter contains the following sections:
Section Topic Page
4.1 Electrical Distribution and Monitoring 56
4.2 Safety Modules 67
4.3 HMI 72
4.4 Controller 79
4.5 Communication 93
4.6 Motor Control 95
4.7 Detection 116

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Hardware

Electrical Distribution and Monitoring

Section 4.1
Electrical Distribution and Monitoring

What Is in This Section?

This section contains the following topics:
Topic Page
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

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 Hardware

PowerPact H-Frame Circuit Breaker - 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 instantaneous (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 04/2014 57
Hardware

Features z Rated current 15...600 A

z Breaking capacity from 18...65 kA at 480 Vac
z 3-pole versions
z 3 frame sizes: PowerPact H (15...150 A), PowerPact J
(150...250 A), and PowerPact L (250...600 A)
z Thermal-magnetic and electronic protection available for
the entire range
z Common accessories and auxiliaries with Compact NSX
range
z Suitable for isolation
z Switch-disconnector versions available
z Compliance with IEC 60947-2 and UL 489
z Certifications: UL, CSA, CCC
Benefits z Multistandard compliant: IEC, UL, CSA, CCC
z Worldwide available with unique global part numbers
z Flexible and simple offer, with proven performance
z With direct access to energy metering and energy efficiency
thanks to the Micrologic control units
Applications Feeder protection and circuit disconnect solutions when a
multistandard approach for one global design machine is
needed.
z International & global multi-site OEMs applications
z Regional OEMs exporting to USA, with production in
different countries, and in need of local
support/maintenance.

For more information, refer to PowerPact Multistandard, Catalogue, LVPED212023EN.

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Multi-9 C60 (UL 1077) Circuit Breaker - 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.
z 0.5...63 A at 480Y/277 Vac
z Up to 10 k AIR
z 1-, 2-, 3-, and 4-pole versions
z Common tripping of all poles
z 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)
z Current limiting capability is standard
z Full line of accessories
z Only 0.71 in. (18 mm) width per pole
z Flush, surface, or DIN rail mountable
z UL 1077, IEC 60947-2, and CE marked

EIO0000001678 04/2014 59
Hardware

New accessories with UL ratings include the following:

z Comb bus bars - UL recognized comb bus bars for UL 1077 supplementary protectors simplify
wiring. They are available in 1-, 2-, and 3-phase versions. They are fixed length of 12 poles and
cannot be cut. (A wide variety of IEC rated comb bus bars is also available).
z Tooth caps for the unused teeth of the comb bus Bar are also available. They come in bags of
4 strips of 5 (for a total of 20 poles), but can be snapped apart to be used individually.
z Ring tongue terminal Kit: A field-installable kit provides isolation barriers and ring terminals to
convert a standard box lug Multi-9 C60 (UL 1077) miniature supplementary protector.
For more information, refer to Multi 9 System, Catalog, 0860CT0201.

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Multi-9 C60 (UL 489) Circuit Breaker - 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.
z 1-, 2-, and 3-pole configurations
z 17 UL 489 ratings 0.5 A...35 A
z 2 trip curves available: C curve (7...10 times handle rating); D curve (10...14 times handle
rating)
z Small size: less than 19.05 mm (0.75 in.) wide per pole
z Interrupting ratings 10K AIR standard
z System voltages include 120/240 Vac and 240 Vac; also DC ratings of 60 Vdc (1P) and 125 Vdc
(2P)
z Ring terminals available (with finger-safe option)
z Padlock attachments for locking in the "OFF" position only
z Common tripping of all poles
z 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.
z Mounting base for 12...60 poles.
For more information, refer to Multi 9 System, Catalog, 0860CT0201.

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Hardware

Phaseo Power Supply Universal - 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.
z Local or remote diagnostic functions
z Current limiting or stop in event of an overload
z Function modules to ensure continuity of service
z Power reserve for absorbing the transient current peaks

Standards and UL, CSA, TÜV, C-Tick

certifications
Power range 72…960 W
Voltage range Input: 100…500 Vac
Output: 24 Vdc
Degree of protection IP 20 conforming to IEC 60529
Dimensions 6 different types (W x H x D):
44…165 x 143 x 120…155 mm (1.73…6.5 x 5.63 x
4.72…6.1 in.)

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 Hardware

For more information, refer to :

z The essential guide for power supplies and transformers, DIA3ED2070412EN
z Phaseo power supplies and transformers, Catalogue Pages, 14082-EN

Wiring
Connection overview ABL8RPS24100

Wiring example: 200…500 V single phase

EIO0000001678 04/2014 63
Hardware

iEM31xx Energy Meter Series - 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.
z Graphical display for easy viewing
z Self-powered meters
z Direct measurement up to 63 A
z Onboard Modbus, LON, M-Bus or BACnet communication
z Commissioning safely with ease
z Compact size

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

64 EIO0000001678 04/2014
 Hardware

Functions (depending on the model z Active energy measurement

z Electrical measurements such as I, V, P, and so on.
z Alarm
z Digital output for pulse
z MID (legal metrology certification)
Degree of protection z front panel: IP40
z casing: IP20

Dimensions W x H x D: 90 x 95 x 69 mm (3.54 x 3.74 x 2.72 in.)

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••

The graphic shows the connection diagram of iEM3100 / iEM3110 / iEM3115:

EIO0000001678 04/2014 65
Hardware

The figure shows the connection diagram of iEM3150 / iEM3155:

66 EIO0000001678 04/2014
 Hardware

Safety Modules

Section 4.2
Safety Modules

What Is in This Section?

This section contains the following topics:
Topic Page
Modicon TM3 Embedded Safety Module - Hardware 68
Preventa Detection and Dialog - Hardware 71

EIO0000001678 04/2014 67
Hardware

Modicon TM3 Embedded Safety Module - Hardware

Front View
Modicon TM3 embedded safety module

Special Note
At the time of this writing, not all products documented in the proposed architecture(s) may be
commercially available. Although, the architecture(s) documented herein have been tested and
functionally validated, for some of the products prototypes were used for proof of concept and
general functionality representative of the final products. Nonetheless, there is the possibility that
perhaps certain product characteristics, configuration methods and/or product references may be
subject to change without notice in the commercial versions of those products documented herein.
Finally, for some of the products documented herein, certain agency certifications are pending the
availability of the commercial versions of the products. For more information concerning product
availability, certifications and the latest product characteristics, please contact your local service
representative.

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 embedded safety modules. These
Modicon TM3 embedded safety modules contain digital inputs and relay outputs to manage one
safety function at any one 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 embedded safety modules supporting multiple functions.
The achieved 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.

68 EIO0000001678 04/2014
 Hardware

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 EN/IEC 62061:2005
(SIL)
Safety-related functions z 2 channel operation via potential-free contacts with cross circuit detection
z Each function with monitored or non-monitored start

Standards and CE (pending), cULus (pending),UL 508:2010 (pending), EN/ISO 13849-1:2008

certifications (pending), EN/IEC 62061:2005 (pending), CRM (pending), EAC (pending)
Power supply 24 Vdc
Power consumption 3.6 W (power supply), 0.2 W (TM3 I/O bus)
Input channels 2 safety-related inputs and start (monitored or non-monitored)
Output channels 3 relay outputs normally open controlled together,
AC-15: 230 V, 5 A per output
DC- 13: 24 V, 4 A per output
Degree of protection IP 20

Components

1 Status LEDs
2 Clip-on lock for 35 mm (1.38 in) DIN-rail
3 Relay output removable screw terminal block
4 Input removable screw terminal block

EIO0000001678 04/2014 69
Hardware

5 Expansion connector for I/O bus (one on each side)

6 Locking device for attachment to the previous module
7 Relay output removable spring terminal block
8 Input removable spring terminal block

Wiring
Wiring example of emergency stop connection to a TM3SAF5R• module

S1 Emergency stop switch

S2 Start button
(1) Safety outputs
(2) Monitored start
(3) Non-monitored start
(4) For automatic start, directly connect [S33] and [S39] terminals
(5) Second external device monitoring channel. Connect [S41] and [S42] terminals if not used.
(6) Fuses: Power supply max. 4 A (gG), output max. 4 A (gG) or 6 A (F)
(7) Non-safety related I/O bus communication with logic controller

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 Hardware

Preventa Detection and Dialog - Hardware

Front View
Preventa product range

Description
The Preventa product range, offered under the Telemecanique Sensors brand, consists of safety
detection products, safety dialog products, safety motor control products, safety automation
products, and so on.
Preventa modules help to easily reach the required safety machinery and standards level in
conformance with directives and standards.
The Preventa product range includes: Safety switches, limit switches, light curtains, emergency
stop, foot switches, safety modules, and so on.
For more information, refer to
z Preventa, Machine Safety Products, MKTED208051EN
z The essential guide: Preventa machine safety, DIA4ED2041204EN

EIO0000001678 04/2014 71
Hardware

HMI

Section 4.3
HMI

What Is in This Section?

This section contains the following topics:
Topic Page
Magelis HMI STO - Hardware 73
Harmony XB5R ZBRRC Wireless Access Point - Hardware 76
Harmony Control and Signaling - Hardware 78

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 Hardware

Magelis HMI STO - 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.
z 3.4" monochrome touch screen, available with 2 different types of backlighting:
z Green, orange, red
z White, pink, red

z Tool free mounting with Magelis spring clips

z Connectivity depending on the model:
z Ethernet
z Serial line

z 2 USB V2.0 ports for data transfer

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 z Front panel: IP 65
z Rear panel: IP 20

Interfaces Type HMI STO 53•:

z Ethernet port: 1x RJ45
z USB: 1x mini-B (2.0) + 1x Type-A (2.0)

EIO0000001678 04/2014 73
Hardware

Display 3.4", 200 x 80 pixels, 2 versions 3 colors

Memory z Application: 16 Mb
z Backup: 128 Kb

Dimensions W x H x D: 117 x 78 x 28 mm (4.6 x 3.1 x 1.1 in)

For more information, refer to Magelis Small Panels HMI STO, User Manual, EIO0000000239.

Wiring

Side HMI STO 53x

Front

Rear

74 EIO0000001678 04/2014
 Hardware

Side HMI STO 53x

Bottom

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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Hardware

Harmony XB5R ZBRRC Wireless Access Point - Hardware

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:
z packing lines
z automatic doors in logistic centers
z automobile industries
z bag filling in cement industries
z office lighting for efficient usage of the power

Standards and BT2006/95EC, CE: R:TTE1999/5/EC, EMC2004/108/EC, C-Tick, UL,

certifications CSA, CCC, Gost, RSS, ANATEL, SRRC, FCC, ICASA, ARIB T66
Rated voltage 24 Vdc
Degree of protection IP 20
Dimensions W x H x D: 36 x 108 x 70.66 mm (1.42 x 4.25 x 2.78 in.)

For more information, refer to Harmony XB5R, Expert Instruction Sheet, EIO0000000812 (EN).

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 Hardware

Wiring
Wiring example Harmony XBRRC

(1) 500 mA fuse fast-blow

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Hardware

Harmony Control and Signaling - Hardware

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.

78 EIO0000001678 04/2014
 Hardware

Controller

Section 4.4
Controller

What Is in This Section?

This section contains the following topics:
Topic Page
Modicon M221 Modular Logic Controller - Hardware 80
Modicon TM3 Modules - Hardware 85
TM3XTYS4 TeSys Module - Hardware 87

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Hardware

Modicon M221 Modular Logic Controller - Hardware

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
(see SoMachine Basic, Operating Guide).
The SoMachine Basic software supports the following IEC 61131-3 programming languages:
z IL: Instruction list
z LD: Ladder diagram

The following communication functions, depending on the model, are supported by the controllers:
z Ethernet
z USB programming
z Serial line

The following embedded I/O types are available, depending on the controller reference:
z Regular inputs
z Fast inputs associated with counters
z Regular transistor outputs
z Fast transistor outputs (PWM/PLS)
z Regular relay outputs
z Analog inputs

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 Hardware

Standards and certifications IEC/EN 61131-2, UL 508

Rated voltage 24 Vdc
Degree of protection IP 20
Memory z RAM: 640 Kbytes, of which 256 Kbytes are available for the
application
z Flash: 2 Mbytes - of which 256 Kbytes are used to back up the
user application
Dimensions W x H x D: 70 mm (3.35 in) x 102 mm (4.02 in) x 85 mm (3.35 in)
Options z SD card
z TM2 I/O modules
z TM3 I/O modules

For more information, refer to :

z Modicon M221 Logic Controller, Hardware Guide, EIO0000001384
z Modicon M221 Logic Controller, Programming Guide, EIO0000001360

M221 Modular Logic Controllers

Reference Digital inputs Digital outputs Analog inputs Communication

ports
TM221M16R/ 4 regular inputs3 8 relay outputs 2 analog inputs 2 serial line ports
TM221M16RG1 0...10 V 1 USB mini-B
4 fast inputs (HSC)4
programming port
TM221M16T/ 4 regular inputs3 6 regular transistor 2 analog inputs 2 serial line ports
TM221M16TG1 outputs 0...10 V 1 USB mini-B
4 fast inputs (HSC)4
2 fast transistor outputs programming port
(PWM/PLS)5
TM221ME16T/ 4 regular inputs3 6 regular transistor 2 analog inputs 1 serial line port
TM221ME16TG1 4 fast inputs (HSC)4 outputs 0...10 V 1 USB mini-B
2 fast transistor outputs programming port
(PWM/PLS)5 1 Ethernet port

TM221M32TK2 12 regular inputs3 14 regular transistor 2 analog inputs 2 serial line ports
outputs 0...10 V 1 USB mini-B
4 fast inputs (HSC)4
2 fast transistor outputs programming port
(PWM/PLS)5
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
functions, or reflex outputs for HSC.

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Reference Digital inputs Digital outputs Analog inputs Communication

ports

TM221ME32TK2 12 regular inputs3 14 regular transistor 2 analog inputs 1 serial line port
outputs 0...10 V 1 USB mini-B
4 fast inputs (HSC)4
2 fast transistor outputs programming port
(PWM/PLS)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
functions, or reflex outputs for HSC.

Controller Components

1 System LED 9 Run/Stop switch

2 Input removable terminal block 10 Removable analog inputs cover

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3 Output removable terminal block 11 Analog input terminal block

4 Clip-on lock for 35 mm (1.38 in) DIN-rail 12 SD card port
5 USB mini-B programming port, for terminal 13 TM3/TM2 bus connector
connection to a programming PC
(SoMachine Basic)
6 24 Vdc power supply 14 SD card, Run/Stop switch, and USB mini-B
programming port protective cover.
7 Ethernet / RJ45 15 Locking hook
8 Serial line port / RJ45 (RS-232 or RS-485) 16 Battery holder

Wiring Diagrams for TM221ME16T

Connection of the DC power supply of the controller

Connection of the digital inputs to the sensors

(1) The COM0 terminals are connected internally.

A Sink wiring (positive logic).
B Source wiring (negative logic).

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Connection of the digital outputs to the actuators

* Type T fuse
(1) The V+ terminals are connected internally.

Connection of the analog inputs to the sensors

The (-) poles are connected internally.

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Modicon TM3 Modules - Hardware

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:
z Local or remote expansion via the local TM3 expansion bus on M221, M241, and M251
controllers.
z Wide range of I/O expansion modules:
z Digital I/O modules
z Analog I/O modules
z Expert I/O modules
z Safety I/O modules
z Transmitter and receiver modules

Simplified maintenance installation:

z Embedded diagnostics for local and distant supervision
z Wiring simplicity: spring terminals, removable terminal blocks

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

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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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TM3XTYS4 TeSys Module - Hardware

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:
z TeSys U system equipped with the LUFC00 parallel wiring module
z GV and TeSys D system equipped with the LAD5C•• wiring adapter

The TM3XTYS4 module provides:

z 4 channels each with an RJ45 connector
z Each channel provides:
z 3 sink transistor inputs (24 Vdc type 1 (IEC/EN 61131-2))
z 2 source transistor outputs (24 Vdc / 0.3 A)

z Removable 24 Vdc power supply terminal block

For more information, refer to Modicon TM3, Expert I/O Modules, Hardware Guide,
EIO0000001420

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Physical Overview

1 LEDs for displaying the state of the I/O channels

2 TeSys RJ45 connectors
3 Removable power supply screw terminal block
4 Clip-on lock for 35 m (1.38 in) top hat section rail (DIN-rail)
5 Expansion connector for I/O bus.
6 Locking device for attachment to the previous module

I/O Channel RJ45 Connector

The TM3XTYS4 module is equipped with 4 channel RJ45 connectors.

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Pin Assignment
RJ45 connector

Pin Type Signal Description

1 Output 1 Direction 1 control Drives to direct (forward) command of the motor
2 Output 2 Direction 2 control Drives to direct (backward) command of the motor
3 0V - -
4 Input 1 Ready Active if the selector of the TeSys is in the ON position
5 Input 2 Run Input active if the power contacts of TeSys are closed.
6 N.C. - Reserved. Do not connect.
7 Input 3 Trip Input active if the selector of TeSys is in the TRIP
position (only for TeSys U).
8 24 Vdc input Common for sensors Power supply for inputs 1, 2 and 3 (pins 4, 5 and 7).
common

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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DC Power Supply Wiring Diagram

* Type T fuse
24 Vdc Is dedicated to outputs power supply
24 Vdc Aux Is dedicated to inputs power supply

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Application Example with TeSys U

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Application Example with TeSys D

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Communication

Section 4.5
Communication

ConneXium Ethernet Switch (Unmanaged) - Hardware

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.
z Multi-address capability
z Storage and rerouting of received data
z Data packets with VLAN tags are transmitted unchanged (IEEE 802.1 Q)

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z Automatic negotiation of 10/100 Mbit/s and duplex mode

z Automatic change of polarity
z Low-cost wiring solution

Standards and UL508, CSA 22.2 No.142, CE

certifications
Power supply 24 Vdc
Operating voltage 9.6...32 Vdc
Ports 3, 4, 5,8
Degree of protection IP 30
Dimensions W x H x D: 25 x 114 x 79 mm (0.98 x 4.49 x 3.1 in.)
(TCSESU053FN0)

For more information, refer to ConneXium Ethernet Switches, TCSESU0••F•N0, Quick Reference
Guide, 31007950.

Wiring
TCSESU053FN0 connector overview

1 3-pin terminal block for power supply

2 Power indicator
3 10/100 base-TX (RJ45 connectors)
4 Port ACT/LNK LEDs

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Motor Control

Section 4.6
Motor Control

What Is in This Section?

This section contains the following topics:
Topic Page
TeSys D Contactor - Hardware 96
TeSys GV2 Motor Circuit Breakers - Hardware 98
TeSys U LU2B Motor Starter- Hardware 100
TeSys GV2DP - Hardware 104
TeSys LAD5Cxx Wiring Adapter - Hardware 106
Altistart 01 Soft Starter - Hardware 108
Altivar 12 Variable Speed Drive - Hardware 112

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TeSys D Contactor - Hardware

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.
z AC, DC, and low-consumption DC control circuit
z All types of starter: reversing or non-reversing, star/delta, by auto-transformer, and so on.
z Various connectors: spring terminal, EverLink terminal block, screw clamp, ring-type
connection, faston connector
z Easy and simple direct mounting between contactor and circuit breaker, according to EverLink
terminal block (40...65 A)

Standards and IEC/EN 60947-4-1, IEC/EN 60947-5-1, UL 508,

certifications CSA C22.2 n° 14, UL, CSA, CCC, GOST, GL, DNV, RINA, VB,
LROS
Rated operational current 9…150 A
(Ie)I in AC-3 (Ue max.
440 V)
Rated control circuit 12(24*)…690(500*) Vac
voltage (Uc) 12(24*)…440 Vdc
*D115 and D150
Degree of protection (front IP 20 (conforming to IEC 60529)
face)
Protective treatment "TH" (conforming to IEC 60068-2-30)

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Dimensions 19 different types without add-on blocks or cover (WxHxD):

45…155 x 77…158 x 84…132 mm (1.77…6.1 x 3.0…6.22 x
3.3…5.2 in.)
Options Various connector types, wide range of auxiliary contact blocks
and modules, power connection accessories, suppressor
modules

For more information, refer to Control and protection components, MKTED210011EN.

Wiring
TeSys D09…150 3-pole contactors wiring diagram

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TeSys GV2 Motor Circuit Breakers - Hardware

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 diverse characteristics following is presented only the
GV2 P, which is integrated into the TVDA.
The TeSys GV2 P motor circuit-breakers are 3-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.
z Motor and personnel protection
z Live parts are protected from direct finger contact
z Compact size
z Easy to install: screw mounting or clip-on mounting
z Control by rotary knob
z Connection by screw clamps

Standards and IEC 60947-1, 60947-2, 60947-4-1, EN 60204, UL508,

certifications CSA C 22.2 n° 14-05, NF C 63-650, 63-120, 79-130,
VDE 0113, 0660, UL*, CSA, PTB, EZU, Gost, TSE, DNV,
LROS, GL, BV, RINA, CCC, ATEX

*UL508 type E for GV2 P••H7 (line spacer included)

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Operational voltage 690 V

Degree of protection IP 20
Dimensions W x H x D: 44.5 x 89 x 97 mm (1.75 x 3.5 x 3.82 in.)
Options z Combination block
z Sets of 3-pole busbars
z Protective end cover
z Terminal blocks
z Padlock able external operator
z Contact blocks: Fault signaling contact and instantaneous
auxiliary contacts
z Undervoltage/Shunt trips
z Padlocking devices

For more information, refer to Control and protection components, MKTED210011EN.

Wiring
TeSys GV2 P contactors wiring diagram

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TeSys U LU2B Motor Starter- Hardware

Front View
TeSys U LU2B•• motor starter

Description
The TeSys U starter-controller is a D.O.L. starter which performs the following functions:
z Protection and control of single-phase or 3-phase motors:
z isolation and breaking function
z overload and short-circuit protection
z thermal overload protection
z power switching

z Control of the application:

z protection function indication
z application monitoring (running time, number of detected faults, motor current values, and so
on)
z logs (last 5 detected faults saved, together with motor parameter values)

These functions can be added by selecting control units and function modules which simply clip
into the power base. This late customization is even possible after power and control circuit wiring
has been completed.
TeSys U is a flexible range that meets the current and future needs of system builders, panel
builders, and machine manufacturers, as well as those of additional systems.

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From design through to operation, TeSys U offers many advantages and simplifies the selection
of components in comparison with a traditional solution.
z The breaking, isolation, and contactor functions are incorporated in a single block. This means
fewer references to be ordered and easy selection because a single reference covers all needs
up to 15 kW.
z The control unit has a wide setting range. It can operate on a d.c. or a.c. supply.

The compact components in the TeSys U range are mounted on a single rail, so 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 in enclosures.
Setting-up accessories simplify or completely save wiring between components, and allow easy
selection and ordering.
With a capacity of up to 32 A/15 kW, TeSys U consists of:
z One 45 mm (1.77 in.) power base: 2 ratings, reversing or non-reversing, circuit-breaker
function, and built-in interference suppression
z One clip-on control unit:
z Standard CU: protection against overloads and short-circuits
z Expandable CU: in addition alarm and fault differentiation
z Multifunction CU: real-time control of motor load, local or remote diagnostics and parameter
setting
z 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
z 2 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:
certifications with phase barrier LU9SP0, UL, CSA, CCC, Gost, ASEFA,
ABS, BV, DNV, GL, LROS, ATEX
Power range 0…15 kW at 400 V
Rated insulation voltage z Conforming to IEC/EN 60947-1, overvoltage category III:
690 V
z Conforming to UL508, CSA C22-2 n° 14: 600 V

Degree of protection z Front panel outside connection zone: IP 40

z Front panel, wired terminals, and other faces IP 20

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)

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Options z 4 different control units

z Detected fault signaling modules
z Communication modules
z Auxiliary contact modules
z Load level modules
z Reverser block
z Plug-in terminal blocks
z Control circuit pre-wiring system

For more information, refer to :

z Control and protection components, MKTED210011EN
z TeSys U, Starter-controllers, Catalogue, DIA1ED2081003EN

Components
TeSys U - non-reversing

1 Power supply terminal block

2 On/Off/Reset control handle
3 "Motor" terminal block
A Power base
B Control units
C Auxiliary contact modules (LUF), thermal overload signaling, detected fault signaling modules, or load level
modules
D Communication modules
E Auxiliary contact module (LUA)
F Terminal block

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TeSys U - reversing

A Reverser block
B Plug-in terminal blocks
C Control circuit pre-wiring system

A preassembled reversing power base can be ordered by a specific part number.

Wiring
TeSys U - reversing

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TeSys GV2DP - Hardware

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
z Direct online (D.O.L.) or reversing starters, 45 mm (1.77 in), and 90 mm (3.54 in) wide
respectively
z Motor circuit-breaker with control via push-buttons (GV2ME) or selector switch (GV2P)
z Circuit-breaker with built-in overload protection
z Type 1 or type 2 coordination
z Breaking capacity up to 130 kA
z Enclosure for thermal-magnetic circuit breakers TeSys GV2ME

Each pre-assembled combination comprises:

z 1 motor circuit breaker GV2ME or GV2P
z 1 3-pole contactor LC1D or LC2D
z 1 combination block GV2AF3

For more information, refer to :

z The essential guide, TeSys for power control & protection, DIA1ED2040401EN
z Control and protection components, MKTED210011EN

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Wiring

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TeSys LAD5Cxx Wiring Adapter - Hardware

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:

Reference Motor control Motor starter combination

LAD5C11 Non-reversing GV2ME/GV2P with LC1D09BL to LC1D32BL
LAD5C12 Reversing GV2ME/GV2P with LC2D09BL to LC2D32BL
LAD5C31 Non-reversing GV3P with LC1D40ABD to LC1D65ABD
LAD5C32 Reversing GV3P with LC2D40ABD to LC2D65ABD

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Notes:
z GV2AF3 combination block is required for GV2 circuit breaker/contactor assembling.
z GVAE20 auxiliary contact block must be assembled on GV2 and GV3 circuit breaker before
LAD5C••
z 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

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Altistart 01 Soft Starter - Hardware

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.
z Reduce mechanical stress on drive-train components
z Ensure smooth acceleration of conveyors
z Suppress water hammer on pumping applications
z Eliminate belt slippage on fan loads
z 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 z ATS 01N1••: 0,37...11 KW
z ATS 01N2••: 0.75...75 kW

Voltage range z ATS 01N1••: 110...480 V

z ATS 01N2••: 230, 400, 480 V and 690 V

Functions z 2-wire control

z Adjustable starting time
z Signaling completion of starting

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Degree of protection IP 20
Dimensions W x H x D (depends on the model):
22.5...180 x 100...242 x 100.4...126 mm (0.89...7.1 x 3.94...9.5 x
3.95...4.96 in)

For more information, refer to :

z Characteristics, Soft starters for asynchronous motors Altistart 01, 60541-EN
z Reduce mechanical stress on your machines, DIA2ED1121204EN
z Instruction Sheet ATS01N1...FT, 1624685

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Wiring
Wiring example power supply and motor

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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.

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Altivar 12 Variable Speed Drive - Hardware

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.
z Small: easily integrated in any machine
z Easy communication with all other machine components via integrated universal Modbus serial
link.
z Low noise level
z Product factory set for most applications
z 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 z Single-phase 100…120 V (0.18 to 0.75 kW)
z Single-phase 200…240 V (0.18 to 2.2 kW)
z Three-phase 200…240 V (0.18 to 4 kW)

Output frequency 0.1…400 Hz

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Transient overtorque 150…170 % of the nominal motor torque

Communication Integrated: Modbus
Functions z Switching between local control and control via the terminals
z Motor control profiles: standard, performance, and pump/fan
z Frequency skips
z Preset speeds
z PID regulator
z S ramp, U ramp, ramp switching
z Freewheel stop, fast stop
z Jog operation
z Configuring the logic and analog I/O
z Underload and overload detection
z Viewing the state of the logic inputs on the drive display
z Configuring how the parameters are displayed
z Error log
I/Os z 1 analog input
z 4 logic inputs
z 1 analog output
z 1 logic output
z 1 relay output
Degree of protection IP 20
EMC filter z Integrated: ATV12•••M2 and ATV312H••N4
z Optional: ATV12•••F1; ATV12•••M3

Dimensions ATV12H018M2 (W x H x D):

72 x 142 x 102.2 mm (2.84 x 5.6 x 4.02 in)
Options z SoMove and SoMove Mobile setup software
z Simple-loader and multi-loader configuration tool
z Remote display terminals
z EMC plate

For more information, refer to Altivar 12, Variable speed drives for asynchronous motors, User
manual, BBV28581.

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Wiring
Altivar 12 connector overview

1 Power terminals
2 Control terminals
3 RJ45 communication port

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Wiring examples: power supply and motor

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:
z 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).
z The ground terminal (green screw) is located on the opposite side in comparison with its position
on the ATV 12 (see wiring trap label).

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Detection

Section 4.7
Detection

What Is in This Section?

This section contains the following topics:
Topic Page
OsiSense XG Tap-off box - Hardware 117
OsiSense XGCSx90 RFID - Hardware 118
OsiSense Industrial Sensors - Hardware 122

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OsiSense XG Tap-off box - Hardware

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 :
z Osisense XG, Radio Frequency Identification System, Catalog, 9006CT0902
z RFID OsiSense XG, Compact Stations, W916556690111

Components

1 Green LED indicating the voltage present

2 Subbase to another splitter box (OUT network) - 1x M12 5pin female A-coded connector
3 24 V power supply subbase - 1x M12 4-pin male A-coded connector
4 3 OsiSense XG compact station subbases - 3x M12 5-pin female A-coded connectors
5 Subbase to an API or another tap-off box (IN network) - 1x M12 5-pin male A-coded connector

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OsiSense XGCSx90 RFID - Hardware

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:
z Reset: The RFID part of the smart antenna is reinitialized and assumes its factory default
configuration.
z Init: The smart antenna is reinitialized and operates as it would after being switched back on
(address unchanged, RFID parameters deleted).
z 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.
z 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

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Nominal sensing distance z XGCS4901201: 10...70 mm (0.39...2.76 in) depending on associated tag
z 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 z Interface: RS-485, Modbus RTU and Uni-Telway
z 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:
z XGCS4901201: 40 x 40 x 15 mm (1.56 x 1.56 x 0.59 in)
z XGCS84901201: 80 x 80 x 26 mm (3.15 x 3.15 x 1.01 in)

Options z Network connection box

z RFID hand held terminal
z Field expander
z Connection and mounting accessories

For more information, refer to :

z Osisense XG, Radio Frequency Identification System, Catalog, 9006CT0902
z RFID OsiSense XG, Ethernet Smart Antenna, User Manual, EIO0000001601

Components

1 TAG: Tag LED

2 COM: Communication LED

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Hardware

Wiring
Example of a Modbus network

Maximum length of bus:

The maximum length of the bus ([L] + [L1] + [l4]) depends on the speed of the network:
z 9600 bauds: 1000 m (3281 ft)
z 19,200 bauds: 500 m (1640.4 ft)

Maximum length of tap-offs:

[l1], [l2] and [l3]: 10 m (32.8 ft)

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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.
Station M12 connector pinout

Pin Signal Description

1 (SHLD) drain Cable shielding
2 24 Vdc Station power supply
3 0 V/GND 0V
4 D0 D0 (-/A) RS-485 2-wire
5 D1 D1 (+/B) RS-485 2-wire
Connector casing Shielding Cable shielding

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).

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OsiSense Industrial Sensors - Hardware

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.

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Communication and Wiring
EIO0000001678 04/2014

Communication Topology and Wiring Guide

Chapter 5
Communication Topology and Wiring Guide

What Is in This Chapter?

This chapter contains the following sections:
Section Topic Page
5.1 Introduction to System Communication 124
5.2 Ethernet Network 125
5.3 Modbus Serial Line Network 132

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Introduction to System Communication

Section 5.1
Introduction to System Communication

Introduction

Overview
The TVDA (Tested Validated Documented Architecture) includes 2 different communication
networks.
z 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.
z 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).

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Ethernet Network

Section 5.2
Ethernet Network

What Is in This Section?

This section contains the following topics:
Topic Page
Ethernet Network Topology 126
Ethernet Wiring 127
Modicon M221 Modular Logic Controller - Wiring 129
Magelis HMI STO - Ethernet Wiring 131

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Communication and Wiring

Ethernet Network Topology

Ethernet Topology

#... IP address

The subnet mask is: 255.255.0.0.

Optionally a PC can be linked to the Ethernet network.

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Ethernet Wiring

Overview Ethernet

For more information, refer to Transparent Ready, User Guide, 31006929.

Wiring Accessories

Reference Designation Description Position Cable length

490NTW00002 Ethernet ConneXium cable One RJ45 connector at 1 2.0 m (6.56 ft)
- shielded twisted-pair each end
490NTW00005 5.0 m (16.40 ft)
straight cord
TCSEAAF11F13F00 ConneXium M12 to RJ45 Adapter for panel 3 -
Ethernet adapter mounting
TCSECL1M3M3S2 Ethernet ConneXium cable 1 x IP 67, M12, 4-pin 4 3.0 m (9.84 ft)
- shielded twisted pair (D-coded) connector
and 1 x RJ45
connector

Switch

Reference Designation Description Position

TCSESU053FN0 Ethernet TCP/IP 10BASE-T/100BASE-TX - 5x RJ45 ports 2
unmanaged switch copper cable

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Communication and Wiring

ConneXium Ethernet Adapter

TCSECL1M3M3S2

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

ConneXium Ethernet Cable

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Modicon M221 Modular Logic Controller - Wiring

Ethernet Port
The TM221•E••• controllers are equipped with an Ethernet communication port.
Ethernet port on the controller

Ethernet characteristics

Characteristic Description
Standard Modbus TCP/IP
Connector type RJ45
Driver z 10 M half duplex (auto negotiation)
z 100 M full duplex (auto negotiation)

Cable type Shielded

Automatic cross-over Yes

For more information, refer to Modicon M221 Logic Controller, Hardware Guide, EIO0000001384.

Pin Assignment
RJ45 Ethernet connector pin assignment

Pin Signal
1 TD+
2 TD-
3 RD+
4 N.C.

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Communication and Wiring

Pin Signal
5 N.C.
6 RD-
7 N.C.
8 N.C.

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Magelis HMI STO - Ethernet Wiring

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.

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Communication and Wiring

Modbus Serial Line Network

Section 5.3
Modbus Serial Line Network

What Is in This Section?

This section contains the following topics:
Topic Page
Modbus SL Network Topology 133
Modbus SL Wiring 134
Modicon M221 Modular Logic Controller - Wiring 136

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Modbus SL Network Topology

Modbus SL Topology

#... Slave address

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Communication and Wiring

Modbus SL Wiring

Modbus SL Overview

For more information, refer to Modbus Serial Line, Planning and Installation Guide, 33003925.

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Cable

Reference Designation Description Position Cable length

VW3A8306R10 Modbus SL drop 2 RJ45 connectors 2 1.0 m (3.28 ft)
cable
VW3A8306R30 3 3.0 m (9.8 ft)
LU9GC3 RS-485 hub Modbus SL hub with 10 RJ45 4 -
connectors and 1 terminal block
TCSMCN1F2 Modbus SL cable Shielded cable, 5-way female A- 5 2.0 m (6.56 ft)
TCSMCN1F5 coding M12 / flying leads, for 5.0 m (16.4 ft)
Modbus RS-485 connection
TCSMCN1F10 between one TCSAMT31FP tap- 10.0 m (32.8 ft)
off box and a LU9GC3 box.
TCSMCN1M1F1 Preformed cordset Shielded cable, 5-way male 6 1.0 m (3.28 ft)
TCSMCN1M1F2 for Modbus SL /female A-coding M12, for 2.0 m (6.56 ft)
communication Modbus RS-485 connection
TCSMCN1M1F5 and 24 Vdc power between one TCSAMT31FP tap- 5.0 m (16.4 ft)
TCSMCN1M1F10 supply off box and an XGCS station (or 10.0 m (32.8 ft)
to another tap-off box)
TCSCTN011M11F M12 tee 5-pin female A-coding M12/5-pin 7 -
male A-coding M12 + 5-pin A-
coding female M12, used to
connect the line terminator
FTXCNTL12 Line terminator 120 Ω line terminator, 5-pin male 8 -
A-coding M12

Connection of Line Terminators in Modbus

The use of long network cables may produce signal deformations. The installation of a line
terminator corrects these deformations. Depending on the cable quality and the EMC environment,
a line terminator near the RFID XGCS station (M12 tee) may be necessary.

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Modicon M221 Modular Logic Controller - Wiring

Modbus SL Port

The serial line:

z Is used to communicate with devices supporting the Modbus protocol as either master or slave,
ASCII protocol (printer, modem...), and SoMachine Basic protocol (HMI,...)
z Provides a 5 Vdc power distribution

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

Pin Signal RS-485 Signal RS-232 Description

1 - RxD RS-232: Receive data line
2 - TxD RS-232: Transmit data line
3 - RTS RS-232: Request to send
4 D1 - Modbus SL: D1 (+/B) RS-485 2-wire
5 D0 - Modbus SL: D0 (-/A) RS-485 2-wire
6 - CTS Clear to send
7 5 Vdc - 5 Vdc supplier
8 Common Common Modbus SL signal ground

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Implementation
EIO0000001678 04/2014

Implementation

Chapter 6
Implementation

What Is in This Chapter?

This chapter contains the following sections:
Section Topic Page
6.1 Access the SoMachine Project Template 138
6.2 Software Requirements 141
6.3 Project 142

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Implementation

Access the SoMachine Project Template

Section 6.1
Access the SoMachine Project Template

What Is in This Section?

This section contains the following topics:
Topic Page
Access the SoMachine Project Template 139
Access the SoMachine Basic Project Template 140

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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 all 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.

Step Action Comment

1 Launch SoMachine. The Get started dialog box of SoMachine
Central is displayed.
2 Click New. The New Project dialog box is displayed.
3 Click Templates. The New Project Assistant - Templates dialog
box is displayed.
4 Enter a Project Name. -
5 Select a template from the list. -
6 Click the Create Project button. A new project based on the selected template is
opened in SoMachine Central.
7 Now you can adapt your new project -
according to your requirements.

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Implementation

Access the SoMachine Basic Project Template

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.

Step Action Comment

1 Launch SoMachine Basic. -
2 Click Templates. The browser with the example projects is
displayed. From here, you also have access to
other project-related files as for example the
System User Guide (SUG) or the Vijeo-Designer
project, if available. Whether additional files are
available is indicated by the symbol + in front of
the name of the example project.
3 Select a template from the list. The description is displayed.
4 Click Open Template. A new project based on the selected template is
opened in SoMachine Basic.
5 Now you can adapt your new project -
according to your requirements.

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.

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Software Requirements

Section 6.2
Software Requirements

Software Requirements

SoMachine
The project template of the described architecture is part of SoMachine V4.1 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 V4.1:
z SoMachine components
z SoMachine Logic Builder
z SoMachine Basic
z Vijeo-Designer
z Gateway

z Controllers
z M221

z Repository
z Optimized repository

z Documentation
z 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 V1.1 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 V1.1 software.
For using the project template the following software must be installed on your PC:
z SoMachine Basic V1.1 or later
z Vijeo-Designer V6.2 or later

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Project

Section 6.3
Project

What Is in This Section?

This section contains the following topics:
Topic Page
Controller 143
HMI 144
Devices 145
Application 152
Vijeo-Designer 153

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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
controller.
In addition, the network provides the possibility for a remote connection with the controller and the
HMI.
The Ethernet settings for this architecture are:
z Fixed IP address
z IP address: 172.20.10.167
z Subnet mask: 255.255.0.0

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:
z Physical settings:
z Baud rate: 19200
z Parity: even
z Data bits: 8
z Stop bits: 1
z Physical medium: Modbus SL RS-485 2-wire

z Protocol settings
z Protocol: Modbus RTU
z Addressing: Master
z Response time (x100 ms): 10
z Time between frames (ms): 10

For more information about the serial line configuration, refer to the document Modicon M221 Logic
Controller, Programming Guide, EIO0000001360.

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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
controller.
In addition, the network provides the possibility for a remote connection with the controller and the
HMI.
The Ethernet settings for the panel are:
z Fixed IP address
z IP address: 172.20.10.168
z Subnet mask: 255.255.0.0

For all other parameters, the default settings have been kept.

I/O Manager
The communication between HMI and controller is realized via Modbus TCP protocol based on
Ethernet.
For access of registers in the M221 controller via Modbus-requests the Modbus TCP/IP driver must
be added to the I/O manager of the HMI STO device in Vijeo-Designer.
Whit the adding of the Modbus TCP/IP driver a Modbus equipment is added automatically. This
Modbus equipment represents the M221 controller as a Modbus TCP slave and must be
configured in Vijeo-Designer.
The settings for the Modbus equipment are:
z IP address: 172.20.10.167 (M221 controller)
z IEC 61131 syntax: activated

For all other parameters, the default settings have been kept.
Afterwards the Modbus equipment can be renamed with a meaningful name. In this example, the
name M221Controller was selected for the equipment.
For more information, refer to Magelis XBT G/XBT GT, Modbus TCP/IP driver, 35007091.

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Devices

Overview
In this chapter, all devices configured within the SoMachine Basic project are described.

TM3 Embedded Safety Modules

The TM3 embedded safety modules are handled as I/O expansion modules and must be linked to
the TM3 bus of the controller. The safety function is managed in the module itself and via the TM3
bus the diagnostic and the administrative control functions are provided. The diagnostic and
control signals are provided as I/Os in the controller configuration and can be processed in the
application program which is running on the controller.
In this architecture, the following module was added to the TM3 bus (IO_Bus).

Module name Module type Comment

Module_1 TM3SAF5R Safety module emergency stop Cat. 4

TM3 I/O Expansion Modules

The controller provides the possibility to expand the embedded I/Os by adding TM3 expansion
modules to the controller.
The expansion modules must be configured within the SoMachine Basic project.
In this architecture, the following modules were added to the TM3 bus (IO_Bus).

Module name Module type Comment Configuration

Module_2 TM3DI16 16-channel, 24 Vdc digital input expansion Default
module with 1 common line, sink/source, and
removable terminal block
Module_3 TM3DQ16T 16-channel, 0.5 A source transistor outputs Default
expansion module with 1 common line and
removable terminal block
Module_4 TM3XTYS4 TeSys expansion module, connection of up to 4 Default
TeSys motor starters via RJ45 connection system
Module_5 TM3XTYS4 TeSys expansion module, connection of up to 4 Default
TeSys motor starters via RJ45 connection system

For more information about the TM3 configuration, refer to the documents:
z Modicon M241 Logic Controller, Programming Guide, EIO0000001432 (ENG)
z Modicon TM3, Expansion Modules Configuration, Programming Guide, EIO0000001402

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Energy Meter iEM3110

The architecture implements 1 energy meter of type iEM3110 for energy measurement. The
energy meter provides a pulse output which indicates the energy consumption.
The program code for counting the energy consumption based on the number of pulses is part of
the POU Prg_Main and is called in the Master Task.

GV2DP Motor Starters

The architecture implements 3 motor starters of type GV2DP 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 I/Os of the configuration.
The I/Os for each TeSys GV2DP device are provided via an RJ45 connector on a TM3XTSYS4
expansion module.
z Module_4 X1 is connected to the TeSys GV2DP non-reversing (motor 1)
z Module_4 X2 is connected to the TeSys GV2DP non-reversing (motor 2)
z Module_4 X3 is connected to the TeSys GV2DP reversing (motor 3)
For the control and monitoring of each TeSys GV2DP device, three separate POUs are created in
the application.
All POUs are called in the Master Task.
The POUs are:
z Prg_Motor_Ctrl_1D1S_1 - controls the TeSys GV2DP non-reversing (motor 1)
z Prg_Motor_Ctrl_1D1S_2 - controls the TeSys GV2DP non-reversing (motor 2)
z Prg_Motor_Ctrl_2D1S_1 - controls the TeSys GV2DP reversing (motor 3)

All POUs have several control and monitor functions and provide a standardized interface via
configured Memory bits. Some of these Memory bits are assigned to the inputs and outputs and
others in turn are processed from the HMI via Modbus TCP.
The table shows the Memory bits used in the Prg_Motor_Ctrl_1D1S_1:

Flag/Symbol Comment
I_ X_MOT_CTRL_1D1S_1_SEL_AUT_MODE Command to select auto mode (jog mode).
I_ X_MOT_CTRL_1D1S_1_SEL_MAN_MODE Command to select manual mode.
I_ X_MOT_CTRL_1D1S_1_SEL_LOC_MODE Command to select local mode.
I_ X_MOT_CTRL_1D1S_1_CMD_LOC_FWD Command to start (latch mode) the motor in forward
direction during local mode.
I_ X_MOT_CTRL_1D1S_1_CMD_LOC_STOP Command to stop the motor during manual and local
mode.
I_ X_MOT_CTRL_1D1S_1_CMD_MAN_FWD Command to start (latch mode) the motor in forward
direction during manual mode.
I_ X_MOT_CTRL_1D1S_1_CMD_MAN_STOP Command to stop the motor during manual mode.

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Flag/Symbol Comment
I_ X_MOT_CTRL_1D1S_1_CMD_ERR_RST Command to reset an alarm state.
Q_X_MOT_CTRL_1D1S_1_STAT_AUTMODE Info: Auto mode is selected.
Q_X_MOT_CTRL_1D1S_1_STAT_MANMODE Info: Manual mode is selected.
Q_ X_MOT_CTRL_1D1S_1_STAT_LOCMODE Info: Local mode is selected.
Q_X_MOT_CTRL_1D1S_1_ALARM_OPMODE Info: Invalid operation mode selection has been
done.
Q_ X_MOT_CTRL_1D1S_1_ALARM_FBCKT Info: Module is in alarm state due to a non-detected
feedback during the monitoring time.
I_ X_MOT_CTRL_1D1S_1_EN_FBCK_CTRL Enables the monitoring of the feedback signals,
which indicate, if the motor is really running.
I_ X_MOT_CTRL_1D1S_1_CMD_AUT_FWD Command to start (jog mode) the motor in forward
direction during auto mode.
Q_ X_MOT_CTRL_1D1S_1_ERROR_ACT An error has been detected and is active.
NOTE: The POU Prg_Motor_Ctrl_1D1S_2 uses the same interface variables but with different names.
The ..X_MOT_CTRL_1D1S_1.. is changed to ..X_MOT_CTRL_1D1S_2.. .

The table shows the Memory bits used in the Prg_Motor_Ctrl_2D1S_1:

Flag/Symbol Comment
I_X_MOT_CTRL_2D1S_1_SEL_AUT_MODE Command to select auto mode (jog mode).
I_X_MOT_CTRL_2D1S_1_SEL_MAN_MODE Command to select manual mode.
I_X_MOT_CTRL_2D1S_1_SEL_LOC_MODE Command to select local mode.
I_X_MOT_CTRL_2D1S_1_CMD_LOC_FWD Command to start (latch mode) the motor in forward
direction during local mode.
I_X_MOT_CTRL_2D1S_1_CMD_LOC_REV Command to start (latch mode) the motor in reverse
direction during local mode.
I_X_MOT_CTRL_2D1S_1_CMD_LOC_STOP Command to stop the motor during manual and local
mode.
I_X_MOT_CTRL_2D1S_1_CMD_MAN_FWD Command to start (latch mode) the motor in forward
direction during manual mode.
I_X_MOT_CTRL_2D1S_1_CMD_MAN_REV Command to start (latch mode) the motor in reverse
direction during manual mode.
I_X_MOT_CTRL_2D1S_1_CMD_MAN_STOP Command to stop the motor during manual mode.
I_X_MOT_CTRL_2D1S_1_CMD_ERR_RST Command to reset an alarm state.
Q_X_MOT_CTRL_2D1S_1_STAT_AUTMODE Info: Auto mode is selected.
Q_X_MOT_CTRL_2D1S_1_STAT_MANMODE Info: Manual mode is selected.
Q_X_MOT_CTRL_2D1S_1_STAT_LOCMODE Info: Local mode is selected.

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Flag/Symbol Comment
Q_X_MOT_CTRL_2D1S_1_ALARM_OPMODE Info: Invalid operation mode selection has been
done.
Q_X_MOT_CTRL_2D1S_1_ALARM_FBCKT Info: Module is in alarm state due to a non-detected
feedback during the monitoring time.
I_X_MOT_CTRL_2D1S_1_EN_FBCK_CTRL Enables the monitoring of the feedback signals,
which indicate, if the motor is really running.
I_X_MOT_CTRL_2D1S_1_CMD_AUT_FWD Command to start (jog mode) the motor in forward
direction during auto mode.
I_X_MOT_CTRL_2D1S_1_CMD_AUT_REV Command to start (jog mode) the motor in reverse
direction during auto mode.
Q_X_MOT_CTRL_2D1S_1_ERROR_ACT An error has been detected and is active.

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 I/Os of the configuration.
The I/Os for each TeSys U device are provided via an RJ45 connector on a TM3XTSYS4
expansion module.
z Module_4 X4 is connected to the TeSys U non-reversing (motor 4)
z 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.
Both POUs are called in the Master Task.
The POUs are:
z Prg_TeSysU_HW_1D_1 - controls the TeSys U non-reversing (motor 4)
z Prg_TeSysU_HW_2D_1 - controls the TeSys U reversing (motor 5)

Both POUs have several control and monitor functions and provide a standardized interface via
configured Memory bits. Some of these Memory bits are assigned to the inputs and outputs and
others in turn are processed from the HMI via Modbus TCP.
The table shows the Memory bits used in the Prg_TeSysU_HW_1D_1:

Flag/Symbol Comment
I_X_TESYSU_HW_1D_1_SEL_AUT_MODE Command to select auto mode (jog mode).
I_X_TESYSU_HW_1D_1_SEL_MAN_MODE Command to select manual mode.
I_X_TESYSU_HW_1D_1_SEL_LOC_MODE Command to select local mode.
I_X_TESYSU_HW_1D_1_CMD_LOC_FWD Command to start (latch mode) the motor in forward
direction during local mode.

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Flag/Symbol Comment
I_X_TESYSU_HW_1D_1_CMD_LOC_STOP Command to stop the motor during manual and local
mode.
I_X_TESYSU_HW_1D_1_CMD_MAN_FWD Command to start (latch mode) the motor in forward
direction during manual mode.
I_X_TESYSU_HW_1D_1_CMD_MAN_STOP Command to stop the motor during manual mode.
I_X_TESYSU_HW_1D_1_CMD_ERR_RST Command to reset an alarm state.
Q_X_TESYSU_HW_1D_1_STAT_AUTMODE Info: Auto mode is selected.
Q_X_TESYSU_HW_1D_1_STAT_MANMODE Info: Manual mode is selected.
Q_X_TESYSU_HW_1D_1_STAT_LOCMODE Info: Local mode is selected.
Q_X_TESYSU_HW_1D_1_ALARM_OPMODE Info: Invalid operation mode selection has been done.
Q_X_TESYSU_HW_1D_1_ALARM_FBCKT Info: Module is in alarm state due to a non-detected
feedback during the monitoring time.
I_X_TESYSU_HW_1D_1_EN_FBCK_CTRL Enables the monitoring of the feedback signals, which
indicate, if the motor is really running.
I_X_TESYSU_HW_1D_1_CMD_AUT_FWD Command to start (jog mode) the motor in forward
direction during auto mode.
Q_X_TESYSU_HW_1D_1_ERROR_ACT An error has been detected and is active.

The table shows the Memory bits used in the Prg_TeSysU_HW_2D_1:

Flag/Symbol Comment
I_X_TESYSU_HW_2D_1_SEL_AUT_MODE Command to select auto mode (jog mode).
I_X_TESYSU_HW_2D_1_SEL_MAN_MODE Command to select manual mode.
I_X_TESYSU_HW_2D_1_SEL_LOC_MODE Command to select local mode.
I_X_TESYSU_HW_2D_1_CMD_LOC_FWD Command to start (latch mode) the motor in forward
direction during local mode.
I_X_TESYSU_HW_2D_1_CMD_LOC_REV Command to start (latch mode) the motor in reverse
direction during local mode.
I_X_TESYSU_HW_2D_1_CMD_LOC_STOP Command to stop the motor during manual and local
mode.
I_X_TESYSU_HW_2D_1_CMD_MAN_FWD Command to start (latch mode) the motor in forward
direction during manual mode.
I_X_TESYSU_HW_2D_1_CMD_MAN_REV Command to start (latch mode) the motor in reverse
direction during manual mode.
I_X_TESYSU_HW_2D_1_CMD_MAN_STOP Command to stop the motor during manual mode.
I_X_TESYSU_HW_2D_1_CMD_ERR_RST Command to reset an alarm state.
Q_X_TESYSU_HW_2D_1_STAT_AUTMODE Info: Auto mode is selected.
Q_X_TESYSU_HW_2D_1_STAT_MANMODE Info: Manual mode is selected.

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Flag/Symbol Comment
Q_X_TESYSU_HW_2D_1_STAT_LOCMODE Info: Local mode is selected.
Q_X_TESYSU_HW_2D_1_ALARM_OPMODE Info: Invalid operation mode selection has been done.
Q_X_TESYSU_HW_2D_1_ALARM_FBCKT Info: Module is in alarm state due to a non-detected
feedback during the monitoring time.
I_X_TESYSU_HW_2D_1_EN_FBCK_CTRL Enables the monitoring of the feedback signals, which
indicate, if the motor is really running.
I_X_TESYSU_HW_2D_1_CMD_AUT_FWD Command to start (jog mode) the motor in forward
direction during auto mode.
I_X_TESYSU_HW_2D_1_CMD_AUT_REV Command to start (jog mode) the motor in reverse
direction during auto mode.
Q_X_TESYSU_HW_2D_1_ERROR_ACT An error has been detected and is active.

Altivar with 2 Motors

The architecture implements a motor control function comprising of two motors and one variable
speed drive of type Altivar 12.
It must be preselected which motor should be operated via the Altivar drive. The other motor
cannot be operated during this time. The switching between the motors is realized via hardwired
signals and the control of the Altivar drive is realized via Modbus SL communication.
The program code for this motor control function is created in the POU
Prg_VSD_HW_2Motors_2DVS.
The Modbus SL communication between the controller and the Altivar drive is programmed in the
POU ModbusCommunication.
Both POUs are called in the Master Task.
Both POUs have several control and monitor functions and provide a standardized interface via
configured Memory bits. Some of these Memory bits are assigned to the inputs and outputs and
others in turn are processed from the HMI via Modbus TCP.
The table shows the Memory bits used in the Prg_VSD_HW_2Motors_2DVS:

Flag/Symbol Comment
I_X_VSD_1_SEL_AUT_MODE Command to select auto mode (jog mode).
I_X_VSD_1_SEL_MAN_MODE Command to select manual mode.
I_X_VSD_1_SEL_LOC_MODE Command to select local mode.
I_X_VSD_1_CMD_LOC_FWD Command to start (latch mode) the motor in forward
direction during local mode.
I_X_VSD_1_CMD_LOC_REV Command to start (latch mode) the motor in reverse
direction during local mode.
I_X_VSD_1_CMD_LOC_STOP Command to stop the motor during manual and local
mode.

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Flag/Symbol Comment
I_X_VSD_1_CMD_MAN_FWD Command to start (latch mode) the motor in forward
direction during manual mode.
I_X_VSD_1_CMD_MAN_REV Command to start (latch mode) the motor in reverse
direction during manual mode.
I_X_VSD_1_CMD_MAN_STOP Command to stop the motor during manual mode.
I_X_VSD_1_CMD_ERR_RST Command to reset an alarm state.
Q_X_VSD_1_STAT_AUTMODE Info: Auto mode is selected.
Q_X_VSD_1_STAT_MANMODE Info: Manual mode is selected.
Q_X_VSD_1_STAT_LOCMODE Info: Local mode is selected.
Q_X_VSD_1_ALARM_OPMODE Info: Invalid operation mode selection has been
done.
I_X_VSD_1_CMD_AUT_FWD Command to start (jog mode) the motor in forward
direction during auto mode.
I_X_VSD_1_CMD_AUT_REV Command to start (jog mode) the motor in reverse
direction during auto mode.
I_X_VSD_1_SEL_DRIVE_1 Command to select motor 1 for operation.
I_X_VSD_1_SEL_DRIVE_2 Command to select motor 2 for operation.
Q_X_VSD_1_ERROR_ACT An error has been detected and is active.

OsiSense RFID Smart Antennas

The architecture implements three OsiSense RFID smart antennas of type XGCS•90.
The antennas are linked to the controller via Modbus SL.
It is checked periodically if a tag is detected by an antenna. If a tag is in front of an antenna, the
reading or the writing of data is executed.
The data exchange between the controller and a tag through an antenna is defined as follows:
z Antenna 1 (Modbus address 2): writing of two WORDs on the tag
z Antenna 2 (Modbus address 3): reading of two WORDs from the tag
z Antenna 3 (Modbus address 4): reading of two WORDs from the tag

The program code to control the data exchange between the controller and the antennas is created
in the POU Prg_RFID_Read_Write. The Modbus SL communication between the controller and
the antennas is programmed in the POU ModbusCommunication. Both POUs are called in the
Master Task.

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Application

Task Configuration
The M221 modular logic controller supports the following task types:
z Master Task
z Periodic Task
z 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 Master
Task is configured as periodic.
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. The period
of the Master Task is set to 10 ms.

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 device. Which POU is related to which device can be
easily detected by the name of the POU.
In addition to the POUs for the devices further POUs are created for general functions of the
application. These are:
z Prg_Main: Processing of summary information about devices, communication, and safety state
z ModbusCommunication: Processing of Modbus messages which are sent and received via
the serial line interface of the controller

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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 532.
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.

Alarm Page
The alarm page provides detailed alarm messages sorted by time of occurrence.
In addition to the alarm page the backlight of the panel is switching to red whenever an alarm is
active.

Energy Page
The energy page provides information about the energy consumption of the architecture.

Device Pages
The device pages provide monitor and control functions for each device grouped by products:
z MotorCtrl: TeSys GV2DP motor starter (motor 1 - motor 3)
z TeSys U: TeSys motor starter controller (motor 4 and motor 5)
z VSD: Variable speed drive Altivar 12 (motor 6 and motor 7)
z RFID: OsiSense RFID smart antennas, data to read or write
z I/Os: Displaying of signals from the wireless and batteryless push-buttons

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System Setup
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Chapter 7
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:
z Thoroughly read this manual and the respective related documents before running this
application.
z Install the drives according to their usage and configure the connected motors.
z Thoroughly verify your installation.
z Set up the communication parameters of the devices.

WARNING
LOSS OF CONTROL
z 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.
z Separate or redundant control paths must be provided for critical control functions.
z System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
z Observe all accident prevention regulations and local safety guidelines.1
z 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.

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What Is in This Chapter?

This chapter contains the following sections:
Section Topic Page
7.1 Setup Controller and HMI 157
7.2 Setup Other Devices 160

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Setup Controller and HMI

Section 7.1
Setup Controller and HMI

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:
z Via an USB cable (linked to the integrated mini USB port on the devices)
z Via an SD card (plugged into the SD card slot on the front of the M221 controller)
z With an USB key (linked to the integrated USB port on the HMI)
z 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 V1.1 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 V4.1.

Download the SoMachine Basic Application

For the download procedure described in this section, an USB connection between PC and
controller is used.
To set up a communication between a controller and a PC via USB, use one of the following cables:
z TCSXCNAMUM3P
z BMXXCAUSBH045

Using the established USB connection between PC and M221 controller, proceed as follows to
download the SoMachine Basic application.

Step Action Comment

1 Click the Commissioning tab in The Commissioning tree opens
SoMachine Basic
2 Select Connect in the The Connect window is displayed on the right.
Commissioning tree.
3 Select the USB device in the Local The field Local Devices displays all logic controllers
Devices field. directly connected to the PC with the physical COM
ports of the PC (COM1, for example), with USB cables,
or through virtualized COM ports (by USB-to-serial
converters or Bluetooth dongles).

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Step Action Comment

4 Click the Login button When the connection is successfully established, details
about the logic controller appear in the Selected
Controller area of the window and the button to
download the application is available.
5 Click the PC to Controller The download of the application starts.
(download) button.
6 To run the application you have If the message Unable to start controller (RUN mode)
downloaded, click Run Controller appears, click Close and check whether the RUN/STOP
and click OK to confirm the action. switch on the logic controller is in the STOP position.
Refer to the Hardware Guide (see Modicon M221 Logic
Controller, Hardware Guide) of the logic controller for
details.

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).

Download the Vijeo-Designer Application

For the download procedure described in this section, an USB connection between PC and HMI is
used.
To set up a communication between an HMI and a PC via USB, use one of the following cables:
z TCSXCNAMUM3P
z BMXXCAUSBH045

Using the established USB connection between PC and HMI, proceed as follows to download the
Vijeo-Designer application.

Step Action Comment

1 Open the project in Vijeo-Designer. -
2 Select the Target node in the project The property window of the target
tab of the navigator window. opens.
3 Select the General node in the The editor for the general settings of
properties window. the target opens.
4 Select USB in the Download field. -

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Step Action Comment

5 Right-click the Target node in the Downloading erases the files on your
project tab of the navigator window target. You can preserve them by
and select Download to (USB). using the Preserve Run-Time Data
feature.

For more information, refer to the Vijeo-Designer online help.

NOTE: The Vijeo-Designer project and Vijeo-Designer runtime must be compatible. In most cases,
you will not have to install Vijeo-Designer runtime separately from installing the Vijeo-Designer
project. When you download the project from Vijeo-Designer, Vijeo-Designer automatically
downloads and updates the Vijeo-Designer runtime on the target machine. In some cases, you
may want to install Vijeo-Designer runtime separately. Therefore the Vijeo-Designer runtime
installer tool is used to download, install, and upgrade the target’s Vijeo-Designer runtime.

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Setup Other Devices

Section 7.2
Setup Other Devices

What Is in This Section?

This section contains the following topics:
Topic Page
Network and Device Parameter Settings 161
TeSys U Motor Starter - Setup 162
Altivar 12 Variable Speed Drive - Setup 163
Altistart 01 Soft Starter - Setup 165
OsiSense XGS - Setup 167
iEM3110 Energy Meter - Setup 169
Harmony ZBRRC Wireless Receiver - Setup 171

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Network and Device Parameter Settings

Overview
This section describes the steps required to initialize and configure the different devices required
to attain the described system function.
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
z 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.
z Before performing any of these operations, consider the effect on all connected equipment.
z 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), checking for 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.

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TeSys U Motor Starter - Setup

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.

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Altivar 12 Variable Speed Drive - Setup

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:
z By the local HMI on the front of the drive
z By a remote display terminal*
z By the software SoMove lite installed on a PC*

(* linked to the integrated communication port of the drive)

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.

DANGER
UNINTENDED EQUIPMENT OPERATION
z Make sure that both wiring and mounting are correct before you start to configure the drive.
z Verify that an unintentional start of the connected motor will not endanger personnel or
equipment in any way.
Failure to follow these instructions will result in death or serious injury.

If necessary, disconnect the motor from the drive to prevent an unintentional motor start.
For more information, refer to :
z Altivar 12, Variable speed drives for asynchronous motors, User manual, BBV28581.
z 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.

Step Action Comment

1 Switch on the power supply. Do not give a run command to the drive.
2 Configure the parameter [R1 assignment] under In this example, the output R1 is used to
the menu: (FULL) -> (I_O-) -> (r1). control the brake contactors. Therefore the
assignment of R1 is set to (RUN) what is
signaling the drive is running.

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Step Action Comment

3 Configure the motor parameters under the menu: Refer to the motor rating plate. Values have
(FULL) -> (drc-): to be adjusted if the factory settings differ
z [Standard mot. freq.] (bfr) with your application.
z [Rated mot. power] (nPr)
z [Rated mot. volt.] (UnS)
z [Rated mot. current] (nCr)
z [Rated mot. freq.] (FrS)
z [Rated motor speed] (nSP)

4 Configure the parameter [Reference Channel 1] The drive is operated via Modbus. The
under the menu: (FULL) -> (CtL-) -> (Fr1). parameter [Reference Channel 1] is
set to Modbus (Mdb).
5 Configure the ramp parameters under the menu: In most cases, the factory settings can be
(FULL) -> (FUn-) -> (rPt-): maintained for a quick start. But
z [Acceleration] (ACC) nevertheless, you have to verify the values.
z [Deceleration] (dEC)

6 Configure the speed limit parameters under the menu: In most cases, the factory settings can be
(FULL) -> (FUn-) -> (SPL-): maintained for a quick start. But
z [Low Speed] (LSP) nevertheless, you have to verify the values.
z [High Speed] (HSP)

7 Configure the [Motor thermal current] under the Refer to the motor rating plate. Values have
menu: (FULL) -> (Flt-) -> (tHt-) -> (itH). to be adjusted if the factory settings differ
from your application.
8 Configure the communication parameters under the The communication parameters in this
menu: (FULL) -> (COM-): example are set as follows:
z [Modbus Address] (Add) z [Modbus Address] = 1
z [Modbus baud rate] (tbr) z [Modbus baud rate] = 19.2
z [Modbus format] (tFO) z [Modbus format] = 8E1
z [Modbus time out] (ttO) z [Modbus time out] = 2 seconds

WARNING
UNINTENDED EQUIPMENT OPERATION
Power cycle the drive after any configuration changes or adjustments (power removal followed
by power reapplied).
Failure to follow these instructions can result in death, serious injury, or equipment
damage.

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Altistart 01 Soft Starter - Setup

Soft Start Functions

Starting time
The ATS01N1 soft starter controls the starting time of the motor by ramping up the voltage applied
to one phase of the motor.
The starting voltage ramp time can be adjusted 1...5 seconds with the potentiometer on the front
of the soft starter. Since the actual motor starting time is dependent on the level of the applied load,
the scale on the front of the soft starter is calibrated from A to E rather than 1...5 seconds, with A
being the shortest time and E being the longest time.
The starting voltage ramp begins at the AC line voltage level set by the initial voltage adjustment.
See the diagram below for more detail.
The ATS01 soft starter is internally bypassed at the end of the time set by the start time adjustment.
If the motor is not up to speed by that time (due to a heavy load), the internal contactor can be
damaged, requiring replacement of the soft starter.

CAUTION
INOPERABEL EQUIPMENT
Set the start time at a level achievable while the motor is under its highest load level.
Failure to follow these instructions can result in injury or equipment damage.

Voltage start ramp, initial voltage, and up to speed

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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

U1 Level of input voltage

U2 Level of voltage on control terminals
U3 Level of output voltage (motor)
P1 Potentiometer for starting voltage ramp time adjustment, A (min.) to E (max.)
P2 Potentiometer for initial voltage adjustment, A (min.) to E (max.)

For more information, refer to Altistart 01, Soft Starts for Single-Phase and Three-Phase
Asynchronous Motors, 45A01SS.

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OsiSense XGS - Setup

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:
z Using the XGS ZCNF01 configuration badge (supplied with the station)
z Via the network (Modbus or Uni-Telway write command)

Configuration Badge
The addressing procedure is described on the back of the configuration badge:

Configuring the station network address:

Step Action Comment

1 Power up the station. Station self-test
Wait for 5 seconds.
2 Place the configuration badge in front of the station. The TAG LED flashes red.
Count the number of flashes. Each red flash emitted corresponds to
one increment of the network address.

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Step Action Comment

3 Remove the configuration badge when the required The TAG LED flashes green.
network address is reached. The number (if green) corresponds to
the network address that has been
configured.
4 Place a ’normal’ (XGHB) tag in front of the station. The configured network address is
confirmed and saved in the station.

NOTE: The network address ranges from 1...15.

For more information, refer to RFID OsiSense XG, Compact Stations, W916556690111.

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iEM3110 Energy Meter - Setup

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 currently 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.

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System Setup

Basic Configuration
Before starting the configuration of the energy meter,check the correct installation.

Step Action Comment

1 Set date and time. When the power is interrupted, the iEM3110 automatically resets the
date and time.
By default the required password is 0010.
2 Enter the configuration The display switches to configuration mode.
mode.
Press and hold ESC +
OK for at least
2 seconds.
3 Select the submenu The default wiring parameter is set to 3PH4W.
Wiring and set the
parameter for it.
4 Select the submenu The default frequency parameter is set to 50 Hz.
Frequency and set the
parameter for it.
5 Select the submenu The default pulse output is set to 100 imp/kWh.
Pulse Output and set In this architecture, you have to set the value to 1000 imp/kWh
the parameter for it.
6 Leave the setup menu –
by pressing ESC .

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.

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Harmony ZBRRC Wireless Receiver - Setup

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.

Step Action Graphic/Comment

1 Enter the teach/unteach mode
for push-buttons:
z Press the arrow key for
approximately 3 seconds.

Release the key when only the Q1 indicator lamp on the device
starts flashing green.
2 Select the output for teaching
or unteaching:
z Press the arrow key to
switch between output 1, 2,
3, or 4.

During selection between the outputs, the corresponding LED

is flashing with 4 Hz.

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Step Action Graphic/Comment

3 Activate the output for teaching
or unteaching:
z Press the OK button to
activate the desired output.

When the output is selected, the corresponding LED is flashing

with 2 Hz. The teach procedure has to be performed within
1:30 minutes.
4 Teach-in the push button:
z Push the wireless button 3
times within 3 seconds.
5 Unteach the push button:
z Push the wireless button 6
times within 6 seconds.

Transmission indicator LED at the bottom turns on if teaching

is completed.
6 Exit the teach/unteach mode
for push buttons:
z Press the arrow key for
approximately 3 seconds.

For more information, refer to Harmony XB5R, Expert Instruction Sheet, EIO0000000812 (EN).

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Bill of Material
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Bill of Material (BOM)

Chapter 8
Bill of Material (BOM)

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:
z IEC 60-204 safety of machinery
z 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
Be sure 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.

Schneider Electric offers UL 508A support on the website at www.Schneider-Electric.us. A number

of educational and product search tools are available on the website, including overview
information, a UL 508A SCCR (Short Circuit Current Rating) determination flow chart, and
information on Schneider Electric individual or product combination SCCRs. Underwriters
Laboratories also publish SCCR tested combination ratings on its website. Updated tested
combination ratings of Schneider Electric can be found on both websites and are free to download.
The UL 508A support website of Schneider Electric is located at:
http://www.schneider-electric.us/sites/us/en/support/product-support-resources/ul-508a-
support/ul-508a-support.page

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The UL 508A combination motor controller website of UL is located at:

http://www.ul.com/global/eng/pages/offerings/industries/powerandcontrols/industrialcon-
trolequipment

Main Switch

Quantity Description Reference IEC UL

1 PowerPact H-Frame multistandard circuit breaker, NHGF36015TW x x
main switch, 3pin, 35 kA
1 Lug kit 15...150 A AL150HDS x x
1 Short lug shield S37446 x x
1 Extended rotary handle LV429502 x x
1 Red rotary handle on yellow bezel LV429340 x x

Energy meter

Quantity Description Reference IEC UL

1 Energy meter iEM3110, direct measurement up to A9MEM3110 x x
63 A, pulse output

Emergency Stop

Quantity Description Reference

1 TM3 embedded safety module TM3SAF5R
1 Emergency stop push-button, 2 NC, 22 mm, complete unit XB5AS8444
1 Emergency stop push-button, complete plastic control station, XALK178F
yellow/ red, 2 NC
1 Illuminated push-button, blue, 1 NO + 1 NC, integral LED, complete XB5AW36B5
unit
1 Circular yellow legend for emergency stop push-button "emergency ZBY8330
stop"
2 TeSys D contactor, AC-3 400 V / 7.5 kW LC1D18BD

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Display and Indicators

Quantity Description Reference

1 Pilot light with integral LED 24Vac/dc, white, complete unit XB5AVB1
1 Harmony Wireless access point ZBRRC
1 Plastic control station, empty, 2 cut-outs, IP 66 XALD02
1 Wireless push-button green ZB5RTA3
1 Wireless push-button red ZB5RTA4
1 Empty plastic box for mobile transmitter, 1 cut-out ZBRM01
1 Wireless push-button blue ZB5RTA6
1 Plastic control station, empty, 3 cut-outs, IP 66 XALD03
2 Push-button, green, 1 NO, complete unit XB5AA31
1 Push-button, red, 1 NC, complete unit XB5AA42
5 Legend holder and blank label (white or yellow) 18x27 mm ZBY6102
1 Mounting plate for use on vertical support of tower light XVBC12
1 Mounting base with support tube 80 mm, black XVBZ02
1 Base unit for tower light XVBC21
1 Set of 6 colored markers for the position XVBC22
1 Signal element for tower light, green XVBC2B3
1 Signal element for tower light, red XVBC2B4
1 Signal element for tower light, blue XVBC2B6
1 Signal element for tower light, clear XVBC2B7

Automation Components

Quantity Description Reference

1 Modicon M221 Logic Controller 24 Vdc, 8x DI, 8x DOs, 2x AI, 1x SL, TM221ME16T
1x Ethernet
1 TM3 expansion module 16 DI TM3DI16
1 TM3 expansion module 16 DO TM3DQ16T
2 TM3 expansion module TeSys, 4x RJ45 connector for TeSys motor TM3XTYS4
starter

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Magelis HMI

Quantity Description Reference

1 Magelis HMI small panel with touch screen 3.4" (monochrome), HMI ST0532
Ethernet

Control Voltage Power Supply and Distribution

Quantity Description Reference IEC UL

1 Circuit breaker Multi9 UL1077 2P, C, 3 A (~230 V) 24444 x x
1 Power supply 230 Vac / 24 Vdc, 10 A ABL8RPS24100 x x
2 Circuit breaker Multi9 UL1077 1P, C, 1 A (24 Vdc) 24425 x x
9 Circuit breaker Multi9 UL1077 1P, C, 2 A (24 Vdc) 24426 x x
1 Ground disconnect terminal 9760 U/8 TKE 48 57.110.1655.0 (Wieland) x x

Drives and Power

Quantity Description Reference IEC UL

TeSys D
2 TeSys D motor starter combination, 24 Vdc, GV2DP104BD x x
3~400 V/ 0.18 kW
1 TeSys D motor starter combination reversing, GV2DP204BD x x
24 Vdc, 3~400 V/ 0.18 kW
2 SoLink wiring kit TeSys D motor starter LAD5C11 x x
combination
1 SoLink wiring kit TeSys D motor starter LAD5C12 x x
combination reversing
3 TeSys connection cable (SoLink), 2x RJ45, 1 m LU9R10 x x
(3.28 ft)
2 Auxiliary contact block TeSys D contactor, 1 NO + LADN11 x x
1 NC
3 Auxiliary contact for circuit breaker, 2 NO GVAE20 x x
3 Auxiliary contact for circuit breaker, 1 NO, 1 NC GVAN11 x x
1 Set of 3-pole 63 A busbar 5 tap-offs, 54 mm GV2G554 x x
(2.13 in)
1 Terminal block for supply busbar sets GV1G09 x x
1 Cover for unused busbar connection points GV1G10 x x
1 Altistart softstarter 3~400 V/ 1.1 kW (3 A) ATS01N103FT x x
TeSys U

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Quantity Description Reference IEC UL

1 TeSys U base module, 12 A (without terminals) LUB120 x x
1 TeSys U base module reversing, 12 A (without LU2BA0BL x x
terminals)
2 TeSys U control unit, standard 0.15…0.6 A LUCAX6BL x x
1 TeSys U wiring kit coil LU9BN11C x x
1 TeSys U wiring kit coil (reversible) LU9MRC x x
2 TeSys U function module parallel wiring LUFC00 x x
1 Set of 3-pole 63 A busbar 2 tap-offs, 54 mm GV2G254 x x
(2.13 in)
2 TeSys connection cable (SoLink), 2x RJ45, 1 m LU9R10 x x
(3.28 ft)
Altivar 12 - 2 motors
1 Altivar 12 variable speed drive, 0.37 kW ATV12H037M2 x x
1 Magnetic circuit breaker, 6.3 A (1~230 V) GV2L10 x -
1 Auxiliary contact for circuit breaker, 1 NO, 1 NC GVAE11 x -
1 Thermal-magnetic circuit breaker, 4.0...6.3 A GV2P10 - x
(1~240 V)
1 Insulating barrier for motor circuit breaker GV2GH7 - x
1 Auxiliary contact for circuit breaker, 1 NO, 1 NC GVAN11 - x
4 TeSys D contactor, AC-3 400 V / 4 kW LC1D09BD x x
2 Auxiliary contact block TeSys D contactor, 1 NO, 1 LADN11 x x
NC
2 Auxiliary contact for Multi9 circuit breaker 60137 x x
2 Circuit breaker Multi9 UL489 2P, C, 2 A (~230 V) 26925 x x

Sensors

Quantity Description Reference

1 OsiSense tap-off box for 3 stations XGCS, Modbus SL, 24 Vdc TCSAMT31FP
1 Power cable tap-off box with M12 connector at one end and flying XGSZ09L2
leads at the other end, 2.0 m (6.56 ft)
3 Compact station flat form 40(1) M12 male connector on flying lead XGCS4901201
3 Modbus shielded connecting cable, IP 67 M12 connectors, TCSMCN1M1F1
male/female, A coding, 1 m (3.28 ft)

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Ethernet Wiring

Quantity Description Reference

1 Ethernet TCP/IP unmanaged switch, 10BASET/100BASE-TX, 5x TCSESU053FN0
RJ45 ports copper cable
3 Ethernet ConneXium cable,shielded twisted- 2.0 m (6.56 ft) 490NTW00002
pair straight cord,RJ45 connector at each end
1 ConneXium M12 to RJ45 Ethernet adapter TCSEAAF11F13F00

Modbus SL Wiring

Quantity Description Reference

1 Modbus splitter block - 10 RJ45 and 1 screw terminal block LU9GC3
1 Modbus shielded pre-wired M12 connector, IP 67, female/bare wires, TCSMCN1F5
A coding, 5 m (16.4 ft)
1 Modbus SL drop cable, RJ45 connector at each end, 1.0 m (3.28 ft) VW3A8306R10
1 Modbus SL drop cable, RJ45 connector at each end, 3.0 m (9.8 ft) VW3A8306R30
1 M12 tee 5-pin female A-coding M12/5-pin male A-coding M12 + 5-pin TCSCTN011M11F
female A-coding M12, used to connect the line terminator.
1 Line terminator 120 Ω, 5-pin male A-coding M12 FTXCNTL12

Software Tools

Quantity Description Reference

1 SoMachine (includes Vijeo-Designer) on DVD SOMNACS41
1 Single user license for SoMachine SOMNACCZXSPA41
1 SoMachine Basic V1.1 on CD SOMBASAP11
1 Vijeo-Designer V6.2, HMI configuration software single license VJDSNDTGSV62M
1 Programming cable (USB) TCSXCNAMUM3P
1 Ethernet cable M12 - RJ45 TCSECL1M3M3S2
1 SD card, 2 GB TMASD1

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 Compact Modbus SL Logic Controller M221 Book
Glossary
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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.

E
Ethernet
A physical and data link layer technology for LANs, also known as IEE 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).

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Glossary

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
RJ-45
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).

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 Glossary

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.

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 Compact Modbus SL Logic Controller M221 Book
Index
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Index

M
M221 book Modbus SL
SUG, 11
TVDA, 11

S
setup devices
TVDA, 155
SUG (system user guide)
M221 book Modbus SL, 11
system setup
TVDA, 155
system user guide (SUG)
M221 book Modbus SL, 11

T
template
TVDA, 137
TVDA
communication, 123
hardware, 55
implementation, 137
M221 book Modbus SL, 11
safety requirements, 25
setup devices, 155
template, 137
wiring, 123
TVDA Compact Modbus SL M221 book
bill of material (BOM), 173
TVDA Modbus SL M221 book
system architecture, 22

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Index

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