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AAAMMMEEE PPPooowwweeerrrtttrrraaaiiinnn CCCooonnntttrrrooolllsss

PPrroojjeecctt BBooookk

Version 6.0

Revision Information Revision

Date Version Number Document Name

Revision Affected Sections

Revised By

11-1-06 1.0 Project Book V1 First Release All 1-1-07 2.0 Project_Book_-

_Telemecanique_v2 Various part number and architecture corrections (detail)

3.1, 3.3, 4.1, 6.1, 8.1, 8.2, 8.4, 8.5, 8.6

McGinn/ Dollins

7-1-07 3.0 Project_Book_-_Telemecanique_v3

Rearranged sections and various part number changes (detail)

2, 2.1, 2.2, 2.3, 2.4, 3, 3.1, 3.2, 3.3, 4, 4.1, 4.2, 5, 5.2, 6, 7, 8, 8.1, 8.2, 8.3, 8.5, 8.6

McGinn/ Dollins

1-1-08 4.0 Project_Book_-_Schneider_Electric_v4

Removed Daimler name and various part number changes (detail)

1, 2.3.1-2.3.5, 5.1.1, 5.5.4, 5.5.7, 5.5.8, 5.6.1, 5.6.5

Perez/ Dollins

1-1-09 5.0 Project_Book_-_Schneider_Electric_v5

Added Contacts in India & Mexico (detail)

Perez

1-1-10 6.0 Project_Book_-_Schneider_Electric_v6

Various part number additions and changes, contact in Italy added (detail)

1, 2.1.2, 2.1.3, 2.2.1, 2.2.2, 5, 5.1.1, 5.1.2, 5.1.3, 5.1.5, 5.2.1, 5.2.3, 5.3.1, 5.3.1, 5.3.3, 5.4.1, 5.5.2, 5.5.3, 5.5.4, 5.5.6, 5.5.8, 5.5.9

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Index/Contents 1 Supplier Information / Contact information ............................................................... 4 2 Scope of Supply ....................................................................................................... 5

2.1 Automation ......................................................................................................... 7 2.1.1 PLC Equipment .......................................................................................... 7 2.1.2 HMI Equipment .......................................................................................... 8 2.1.3 Networks .................................................................................................. 10 2.1.4 Motion Control and Drives........................................................................ 13 2.1.5 Safety ....................................................................................................... 14

2.2 Control Products............................................................................................... 16 2.2.1 I/O Devices............................................................................................... 16 2.2.2 Other Machine Control Products .............................................................. 17 2.2.3 Network I/O & Devices ............................................................................. 18

2.3 Power Distribution ............................................................................................ 19 2.4 Engineering Services........................................................................................ 20

2.4.1 Program Management ............................................................................. 20 2.4.2 Integration Services ................................................................................. 20

3 Architecture............................................................................................................ 21 3.1 Assembly Architecture ...................................................................................... 21

3.1.1 Assembly Architecture: Auto and Semi-Auto Stations.............................. 22 3.1.2 Assembly Zone Architecture: Line Layout ................................................ 23 3.1.3 Assembly Distributed Architecture: Line Layout ....................................... 24 3.1.4 Assembly Conveyor Controller: Separate Conv Control / Sta Control..... 25 3.1.5 Assembly Manual Station in Zone Architecture........................................ 26 3.1.6 Assembly Manual Station in Distributed Architecture............................... 27 3.1.7 Hybrid: Example showing three grouped manual stations........................ 28

3.2 Machining Architecture: .................................................................................... 29 3.2.1 Transfer Machine Architecture ................................................................. 30 3.2.2 Flexible Machining Cell Architecture ........................................................ 32

3.3 Architecture for General Machines ................................................................... 35 4 Software Approach................................................................................................. 36

4.1 Logic Structure ................................................................................................. 37 4.1.1 Integrated Diagnostics and HMI paging ................................................... 37 4.1.2 System Reporting..................................................................................... 38 4.1.3 Object Based............................................................................................ 38 4.1.4 Configuration versus Programming.......................................................... 38 4.1.5 Model Management ................................................................................. 39 4.1.6 Alternative approaches (PL7 vs. Unity) .................................................... 39

4.2 Device Interfaces.............................................................................................. 39 4.3 HMI Screens..................................................................................................... 40 4.4 Programming Software ..................................................................................... 40 4.5 Flex Cell Agent Technology.............................................................................. 40

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5 Program Components ............................................................................................ 41 5.1 Automation Controls ......................................................................................... 42

5.1.1 PLC Equipment ........................................................................................ 42 5.1.2 Intelligent Modules ................................................................................... 43 5.1.3 PLC Programming Software..................................................................... 44 5.1.4 PC to PLC Programming Cables.............................................................. 44 5.1.5 Operator Interface .................................................................................... 44

5.2 Networking........................................................................................................ 45 5.2.1 Ethernet Hardware ................................................................................... 45 5.2.2 CanOpen Hardware ................................................................................. 46 5.2.3 ASi Hardware ........................................................................................... 46

5.3 Inputs/Outputs .................................................................................................. 47 5.3.1 I/O (Racks and Telefast) .......................................................................... 47 5.3.2 Network I/O (Flex IP20)............................................................................ 48 5.3.3 Network I/O (Field IP65/67)...................................................................... 49 5.3.4 Terminals ................................................................................................. 52

5.4 Safety ............................................................................................................... 53 5.4.1 Safety Relays ........................................................................................... 53 5.4.2 Asi Safety ................................................................................................. 53 5.4.3 Programmable Safety .............................................................................. 53

5.5 Devices............................................................................................................. 54 5.5.1 RF Tag System ........................................................................................ 54 5.5.2 Servo Motors And Drives ......................................................................... 54 5.5.3 Frequency Drives And Soft Starts ............................................................ 55 5.5.4 Motor Control ........................................................................................... 56 5.5.5 Control Relays.......................................................................................... 58 5.5.6 Beacons, Horns & Stack Lights................................................................ 58 5.5.7 Pushbuttons & Pilot Lights ....................................................................... 59 5.5.8 Sensors .................................................................................................... 60 5.5.9 Cables And Sensor Docks ....................................................................... 62 5.5.10 Power Supplies ........................................................................................ 63

5.6 Circuit Protection and Electrical Distribution ..................................................... 64 5.6.1 Disconnect Hardware............................................................................... 64 5.6.2 Circuit Breakers........................................................................................ 64 5.6.3 Fuse Blocks & Splitter Blocks................................................................... 66 5.6.4 Transformers............................................................................................ 66

6 Revision Log .......................................................................................................... 67 6.1 Version 2.0 Revision Detail............................................................................... 67 6.2 Version 3.0 Revision Detail............................................................................... 67 6.3 Version 4.0 Revision Detail............................................................................... 68 6.4 Version 5.0 Revision Detail............................................................................... 68 6.5 Version 6.0 Revision Detail............................................................................... 68

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1 Supplier Information / Contact information Schneider Electric is the corporate manufacturing entity. Schneider Electric products carry different brand names. Most common are the Telemecanique, Square D, Modicon and Merlin-Gerin brands. There are other less common ones as well. See Schneider Electric Brands for more information. Contact Information: Name Role Phone Mobile

Manny Perez International Account Manager +1 248 457 4162 +1 248 835 5824

Armando Martinez Liaison Mexico 5804 5162 044 55 1069 3511 Horst Kuhn Liaison Germany +49 711790887521 +49 1722131456 Imad Siddiqui Liaison India +912240170000/12 +91 9323736111 Masakazu Kase Liaison Japan 81 3 52 932 8000 Alfredo Longhitano Liaison Italy +39112281211 +393299020745

In many countries including the United States, our products are sold through distributor channel partners. When more about OEM locations and project specifics are known, distributor contacts will be identified as well as additional contacts from our other country organizations.

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2 Scope of Supply This project book is primarily intended to demonstrate the range of automation and control architectures Schneider typically implements for powertrain manufacturing operations. This section will serve to explain the large breadth of our potential scope of supply. Automation

PLCs & PACs HMIs (dedicated, PC, web server,

SCADA) Motion Control & Drives Industrial Networks Safety Control

System Capabilities Network Design Production Monitoring Systems Industrial Performance Services

Building Automation HVAC Access Control

Machine Control Motor Control and Soft starts Relays, Terminal Blocks Pushbuttons, Pilot Lights Stack Lights, Beacons Circuit Breakers, Disconnects,

Safety Switches

Control Transformers & Power Supplies

Sensors (proximity, photo, ultrasonic, limit, pressure)

RFID Systems Power Distribution

Substations (LV/MV Switchgear) Panelboards Motor Control Centers Lighting Control Power Monitoring and Metering Power Factor Correction and

Transient Suppression Power Equipment Services

Maintenance and Repair Refurbishment (Retrofit/Retrofill) Arc Fault and Current Fault Potential

Analysis Enterprise Monitoring

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Schneider Electric offers a system that is highly modular and lends itself to open connectivity with systems and devices from third parties. Our breadth of products can be divided into the essential subsystems of a controls architecture. This is intended to provide flexibility and scalability to machine builders while still allowing a great deal of design standardization for the larger scope of the project. Consider the total system as follows:

The device and I/O subsystems themselves employ a further level of modularity. This approach allows for interchangeability of control subsystems as well as devices within those subsystems to be mixed with other vendor solutions in a way that can easily be standardized and validated. This allows the use of a standard for a particular subsystem across varied complete solutions. For example, one could use a common I/O and device strategy with a variety of PLCs and CNCs.

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2.1 Automation

2.1.1 PLC Equipment There are three PLC options, depending on the architecture chosen, including the Premium, M340 and Quantum. Processor capability may determine the architecture chosen. The Premium range can be programmed with Unity or PL7 software while the M340 range is programmed with Unity only and the Quantum is programmed with Unity, Concept or Proworx software. The M340 will be the primary controller for distributed systems with Premium for more central systems and stations requiring complex motion control. The Quantum may be used if process control or PID loops are required. Each system will include Ethernet Modbus TCP/IP as the primary network with options for additional networks to support varied device strategies. Detailed information on each of these processor ranges can be found in Schneider Electric technical documentation. Below is a quick reference of the three CPU ranges.

PREMIUM M340 QUANTUM

Unity, Concept, Proworx Programming Software

Unity, PL7 Unity

Max I/O Configuration

2048 discrete 512 analog

1024 discrete 256 analog

limited only by memory 1024/1024 local

Performance Boolean Instruction

Execution Time .0375 µs .06 µs 0375 µs

Typical Machine Application (65% Boolean) 14 K instr/ms 6.9 K instr/ms 14 K instr/ms

Memory Capacity Code 7168 Kbytes 70 K instructions 7.1 Mbytes

User Data 896 Kbytes plus file 256 Kbytes plus file 768Kbytes plus file

Networks Ethernet Modbus

TCP/IP Ethernet Modbus

TCP/IP Ethernet Modbus

TCP/IP CanOpen, AS-i CanOpen CanOpen, AS-i

Interbus, Profibus, Fip,

MB+ Interbus, Profibus, MB+

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2.1.2 HMI Equipment The primary HMI used will be the XBTGT family. This is a scalable family with systems of various sizes all programmed using Vijeo Designer Software. Templates will be provided per the Chrysler specification with options to support the proposed logic strategy. The use of PCs is generally discouraged and requires special approval from Chrysler. However, PCs still can still provide valuable functionality. Care should be taken to apply them in ways that allow production to continue while PCs are in maintenance. The Compact IPC and Smart IPC ranges can provide integrated PC and HMI functionality using similar templates as developed for the XBTGT and using the same Vijeo Designer programming software. Below is a quick reference for these HMI families.

XBT-GT Magelis IPC Web Browser SCADA

Catalog Numbers XBTGTxxxx Smart, Compact,

Modular Factory Cast HMI

Vijeo Citect SCADA

Programming Software Vijeo Designer

Web tool or Vijeo Designer

Web tool or Vijeo Designer

Vijeo Citect SCADA

Screen Size from 3.8” to 15”

available 12” or 15” Any Any

Display Type STN or TFT TFT, 16K colors Any Any Data Entry Touch or Keypad Touch or Keypad Any Any

Communication Ethernet, Serial, Simatic, Melsec,

etc.

Ethernet, serial, Simatic, Melsec,

etc. Any Any

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As the I/O and device structure can be entirely networked and machine mounted, the PLC and HMI system can be standardized into integrated panels as well. Below is a functional view of variations of this offer:

These systems are typically built on our modular “Tego” enclosure offer. This is a line of customizable enclosure equipment directed to smaller systems. Schneider also has designs for integrated material handling control systems that can be adapted to meet many assembly needs: ConveyorPak.

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2.1.3 Networks One of the architecture goals is to make greater use of network I/O and devices while also reducing the number of networks. The core network for the complete Schneider Electric system will be Ethernet using Modbus TCP/IP protocol. A second device level network will be available and shown for most system options to provide modularity and reduced cost for I/O and devices. The network strategy is based on using Ethernet as the primary network with ASi or other network of choice as required to provide a complete and effective installation. At the machine level, devices and I/O typically rest on a device level network, which, depending upon the system, will be Ethernet, ASi or other network of choice. Controllers will rest on the department level Ethernet network. This network will provide machine interlocking, HMI connection and can serve system data as well. There can be another segregated Ethernet network for systems if preferred, but it is not technically required. HMIs and third party devices such as robots, nut-runners, etc. can rest on either the device network or the department network. Below is a department level view of the network architecture

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The network strategy is based on using Ethernet as the primary network with ASi as required to provide a complete and effective installation. However, other networks are supported to provide a full array of options to support legacy systems or make extensive use of third party technology. Below is an overview of the various networks and their capabilities.

A complete range of Ethernet networking hardware is described in this section. For more detail and for specific detail on other networks (ASi, CanOpen, etc.), follow the links in the product list sections. Schneider’s line of Connexium Ethernet hardware includes a full range of switch and cabling equipment to support a variety of industrial Ethernet networks from simple to highly complex systems. The offer includes:

Basic 3 and 5-port industrial switches

Hardened IP67 5-port switches with M12 connections

Managed switches from 4 to 24 ports (copper or fiber uplink)

Transceivers for media conversion

Industrial Cat-5e cables (RJ45 and/or M12 terminations)

Hardware for field termination of industrial Ethernet cable

Support for redundant networks

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As for the network masters, the Premium, M340 and Quantum controllers have Ethernet interfaces as options built in to the CPUs or as a slot module. Services supported by these networks include: global data, I/O scanning, broadcast with IGMP/GMRP filtering, time-synch with SNTP/PTP, VLAN, BootP, SNMP, DHCP. The Connexium network diagnostic software (ConnexView) provides a great deal of features to support the configuration and troubleshooting of industrial Ethernet networks. This includes configuration, backup, topology discovery, traffic optimization, alarm reporting, port security and many more features. Similarly, CanOpen and ASi master modules are available for all three offers as well as supporting hardware, power supplies, cabling and devices (see device section and product list). As a matter of connectivity, where third party equipment is required, additional interface modules are available (i.e. Profibus, Interbus, DeviceNet). And the Ethernet system can be adapted to support third party protocols via Schneider’s TCP-Open Technology. In 2007 Schneider Electric became a principal member of the ODVA, the standards organization that governs EtherNet/IP and other protocols belonging to the CIP family. Schneider Electric is committed to expanding our Transparent Ready architecture by supporting both Modbus/TCP and EtherNet/IP protocols and services. As a result, we can now offer several Ethernet/IP compatible products, with more to come. Additionally, our Magelis HMIs and VijeoCitect SCADA software already support Ethernet/IP communication along with many more 3rd party communication protocols. Schneider Electric’s commitment to open communications ensures our customers can integrate Schneider Electric products into a wide array of product architectures. This benefits our customers by enabling them to maintain a single network for multiple automation components from various vendors, which simplifies network maintenance and lowers the cost of ownership. Products Now Available: Premium Ethernet/IP Module TSX ETC 100 Advantys STB Ethernet/IP Module STB NIC 2212 Advantys ETB IP67 I/O Modules ETB 1EI ***** Altivar 71 VFD Communications Card VW3A3316

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2.1.4 Motion Control and Drives The growth in intelligent drive technology has made most applications of PLC motion modules redundant. In most applications servo drives can be adequately controlled over a device network with handshake and data exchange over the network, with motion profiles contained in the drive. Such is the case with Schneider Electric’s Lexium-15 and Lexium-05 ranges. The servo system can be managed in one of three ways: via direct bus, through an Automation Island bridge or, where tight axis coordination is required, via a PLC Sercos card. Schneider has also supported third party interfaces to other servo controller offers.

The Lexium-05 Servo Drive and Altivar-312 Frequency Drive are based on the same platform and make a very cost effective system for applications other than machining.

As for the CNC Machining Centers themselves, Schneider Electric accepts that these will probably be treated as “OEM” systems and intends to pursue an open approach to supporting CNC solution(s) of choice be they NUM, Indramat, Siemens, Fanuc, Mitsubishi or other vendor. Our intent is to offer the same I/O and device structure as the rest of the machining equipment regardless of the controller in use. Simply change the network interface and keep the I/O and device structure the same.

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2.1.5 Safety Schneider Electric offers a variety of safety approaches to choose from based on the needs of your system and architecture:

● Traditional safety relay systems ● Configurable multi-function safety

relays ● ASi network safety relays ● Safety controllers without safety

network ● Safety controllers with safety

network

Schneider Electric also offers a variety of safety control devices including:

● E-Stop Pushbuttons

● Safety Gate Switches ● Non-contact Safety Switches ● Floor Mats and Foot Switches ● Light Curtains ● Integrated Drive and Servo

Safety

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Schneider Electric can also provide power distribution panels with the safety system integrated. Below is a functional view of a sample PDP design that incorporates safety functions. It provides switched power controlled by the safety circuit as well as control power that can be switched and unswitched. A variation provides only 460V and 110V to a secondary bus (24V is generated in the plugs – see below) The power distribution concept incorporates safety at the source. Safety inputs are brought into a PDP (power distribution panel) via ASi-Safe (alternatively by a classical safety relay dual channel circuit). The output controlled is the actual power source so no further consideration of safety is required downstream. The full system is protected to Category 4.

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2.2 Control Products

2.2.1 I/O Devices Schneider offers a variety of I/O possibilities for control systems. The PLC offer provides for rack I/O as well as remote rack I/O. Several networks are supported with a variety of I/O in both IP20 and IP67 form factors. The I/O and device structure is shown in the larger Schneider controls architectures contained in Section 3. The architectures support three basic approaches for device networking: ASi, Ethernet and using the “Automation Island” concept. In the latter case, one or more of these “islands” provides a single point of connection to the control system. That connection is via the network most ideal for the host controller (Ethernet for Schneider PLC, others to support different host controllers as well).

The remote I/O offer can work seamlessly with third party controllers on common industry networks.

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2.2.2 Other Machine Control Products The machine control product offer itself extends to the following additional areas:

Sensors o Mechanical Limit o Inductive Proximity o Photo o Pressure

Relays o Control o Protection

Terminal Strips o Fuse Holders o Distribution Blocks

Pushbutton, Pilot Lights Frequency Drives Motor Control

o Contactors o Starters o Motor Circuit Protectors o Motor Management

System o Soft starts

Alarm Beacons o Stack Lights o Horns

Safety Disconnects Control Transformers Transformer Disconnects Panel Main Disconnects Power Supplies Circuit Breakers

o Molded Case o Compact o Automatic Switch

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2.2.3 Network I/O & Devices What is shown in the architecture drawings in section 3 is meant to leave some interpretation for OEMs regarding exact topology and the mix of devices that connect discretely or over a network. More than one option exists for many devices. Connectivity to other networks is also an option.

Examples of devices that can be connected to the ASi network

Examples of devices other than PLCs and HMIs that can also be connected on the machine Ethernet network are shown below.

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2.3 Power Distribution Contact Square D/Schneider Electric for any power distribution needs. Power distribution is not covered in this document. However, Schneider Electric provides a complete range of industrial power products and technologies for distributing and monitoring power. For example, I-Line Busway, Bus225, PowerLogic monitoring systems, harmonic filtering and power factor correction equipment, and power system engineering services. Additionally, the new UL508A and NEC409 regulations may warrant a closer look at engineered MCCs (motor control centers) and panelboards on the floor level for machine power distribution.

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2.4 Engineering Services

2.4.1 Program Management Depending on the Schneider Electric product content, a typical powertrain manufacturing system project includes a support package managed by Schneider’s Program Management Group. In addition to a manager, engineers with powertrain experience are assigned to support both the OEMs and the plant site. Warranty and material expediting are managed by this group. The group also manages customer reporting, on-site training and simultaneous engineering functions.

2.4.2 Integration Services Network Design: Schneider Electric offers a variety of services and expertise to support your industrial networking needs.

Plant Systems: Schneider Electric can provide engineering and integration services for plant systems. This would include andon systems, production monitoring (FIS) systems, production history, production scheduling, quality, birth history, error proofing, tool monitoring and more.

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3 Architecture One of the goals of this project book is to provide OEMs with the information and tools necessary to build a controls architecture that best meets their individual needs. Depending on the machine or process, the best architecture may change. This sections presents sample architectures for the following machine types:

Assembly Systems Transfer Lines Machining Cells Gantries Automation and Simple Machines Facilities

3.1 Assembly Architecture The assembly system is shown as a unique system because of some of its unique needs:

More of a system than a collection of machines Simple manual stations in addition to more complex systems Low power requirements compared to machining systems Greater use for enclosed equipment to reduce/eliminate custom panels

For these reasons the approach differs from other parts of the complete Powertrain manufacturing process. Also, subassembly systems and some simple automation might use more of the assembly architecture than the machining architecture. There are numerous possibilities, but examples shown here are for 3 types of architectures. If these architectures do not suit a specific OEM design, Schneider Electric will consult with the OEM to customize an architecture that best suits their needs.

1) Zone Architecture – The line will be broken up into zones and each zone will have a zone controller which will control the transport, stops, manual stations, manual back-up stations, and lifts and rotates that are not included in automatic stations. Each Automatic station will have its own controller.

2) Distributed Architecture – There are no zone controllers. Every manual station, lift, rotate and automatic station will have its own controller. There may be additional conveyor controllers to handle sections of conveyor with stops and any other device not associated with a specific station.

3) Hybrid – The Chrysler specification limits an area system to five stations. Any combination of equipment from fully distributed to this is acceptable.

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3.1.1 Assembly Architecture: Auto and Semi-Auto Stations

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3.1.2 Assembly Zone Architecture: Line Layout

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3.1.3 Assembly Distributed Architecture: Line Layout

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3.1.4 Assembly Conveyor Controller: Separate Conv Control / Sta Control

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3.1.5 Assembly Manual Station in Zone Architecture

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3.1.6 Assembly Manual Station in Distributed Architecture

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3.1.7 Hybrid: Example showing three grouped manual stations

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3.2 Machining Architecture: For the purposes of this book, machining architectures shall refer to transfer line equipment and CNC machining cells. Specific architectures for transfer line stations and gantries will be shown. Operation level architectures will be shown for transfer lines and flexible machining cells. As Schneider is not proposing a CNC controller, the latter architecture will show connectivity to an unnamed CNC controller. The rest of the system will use PLCs for all control other than the CNC machine tool itself. This provides for the production critical equipment to be controlled in a familiar fashion, while allowing the machine tools, whose downtime affects production incrementally, to be treated as “white appliance” machines. This is not unlike past applications in Crank/Cam machining. So the following will be shown:

1) Transfer Machine Architecture – For the purpose of this approach, the station architecture and the transfer architecture are the same with console functionality available at any station through “virtual console”. Both the station detail and a machine operation overview are shown.

2) Flexible Machining Cell Architecture – An overall operation overview is shown as well as a gantry system detail. A potential architecture using similar technology with an OEM specified CNC is shown for the machine tools themselves.

For other machines that might appear in the machining department (i.e. washers, test equipment, conveyors) see the section for “general machines”

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3.2.1 Transfer Machine Architecture Dedicated machining systems such as transfer lines will utilize a network I/O & Device structure in order to offer consistency across systems. This will be connected over Ethernet to either the Premium Controller or the M340 Controller. Alternatively, a classic discrete I/O structure can be supported with either the Premium or M340.

Note that the servo drives can rest directly on the Ethernet network rather than inside the automation island. Also, for stations requiring interpolation, the drives can rest on a Sercos network from the PLC rack.

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3.2.2 Flexible Machining Cell Architecture Flexible machining systems can utilize the same network I/O & Device structure described in the previous section. This can serve a Premium or M340 PLC in many applications such as Gantries, Conveyors and Washers but can also serve a variety of controllers including third-party CNC controllers using a variety of network interfaces.

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3.3 Architecture for General Machines Machines that are not specifically part of the architectures described above can be accommodated in a similar manner. If a device I/O structure is preferred then machines in the assembly areas should use ASi in a manner similar to the rest of the assembly line architecture and those in machining departments should use automation islands with a network structure similar to the rest of the department. For the case of some general systems (esp. simple equipment, HVAC and filtration equipment) a classical discrete I/O approach may be more suitable than using a device network exclusively. Both the TSX Premium and M340 systems support complete offer of standard discrete I/O to support this need. For facilities equipment, OEMs can make use of custom turn-key Square D equipment from Schneider such as PDPs (power distribution panels) and MCCs (motor control centers).

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4 Software Approach There are two approaches to software design, traditional ladder logic and structured programming. Since traditional ladder logic is familiar to all OEMs, only the structured programming approach will be discussed here. That said, varied approaches may be considered. For the structured programming approach, Schneider Electric has developed a set of software modules that provide necessary control and diagnostic functions for any application. This document will provide an overview of the tools available, but in-depth training on this software approach is available on an as-needed basis. Please contact Schneider Electric for more information. Following is a brief comparison of the two software approaches. Traditional Ladder Logic Structured Programming Generally easy to follow Integrated Diagnostic Lower memory usage Common approach across program

Virtual console functionality Easier to re-order machine sequence Handles non/multi-sequence applications HMI applications are standard Easy to make online message changes

Consistent program look and feel No guarantee on diagnostic Uses more memory HMI applications specific to each PLC Initial learning curve is High No consistency across PLC programs Training required to efficiently modify the program Very difficult to validate The goals of the structured programming approach include:

Integrated Diagnostics and HMI paging Root Cause Diagnostics Structured data to easily support system reporting Object based programming through reusable pre-engineered elements More configuration, less programming High level of modularity

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4.1 Logic Structure

4.1.1 Integrated Diagnostics and HMI paging Standard logical elements integrate these functions with the basic logic. Manual Control, Auto Control, HMI paging, Machine Interlocking and Diagnostic Reporting are all together. This prevents machine creep over time where the basic logical control is not matched by corresponding fault handling. The system cannot stop without a corresponding fault. HMI Reporting The HMI function for discrete control is fully integrated with the logic. No changes are required to the HMI application to add or modify control functions. Console and zone control functionality is available at all stations with access controlled (request/accept) based on a “Virtual Console” implementation Root Cause Diagnostics The system fault reporting is “root cause”, that is the fault reported is not the action that failed to occur but the condition that prevented it. Below is an example map of the methodology:

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4.1.2 System Reporting As all the diagnostic data is managed in the background in a standard manner, data required by the system reporting will be available in the same manner from all machines. This would lead to a significant reduction in the effort to integrate these systems (fault reporting especially)

4.1.3 Object Based The strategy employs a building block approach to programming. Common structures can be embedded into blocks of reusable code. The use of data structures allows these blocks to be easily copied and modified per use. For a complex but common application need, we can map it to a dedicated function. Below is a representative example for a manual workstation:

4.1.4 Configuration versus Programming With this methodology much of the traditional coding is replaced with copy, paste and configure efforts. This also means machine modifications can be substantially easier. The system also supports a common HMI template for all discrete functions. The same HMI application can be applied on very different machines and templates can be developed for different HMI hardware. It does not matter what the client HMI is so long as it runs a proper template.

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4.1.5 Model Management Schneider Electric has created application software to provide model management for assembly system in accordance with the specifications set forth by Chrysler. In addition to the HMI and PLC functionality required to manage the data requirements and drive the Tag configuration, the system uses the embedded SOAP interface to allow XML export of the data table. This may provide the ability to tie the data directly to an external application and/or to edit the values concisely in a spreadsheet. We have created an Excel spreadsheet template to support this feature. Follow the attached link to application information and tools: Chrysler Model Management

4.1.6 Alternative approaches (PL7 vs. Unity) As the purpose of the Project Book effort from the Chrysler perspective is to allow for OEM best practices, this system allows for existing software strategies used on previous programs to continue to be used. By using the Premium controller exclusively, every aspect of the hardware architectures presented can be realized by using PL7 in lieu of Unity programming software. Also, Unity could still be utilized but with a more generic programming approach than that described above. In fact, PL7 applications can be imported into Unity allowing OEMs to maintain past programming practices and migrate to the Unity platform. This also allows OEMs to use their current programming practices and use the more cost effective M340 controller.

4.2 Device Interfaces (reference to component section where appropriate) Wherever possible standard interfaces will be written to interface to devices in a common way. This interface will include logic (probably in the form of a function block) and supporting documentation. Combined with software standards this will provide for a common and validated method of implementing that device within the system. Examples of standard interfaces might include:

Motor Starter RFID Tag VFD Drive Servo Drive Stack Light

Valve Stack Nutrunner Robot Interface Machine Stop others as needed…

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4.3 HMI Screens The logic and HMI structure has been adapted to the screen templates developed by Chrysler AME. Schneider has developed generic HMI screens to support these. They can be developed as specific templates to support the software strategy described above. In this case they are true templates, that is, changes in discrete logic actually affect the required changes to the HMI presentation so no programming of the HMIs is required.

4.4 Programming Software Programming software as described in this document breaks out as follows (please follow links for more detailed product information):

Unity: This is the common programming software for the Premium and M340 PLC ranges. It also supports the Quantum range and future Schneider offers.

PL7: This platform is also available to program the Premium range. Applications developed in PL7 can be imported and converted to Unity

Vijeo Designer: This is the programming software for the XBTGT HMIs Vijeo Citect: This is the programming software for the SCADA system. Powersuite: VF Drive and Softstart configuration software Connexview: Ethernet network configuration and diagnostic software Safety Suite: Safety controller configuration software ASi Design: ASi design software Unilink: Servo drive configuration software TCP-Open: 3rd Party Ethernet protocol configuration utility

4.5 Flex Cell Agent Technology Schneider can provide product and services in the form of our Factory Broker system to implement “Agent Technology” in the flexible machining cells. This provides adaptive intelligence that increases the utilization of machines in a cell by providing optimized use of the material handling equipment (gantries and conveyors) serving the cell machines.

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5 Program Components This section contains a master component list. Each part number in the list contains a link to catalog pages with further information and detail on that specific product. Also below are links to general product information and additional resources. NOTE: All components listed in the Project Book are UL approved.

Links to Component List Sections in this Project Book:

Automation Controls Networking Inputs/Outputs Safety Devices Circuit Protection and Electrical Distribution

Web Links:

Schneider Electric Home Page Schneider Electric Products Schneider Electric Automation and Control Services Schneider Electric Product Technical Library Schneider Electric Customer Training Center CAD Drawings for Schneider Electric Products

Essential Guides:

Automation and Control: The Essential Guide (16.6Mb) Human/Machine Interfaces: The Essential Guide (773Kb) Motion Control: The Essential Guide (6.2Mb) Soft Starters and Variable Speed Drives: The Essential Guide (1.7Mb) Power Control and Protection: The Essential Guide (3.4Mb) Machine Safety Preventa: The Essential Guide (4Mb) Detection: The Essential Guide (3.2Mb) Control and Signaling Units: The Essential Guide (1.3Mb) Interfaces and I/O: The Essential Guide (1.8Mb)

Complete Catalogs:

Automation Platform Modicon Premium (30Mb) Automation Platform Modicon M340 (24Mb) Automation Platform Modicon Quantum (23Mb) Twido Programmable Controllers (11Mb) Human/Machine Interfaces (8Mb) Global Detection Catalog (123Mb) Motion Control Catalog (30Mb)

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5.1 Automation Controls 5.1.1 PLC Equipment Premium Processors TSXP576634M Premium Processor, 600 Series, Unity, Ethernet embedded TSXP575634M Premium Processor, 500 Series, Unity, Ethernet embedded TSXP574634M Premium Processor, 400 Series, Unity, Ethernet embedded TSXP573634M Premium Processor, 300 Series, Unity, Ethernet embedded TSXP572634M Premium Processor, 200 Series, Unity , Ethernet embedded TSXP571634M Premium Processor, 100 Series, Unity , Ethernet embedded TSXP574823AM Premium Processor, 400 Series, PL7, Ethernet embedded TSXP573623AM Premium Processor, 300 Series, PL7, Ethernet embedded TSXP572623M Premium Processor, 200 Series, PL7, Ethernet embedded

TSXP57353LAM

Premium Processor, 300 Series, PL7, Single Slot, Fipio * To be used for retools, upgrading from L1 or L2 single slot CPUs or Atrium replacements

Premium Memory Cards TSXMRPC768K SRAM Memory Card 128K (PL7) / 768K (Unity) TSXMRPC001M SRAM Memory Card 1.0M (Unity) TSXMRPC01M7 SRAM Memory Card 256K (PL7) / 1.7M (Unity) TSXMRPC002M SRAM Memory Card 384K (PL7) / 2.0M (Unity) TSXMRPC003M SRAM Memory Card 512K (PL7) / 3.0M (Unity) TSXMRPC007M SRAM Memory Card 992K (PL7) / 7.0M (Unity) Premium Racks TSXRKY6EX 6 slot standard rack extensible TSXRKY8 8 slot standard rack TSXRKY12 12 slot standard rack TSXRKY8EX 8 slot standard rack extensible TSXRKY12EX 12 slot standard rack extensible TSXCBYxxxK Rack Extension Cables note: xxx = 010, 030, 050, 120, 280, 380 for 1, 3, 5 12, 18, 28, 38 meters respectively TSXTLYEX Rack Terminators (Qty 2) TSXRKA02 Empty Slot Covers (Qty 5) Premium Power Supplies TSXPSY1610M Power Supply 24Vdc 30 w non isolated TSXPSY3610M Power Supply 24Vdc 50 w non isolated TSXPSY2600M Power Supply 110Vac 26 w isolated TSXPSY5500M Power Supply 110Vac 50 w isolated TSXPSY8500M Power Supply 110Vac 77 w isolated

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M340 PLC CPUs BMXP342020 M340 Processor, Ethernet and Serial BMXP3420302 M340 Processor, Ethernet and CanOpen M340 Memory Cards BMXRMS008MP M340 Memory Card, 8 Mb, comes standard with processor BMXRMS008MPF M340 Memory Card, 8 Mb, plus 8 Mb file storage BMXRMS128MPF M340 Memory Card, 8 Mb, plus 128 Mb file storage M340 Racks BMXXBP0400 4 slot standard rack BMXXBP0600 6 slot standard rack BMXXBP0800 8 slot standard rack BMXXBP1200 12 slot standard rack BMXXBE2005 Backplane Extender Kit M340 Power Supplies BMXCPS3500 Standard AC Power Supply BMXCPS2010 Standard DC Power Supply BMXCPS3020 Standard DC Power Supply 5.1.2 Intelligent Modules Ethernet Communication TSXETY4103 Premium Ethernet Module TSXETY5103 Premium Ethernet Module with server capability TSXETC100 Premium Ethernet/IP Module BMXNOE0100 M340 Ethernet Module BMXNOE0110 M340 Ethernet Module with server capability CanOpen Communication TSXCPP110 Premium CanOpen Master M340 CanOpen… Built in to M340 processors note: other network masters available (i.e. Interbus, Profibus, Devicenet, FipIO), link Asi Communication TSXSAY1000 Premium ASi Master BMXEIA0100 M340 ASi Master Sercos Motion Control TSXCSY84 Premium Sercos Motion Control Module (up to 8 axes) Serial Communication TSXSCY21601 Premium Serial Communications BMXNOM0200 M340 Serial Communications

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5.1.3 PLC Programming Software UNYSPUEFUCD41 Unity Pro V4.1 PLC Programming Software, Single License UNYSPUEFGCD41 Unity Pro V4.1 PLC Programming Software, 3 License UNYSPUEFTCD41 Unity Pro V4.1 PLC Programming Software, 10 License UNYSPUEFFCD41 Unity Pro V4.1 PLC Programming Software, Site License TLXCDPL7PP45 PL7 Pro V4.5 PLC Programming Software, Single License TLXCD3PL7PP45 PL7 Pro V4.5 PLC Programming Software, 3 License TLXOTPL7PP45M PL7 Pro V4.5 PLC Programming Software, 10 License TLXOSPL7PP45M PL7 Pro V4.5 PLC Programming Software, Site License 5.1.4 PC to PLC Programming Cables

TSXCUSB485

USB – RS485 external adapter cable Note: must also order TSXCRJDB25

TSXCRJDB25

Mini-DIN junction cable for PLC, (Premium, TSX Micro, Twido)1.5 m Note: must also order TSXCUSB485

UNYXCAUSB033 USB port on a PC terminal, 3.3m 5.1.5 Operator Interface Magelis Graphical Operator Interface, Ethernet XBTGT7340 15" color touchscreen HMI with Ethernet XBTGT6330 12" color touchscreen HMI with Ethernet XBTGT5330 10.4” color touchscreen HMI with Ethernet XBTZGM128 128 MB CF Memory Card for XBTG XBTGK5330 10.4" color touchscreen HMI with Keypad and Ethernet XBTZ9780 Serial connection cable for PLC or tap box note: consider Tego mounting hardware for HMI/pushbutton panels note: smaller HMIs are available but require a deviation to use from Chrysler HMI Software (Vijeo Designer) VJDSNDTGSV50M Vijeo Designer HMI Programming Software – single license VJDGNDTGSV50M Vijeo Designer HMI Programming Software – 3 license VJDTNDTGSV50M Vijeo Designer HMI Programming Software – 10 license VJDFNDTGSV50M Vijeo Designer HMI Programming Software – Site license Compact and Smart IPC/HMI (with approval only)

MPCKT55NAX20H

Magelis Compact iPC 15” PC based HMI (Windows XP Pro with VijeoDesigner RT)

MPCYN00CF100N 1 GB Compact Flash card MPCYK05RAM512 512M RAM option for Compact iPC

MPCST52NAJ20H

Magelis Smart iPC 15” PC based HMI (Windows XPe with Vijeo Designer RT), with 1GB Compact Flash card included

note: many different configurations are available in the IPC range consult Schneider Electric

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5.2 Networking 5.2.1 Ethernet Hardware Connexium Switches, Transceivers TCSESU033FN0 Basic Unmanaged 3-port switch TCSESU053FN0 Basic Unmanaged 5-port switch 499NES18100 Unmanaged 8-port switch TCSESU051F0 IP67 switch, 5-port, M12 connections TCSESM043F23F0 Managed Switch 4-port, 2 plus dual copper uplink TCSESM083F23F0 Managed Switch 8-port, 6 plus dual copper uplink TCSESM083F2CU0 Managed Switch 8-port, 6 plus dual fiber uplink TCSESM103F2LG0 Managed Switch 10-port, 8 plus dual copper uplink, Gigabit TCSESM103F23G0 Managed Switch 10-port, 8 plus dual fiber uplink, Gigabit TCSESM163F2CU0 Managed Switch 16-port, 14 plus dual copper/fiber uplink TCSESM243F2CU0 Managed Switch 24-port, 22 plus dual copper/fiber uplink 499NTR10100 Fiber/Copper Transceiver Ethernet Cables, CAT5e shielded, RJ45 and M12 490NTW000xxU Ethernet Cat5e 490NTW000xxU Ethernet Cat5e crossover note: x = 02, 05, 12, 40, 80 which is meters of length TCSECL1M3MxS2 Ethernet Patch Cable M12 to RJ45 TCSECL1M1MxS2 Ethernet Patch Cable M12 to M12 note: x = 1, 3, 10, 25, 40 which is meters of length TCSEAAF11F13F00 Ethernet bulkhead adapter RJ45 to M12

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5.2.2 CanOpen Hardware Accessories and Cables TSXCANCBx CanOpen Trunk Cable note: x =50,100, 300r meters of length TSXCANKCDF90T CanOpen SubD Connector 90o

TSXCANTDM4 Tap Box 4 x 9-pin Sub-D TSXCANCBDDx Preassembled Drop Cables 9-pin Sub-D note: x =03 for 0.3m, and 1, 3 or 5 for meters of length VW3CANTAP2 Tap Box 3 x RJ45 VW3CANCARRx CanOpen RJ45 cables x = 03 for 30cm and 1 for 1m IP65/67 Network Cabling See section for IP67 Network I/O 5.2.3 ASi Hardware see relevant sections for additional devices and safety monitors System & Device Cabling XZCB11001H 100m Yellow TPE Cable (Signal) XZCB11002H 100m Black TPE Cable (Power) TCSATN011F Cable tee with micro connector XZCE40 Bulkhead gland for ASi cables Power Supplies ASIABLB3004 ASi Bus Power Supply (110/240AC Input) TSXSUPSPEC0734 ASi Bus Power Supply (24VDC Input) Repeater ASIRPT01 ASi Network Repeater Programmer Unit and Connection Kit ASITERV2SET ASi Addressing Kit (incl. programmer and cables)

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5.3 Inputs/Outputs 5.3.1 I/O (Racks and Telefast) Premium Input and Output Modules TSXDEY32D2K 32 DI 24Vdc, type 1, 20 way HE10 connector TSXDEY64D2K 64 DI 24Vdc, type 1, 20 way HE10 connector TSXDSY32T2K 32 DO 24Vdc, 0.1A, 20 way HE10 connector TSXDSY64T2K 64 DO 24Vdc, 0.1A, 20 way HE10 connector TSXDEY16D2 16 DI 24Vdc TSXDSY16T2 16 DO 24Vdc TSXDSY08T22 8 DO 24 VDC 2A per poin TSXDSY08R5A Relay Output Module 8 point protected TSXBLY01 Terminal Module for TSXDxY16 or TSXDSY08 note: for other I/O such as high speed input and counter modules, see link Telefast Flex I/O Extensions ABE7H16R21 16 DI 24Vdc LED (2 rows) ABE7BV20 Addition common rail for ABE7H16R21 ABE7R16S111 16 DO 2A relay LED, 1 common/8 ch ABE7S16S2B0 16 DO 24Vdc 0.5A, LED, fault report ABE7R16S210 16 DO 5A relay, LED, volt free Cables for Telefast I/O TSXCDPxx3 HE10 connector to Telefast2 0.25m note: xx= 05, 10, 20, 30, 50 for 0.5, 1, 3, or 5 meters respectively Premium Analog Modules TSXASY410 4 Channel Analog Output TSXAEY414 Multi-range Analog Input (16 bit) TSXBLY01 Terminals for TSXAEY414 and TSXASY410 M340 Input and Output Modules BMXDDI1602 16pt Input Module 24V sink BMXDDO1602 16pt Output Module 24V BMXDAO1605 16pt Output Module Relays BMXDDI3202K 32pt Input Module 24V sink HE10 Connector BMXDDI6402K 64pt Input Module 24V sink HE10 Connector BMXDDO3202K 32pt Output Module 24V HE10 Connector BMXDDO6402K 64pt Output Module 24V HE10 Connector note: analog, high speed input and counter modules are also available, consult Schneider

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5.3.2 Network I/O (Flex IP20) Advantys STB Interface STBNIP2212 Ethernet Modbus TCP Network Interface Module STBNIC2212 Ethernet/IP Network Interface Module STBNCO2212 CanOpen Network Interface Module note: Interbus, Profibus, Devicenet and FipIO NIMs are also available, see link Advantys STB Virtual Backplane STBXBA1000 Backplane mounting for 13.9mm I/O modules STBXBA2000 Backplane mounting for 18.4mm I/O modules and CAN ext. STBXBA2200 Backplane mounting for power supply modules STBXBE2100 CanOpen field network “Island” extension STBXMP7700 Keying pins for backplane modules (Qty 60) Advantys STB I/O Modules STBDDI3420K 4pt. Input Module, 24VDC Sink Connection Kit STBDDO3410K 4pt. Output Module, 24VDC, 0.5A Connection Kit STBDDO3600K 6pt. Output Module, 24VDC, 0.5A Connection Kit STBDDO3230K 2pt. Output Module, 24VDC, 2A Connection Kit STBDRC3210K 2pt. Output Module, Relay 7A Connection Kit STBXMP6700 customizable label sheets (Qty 25)

note: Connection Kits include a suitable backplane/base (STBXBAxxx), the I/O module, and terminal block (STBXTSxxx). Individual I/O modules may also be ordered separately by

eliminating the K at the end of the part number. note: for analog, counting and high-density parallel interface modules, see link Advantys STB Terminals STBXTS1100 Terminal block for DDI and DDO modules (Qty 20, 2 per unit) STBXTS1110 Terminal block for DRC modules (Qty 20, 2 per unit) STBXTS1130 Terminal block for power supply modules (Qty 10, 2 per unit) STBXMP7800 Keying pins for terminal modules (Qty 96) Advantys STB Power Modules STBPDT3100 24VDC power module STBPDT2100 115/230VAC power module Advantys OTB IP20 I/O (low cost STB alternative) OTB1E0DM9LP Ethernet Module 12in, 8out (2ss, 6 relay) expandable TM2DDI16DT 16pt Input Module 24V sink TM2DDO8TT 8pt Output Module 24V TM2DRA8RT 8pt Output Module Relays TM2DMM8DRT Combo I/O module: 4in 24V sink, 4out relay TM2DMM24DRF Combo I/O module: 16in 24V sink, 8out relay ASI IP20 I/O ASI20MT4I4OSA 4I4O, external 24V, no extended addressing ASI20MT4I3OSAE 4I3O, external 24V, extended addressing ASI20MT4I4OS 4I4O, powered from network, no extended addressing

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5.3.3 Network I/O (Field IP65/67) Advantys FTB FTB1CN08E08SP0 IP67 CanOpen I/O block (8 in, 8 out) FTB1CN12E04SP0 IP67 CanOpen I/O block (12 in, 4 out) FTB1CN16EP0 IP67 CanOpen I/O block (16 in) FTB1CN16CP0 IP67 CanOpen I/O block (configurable) note: also available for DeviceNet, Profibus and Interbus, see link Advantys FTM (modular) FTMCN10 IP67 Modular I/O master: CanOpen note: also available for DeviceNet, Profibus and Interbus, see link FTM1DE08C12 IP67 I/O Block, 8 inputs on 4-M12 FTM1DE08C12E IP67 I/O Block, 8 inputs on 4-M12, expandable FTM1DD08C12 IP67 I/O Block, 8 configurable I/O on 4-M12 FTM1DD08C12E IP67 I/O Block, 8 configurable I/O on 4-M12 expandable FTM1DE16C12 IP67 I/O Block, 16 inputs on 8-M12 FTM1DE16C12E IP67 I/O Block, 16 inputs on 8-M12, expandable FTM1DD16C12 IP67 I/O Block, 16 configurable I/O on 8-M12 FTM1DD16C12E IP67 I/O Block, 16 configurable I/O on 8-M12 expandable General (for FTB or FTM) FTXCN32x Advantys CanOpen cable M12 both ends FTXCA32x Advantys aux 24V cable M12 both ends FTXCA31x Advantys aux 24V cable M12 at one end FTXCB32x Advantys Internal Bus cable (FTM) M12 at both ends FTXDP22x Advantys power cable 7/8 connector at both ends note: x = 03, 06,10, 20, 30, or 50 for 0.3, 0.6, 1, 3, 5 meters respectively FTXDP21x Power cable 7/8 on one end note: x = 15, 30 or 50 for 1.5, 3, 5 meters respectively FTXCY1212 Y connector 2 x M12 to 1 x M12 FTXCNCT1 Power T-Connector 7/8 connection FTXCNTL12 CanOpen Line Terminator FTXCM12B M12 Sealing Plug (lot 10) FTXBLA10 Marking Labels (lot 10) ASi Field I/O ASI67FFB01 Base unit - 4 channels M12 ASI67FFP40E A²Si head module 4I, extended addressing ASI67FFP04D A²Si head module 4O, no extended addressing ASI67FFP03E A²Si head module 3O, extended addressing ASI67FFP22E A²Si head module 2I2O, extended addressing ASI67FFB03 Base unit - 8 channels M12 ASI67FFP44D A²Si head module 4I4O, no extended addressing ASI67FFP43E A²Si head module 4I3O, extended addressing ASI67FFP43EY A²Si head module 4I, extended addressing Dual M12

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Advantys ETB (IP67 Ethernet I/O) I/O Modules

ETB1EM16CP00 Advantys ETB IP67 Block I/O Module, 16 Configurable I/O Points, Dual Port Ethernet Modbus TCP/IP

ETB1EM16EPP0 Advantys ETB IP67 Block I/O Module, 16 Inputs, PNP, Dual Port Ethernet Modbus TCP/IP

ETB1EM12E04SPP0 Advantys ETB IP67 Block I/O Module, 12 Inputs / 4 Outputs, PNP, Dual Port Ethernet Modbus TCP/IP

ETB1EM08E08SPP0 Advantys ETB IP67 Block I/O Module, 8 Inputs / 8 Outputs, PNP, Dual Port Ethernet Modbus TCP/IP

ETB1EI16CP00 Advantys ETB IP67 Block I/O Module, 16 Configurable I/O Points, Dual Port EtherNet/IP

ETB1EI16EPP0 Advantys ETB IP67 Block I/O Module, 16 Inputs, PNP, Dual Port EtherNet/IP

ETB1EI12E04SPP0 Advantys ETB IP67 Block I/O Module, 12 Inputs / 4 Outputs, PNP, Dual Port EtherNet/IP

ETB1EI08E08SPP0 Advantys ETB IP67 Block I/O Module, 8 Inputs / 8 Outputs, PNP, Dual Port EtherNet/IP

Advantys ETB Power Cables for Modbus TCP/IP Modules ETXPC511M400020 5 Pin Power Cable, 90° Female connector, single ended, 2m ETXPC511M400040 5 Pin Power Cable, 90° Female connector, single ended, 4m ETXPC511M300040 5 Pin Power Cable, Female straight conn., single ended, 4m ETXPC512M1M3010 5 Pin Power Cable, Female straight connectors, 1m ETXPC512M1M3020 5 Pin Power Cable, Female straight connectors, 2m ETXPC512M1M3050 5 Pin Power Cable, Female straight connectors, 5m ETXPC512M2M4006 5 Pin Power Cable, 90°connectors, 0.6m ETXPC512M2M4010 5 Pin Power Cable, 90°connectors, 1m ETXPC512M2M4020 5 Pin Power Cable, 90°connectors, 2m Advantys ETB Power Cables for EtherNet/IP Modules ETXPC411M400020 4 Pin Power Cable, 90° Female connector, single ended, 2m ETXPC411M400040 4 Pin Power Cable, 90°connector, single ended, 4m ETXPC411M300040 4 Pin Power Cable, straight Female conn., single ended, 4m ETXPC412M1M3010 4 Pin Power Cable, Female straight connectors, 1m ETXPC412M1M3020 4 Pin Power Cable, Female straight connectors, 2m ETXPC412M1M3050 4 Pin Power Cable, Female straight connectors, 5m ETXPC412M2M4006 4 Pin Power Cable, 90°connectors, 0.6m ETXPC412M2M4010 4 Pin Power Cable, 90°connectors, 1m ETXPC412M2M4020 4 Pin Power Cable, 90°connectors, 2m ETXPC412M2M4050 4 Pin Power Cable, 90°connectors, 5m

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Advantys ETB Sensor Cables ETXSC412M1M3010 I/O Cable - M12 Connectors – 1m ETXSC412M1M3020 I/O Cable - M12 Connectors – 2m ETXSC412M1M3050 I/O Cable - M12 Connectors – 5m ETXSC412U1M3010 I/O Cable – Ultra Lock™ Connectors -1m ETXSC412U1M3020 I/O Cable – Ultra Lock™ Connectors -2m ETXSC412U1M3050 I/O Cable – Ultra Lock™ Connectors -5m ETXSC412U2M3010 I/O Cable – 90° Ultra Lock™ Connectors -1m ETXSC412U2M3020 I/O Cable – 90° Ultra Lock™ Connectors -2m ETXSC412U2M3050 I/O Cable – 90° Ultra Lock™ Connectors -5m

ETXSC413U1M3003 I/O Splitter cable – Ultra Lock™ connector 1 end, 2 M12 connectors at other end - 30 CM Long

Advantys ETB Accessories ETXPA513M Auxiliary Power Tee, 5 Pins for Modbus TCP/IP ETXPA413M Auxiliary Power Tee, 4 Pins for EtherNet/IP ETXPA511M3 Auxiliary Power Receptacle, 5 Pins for Modbus TCP/IP ETXPA411M3 Auxiliary Power Receptacle, 4 Pins for EtherNet/IP ETXSA12B Sealing plug for M12 connectors - 10 per package ETXPA78BE Sealing plug for 7/8 external thread connectors - 1 per pkg. ETXPA78BI Sealing plug for 7/8 internal thread connectors - 1 per pkg. ETXADRJM12 Adapter RJ 45 to M12 connectors, for panel mounting ETXPA5M1 Field Attachable Power Connector 5 Pin Male ETXPA5M3 Field Attachable Power Connector 5 Pin Female ETXPA4M1 Field Attachable Power Connector 4 Pin Male ETXPA4M3 Field Attachable Power Connector 4 Pin Female

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5.3.4 Terminals IEC Terminal Strip Hardware AB1VV435Ux Screw Terminal 4mm2, 6mm spacing (100 p/pck) AB1VV635Ux Screw Terminal 6mm2, 8mm spacing(100 p/pck) AB1VVN1035Ux Screw Terminal 10mm2, 10mm spacing (100 p/pck) AB1VVN1635Ux Screw Terminal 16mm2, 12mm spacing (100 p/pck) AB1VVN3535Ux Screw Terminal 35mm2, 16 mm spacing (100 p/pck) AB1VVN7035Ux Screw Terminal 70mm2, 24mm spacing (100 p/pck)

note: for x blank=grey, BL=blue, GE-orange, RO=red (435/635 only), VE=green (435 only),

BLA=white (435 only), UNO=black (435 only) AB1ET435U Double Screw Term., 6mm spacing, 2 in 2 out, grey (100) AB1ET435U2 Double Screw Term., 6mm spacing, 4 wire, black (100) AB1ET435UTP Double Screw Term., 6mm spacing, Earth, green/yellow (100) AB1ET435UBRO Double Screw Term., 6mm spacing, 24V LED, red (100) AB1ET435UBVE Double Screw Term., 6mm spacing, 24V LED, green (100) note: see catalog for additional numbers: end stops partitions, labels, etc.

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5.4 Safety 5.4.1 Safety Relays Safety Relays General XPSAV11113T050 Fixed time delay relay 0.5 sec,3 N/O + 3 timed + 3 solid state XPSAK311144P Safety Relay 3 N/O + 1 N/C + 4 solid state XPSAR311144P Safety Relay 7 N/O + 2 N/C + 4 solid state XPSECM5131 Extension modules 4 N/O + 1 N/C + 1 solid state XPSECP5131 Extension modules 8 N/O + 1 N/C + 1 solid state XPSBF1132P Safety Relay Two hand control 2 N/O + 2 Solid State XPSVNE1142P 3 phase zero -speed monitoring relay back EMF Safety Relays Configurable/Programmable XPSMP11123P two independent configurable safety functions 5.4.2 Asi Safety ASi Safe Monitors ASISAFEMON1 ASi Safety Monitor 1 output group ASISAFEMON2 ASi Safety Monitor 2 output groups ASi Safe Input Devices ASISSLC1 ASi Safe Interface module with one dual channel M12 ASISSLC2 ASi Safe Interface module with two single channel M12 ASISSLLS ASi Safe Interface module with one dual channel ISO Pending E-Stop box with approved PB and ASi safe interface 5.4.3 Programmable Safety Safety Controllers XPSMC16ZC Controller, 8 independent safety outputs, 16 inputs, CanOpen XPSMC32ZC Controller, 8 independent safety outputs, 32 inputs, CanOpen note: Profibus (change C to P) and Modbus (no C) are optional uplinks instead of CanOpen XPSMF4002 Safety Controller with Ethernet safety network note: EtherSafe remote safety I/O modules are provided in partnership with Hima

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5.5 Devices 5.5.1 RF Tag System Ositrack Tags XGHB211345 256B Cylindrical 18mm XGHB221346 256B Tag 26mm x 26mm XGHB444345 3.4KB Tag 40mm x 40mm XGHB445345 13.6KB Tag 40mm x 40mm XGSTP401 Ositrack Handheld Terminal Unit Ositrack Readers XGCS4901201 Compact Station 40mm x 40mm, M12 connector XGCS8901201 Compact Station 80mm x 80mm, M12 connector TCSMCN1M1Fx Cable for connection between readers and NIMs note: x = 1, 2, 5 or 10 for length in meters Ositrack Network Interface Modules XGSZ33ETH 3-way Ethernet Tap TCSAMT31FP 3-way Tap CanOpen or Modbus 5.5.2 Servo Motors And Drives Lexium 15 Servo Drive/Controllers LXM15LxxxN4 Lexium Drive, low power range (to 6A cont. at 460VAC) LXM15LxxxN4 Lexium Drive, medium power range (to 20A cont. at 460VAC) LXM15LxxxN4X Lexium Drive, high power range, (to 70 cont. A at 460VAC) note: xxx= amp rating, see link Lexium Network Interface (Sercos, Can, Ethernet, others) note: CanOpen and integrated controller are standard AM0ETH001V000 Ethernet Interface Unit AM0SER001V000 Sercos Interface Unit Lexium 05 Servo Drive/Controllers (low cost micro drive) LXM05ADxxN4 Micro Servo/Drive Controller with CanOpen note: xx=14,22,34,57 for "x.x" kW, BSH Motors only Lexium Servo Motors BSHxxxxx22y2A High performance, low inertia servo motors BDHxxxxx22y2A Standard inertia servo motors note: xxxx = size and winding (see catalog), y = F for brake or A for no brake note: xxxx = gearmotors are also available (see catalog) VW3M5x0xRyyy BSH/BDH Motor Power cable note: x is connector type, y is length(See catalog) VW3M8x0xRyyy BSH/BDH Feedback Cable note: x is connector type, y is length(See catalog) note: see catalogs for additional accessories

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5.5.3 Frequency Drives And Soft Starts Compact Frequency Drive for automation applications (Altivar 31) ATV312H0xxN4 Compact Variable Speed Drive 0.5HP / 0.37kW note: xx = 37, 55 or 75 for 0.37kW, 0.5kW and 0.75kW respectively ATV312HUxxN4 Compact Variable Speed Drive 0.5HP / 0.37kW note: xx = 11, 15, 22, 30, 40, 55 or 75 for 1.1, 1.5, 2.2, 3, 4, 5.5 and 7.5 kW respectively ATV312HDxxN4 Compact Variable Speed Drive 0.5HP / 0.37kW note: xx = 11 or 15 for 11kW and 15 kW respectively Standard Frequency Drive (Altivar 71) ATV71H075N4 Variable Speed Drive 1HP / 0.75kW ATV71HU22N4 Variable Speed Drive 3HP / 2.2kW ATV71HU40N4 Variable Speed Drive 5HP / 4kW ATV71HU55N4 Variable Speed Drive 7.5HP / 5.5kW ATV71HU75N4 Variable Speed Drive 10HP / 7.5kW ATV71HD15N4 Variable Speed Drive 20HP / 15kW ATV71HD22N4 Variable Speed Drive 30HP / 22kW ATV71HD30N4 Variable Speed Drive 40HP / 30kW ATV71HD37N4 Variable Speed Drive 50HP / 37kW ATV71HD55N4 Variable Speed Drive 75HP / 55kW VW3A1101 ATV 71 Drive Keypad VW3A3310 ATV 71 Ethernet Modbus TCP Interface Card VW3A3316 ATV 71 Ethernet/IP Interface Card note: standard enclosed drives (IP54) can be ordered: substitute H in part # with W note: higher power drives are also available to 900HP, see link note: Schneider also offers a variety of engineered enclosed drive systems, see link note: additional filters, chokes, reactors and brake resistors also available, see catalog (6Mb) note: Altivar 61 is also available for pump/fan applications (lower function. less cost than 71) Compact Softstart for automation applications ATS01N1xxFT Compact Softstart note: xx = 03, 06, 09, 12 which corresponds to rated Amps Softstart with Built in Bypass Contact ATS22Dxx Softstart with built in bypass contact note: xx = 17, 32, 47, 65, 75, 88 which corresponds to rated Amps ATS22Cxx Softstart with built in bypass contact note: xx = 11, 14, 17, 21, 25, 32, 41, 48, 59 which corresponds to rated Amps x 10 Standard Softstart ATS48DxxY Standard Softstart note: xx = 17, 32, 47, 65, 75, 88 which corresponds to rated Amps ATS48xxxY Standard Softstart in higher amperages note: higher power softstarts are also available, see link Configuration (for ATV71/31 and ATS48 equipment) VW3A8104 Powersuite test and commissioning software VW3A8106 Powersuite PC Cable

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5.5.4 Motor Control Contactors LC1D09BD Contactor 9A AC-3 duty 24 VDC LC1D12BD Contactor 12A AC-3 duty 24 VDC LC1D18BD Contactor 18A AC-3 duty 24 VDC LC1D25BD Contactor 25A AC-3 duty 24 VDC LC1D32BD Contactor 32A AC-3 duty 24 VDC LC1D38BD Contactor 38A AC-3 duty 24 VDC LC1D40BD Contactor 40A AC-3 duty 24 VDC LC1D50BD Contactor 50A AC-3 duty 24 VDC LC1D65BD Contactor 65A AC-3 duty 24 VDC LC1D80BD Contactor 80A AC-3 duty 24 VDC LC1D115BD Contactor 115A AC-3 duty 24 VDC LC1D150BD Contactor 150A AC-3 duty 24 VDC LADN22 Aux module 2NO/2NC other combinations available LA4DE3E Suppressor for D40..D80 (built in for smaller sizes) note: higher power contactors are also available, consult Schneider Electric Reversing Contactors LC2D09BD Contactor 9A AC-3 duty 24 VDC reversing LC2D12BD Contactor 12A AC-3 duty 24 VDC reversing LC2D18BD Contactor 18A AC-3 duty 24 VDC reversing LC2D25BD Contactor 25A AC-3 duty 24 VDC reversing LC2D32BD Contactor 32A AC-3 duty 24 VDC reversing LC2D40ABD Contactor 40A AC-3 duty 24 VDC reversing LC2D50ABD Contactor 50A AC-3 duty 24 VDC reversing LC2D65ABD Contactor 65A AC-3 duty 24 VDC reversing LC2D80BD Contactor 80A AC-3 duty 24 VDC reversing LC2D115BD Contactor 115A AC-3 duty 24 VDC reversing LC2D150BD Contactor 150A AC-3 duty 24 VDC reversing LADN22 Aux module 2NO/2NC other combinations available Mounting Hardware GV2AF3 LC1D and GV2P adapter LAD31 Adapter for aligned mounting of LC1D/GV2P GV2AF4 Adapter (use with LAD31) GV2GH7 Line Side Insulating Barrier for GV2P GV3G66 Line Side Insulating Barrier for GV3P Overload Relays LRD.… and LR.D.… D-Line Overload Relays

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Motor Circuit Protectors GV2P01 0.1 to 0.16 A GV2P02 0.16 to 0.25 A GV2P03 0.25 to 0.4 A GV2P04 0.4 to 0.63 A GV2P05 0.63 to 1 A GV2P06 1 to 1.6 A GV2P07 1.6 to 2.5 A GV2P08 2.5 to 4 A GV2P10 4 to 6.3 A GV2P14 6.3 to 10 A GV3P13 9 to 13 A GV3P18 12 to 18 A GV3P25 17 to 25 A GV3P32 23 to 32 A GV3P40 30 to 40 A GV3P50 37 to 50 A GV3P65 48 to 65 A GVAD0110 GV aux. block 1 N/O state & 1 N/C fault (side mount) GVAE11 GV aux. block 1 N/O, 1 N/C state (front mount) LA4DE3E Varistor Coil Suppressor for D40 … D80 TeSys T Motor Management System LTMR08xBD Motor Management Controller, 8 A LTMR27xBD Motor Management Controller, 27 A LTMR100xBD Motor Management Controller, 100 A note: x = M for Modbus, C for CANopen, D for DeviceNet, P for Profibus, E for Ethernet LTM EV40BD Extension Module with voltage measurement on the 3 phases LTMCU Operator control unit note: consult catalog for additional accessories and information ASi enclosed motor starters LF3MPxxDU Non-reversing ASi motor starter LF4MPxxDU Reversing ASi motor starter

note: xx= 02 for .16-.25A, 03 for .25-.4A, 04 for .4-.63A, 05 for .63-1A, 06 for 1-1.6A, 07 for 1.6-

2.5A, 08 for 2.5-4A, 10 for 4-6.3A, 14 for 6-10A, 16 for 9-14A

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5.5.5 Control Relays IEC Control Relays CAD32BD Relay 24Vdc instantaneous 3NO+2NC CAD50BD Relay 24Vdc instantaneous 5NO LADN20 2 N/O Front Mount Aux module LADN11 1 N/O 1 N/C Front Mount Aux module LADN40 4 N/O Front Mount Aux module LADN22 2 N/O, 2 N/C Front Mount Aux module Miniature IEC Control Relays CA3KN40BD Relay 24Vdc instantaneous 4NO CA3KN22BD Relay 24Vdc instantaneous 2NO+2NC LA1KNxx Aux modules (various consult catalog) Ice Cube Relays Tele RUM Series Control Relay Equipment Timers note: per Chrysler spec all non-safety timing functions should be in PLC 5.5.6 Beacons, Horns & Stack Lights XVC Complete Pre-wired Indicating Banks XVC4Bx 40mm, support tube mount, w/out buzzer, steady light only XVC4Bx5S 40mm, support tube mount, w/ buzzer, steady or flashing light XVC4BxK 40mm, base mount, w/out buzzer, steady light only XVC6Bx 60mm, support tube mount, w/out buzzer, steady light only XVC6Bx5S 60mm, support tube mount, w/ buzzer, steady or flashing light XVC6BxK 60mm, base mount, w/out buzzer, steady light only XVC6Bx5SK 60mm, base mount, w/ buzzer, steady or flashing light XVC1BxK 100mm, base mount, w/out buzzer, steady light only XVC1BxSK 100mm, base mount, w/ buzzer, steady or flashing light

note: for x (number of lights): 1=R 2=R,O 3=R,O,G 4=R,O,G,B 5=R,O,G,B,C

Signaling colors: R: Red, G: Green, O: Orange, B: Blue, C: Clear. The colors are listed in the same order as the mounting order of the illuminated units (from top to bottom). Flashing function is selected/programmed by wiring. For XVC Stack Light accessories see catalog.

XVB Stack Lights XVBC2Bx Stack Light Beacon Lens note: for x: 3=green, 4=red, 5=orange, 6=blue, 8=yellow DL1BDBx Stack Light Base 24 volt LED Module note: for x: 1= white (clear), 3=green, 4=red, 5=orange, 6=blue, 8=yellow XVBC21 Standard Beacon Stack Light Base and Cap XVBC21A ASI Beacon Stack Light Base and Cap Beacon Lights XVBL3x Beacon Light XVBL8Bx High Intensity Flasher note: for x: 3=green, 4=red, 5=orange, 6=blue, 7=clear, 8=yellow Audible Horn XVSB1 Standalone 24V Alarm Horn XVBC9B Sounder Unit 24V as part of stack light

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5.5.7 Pushbuttons & Pilot Lights Pushbutton Head ZB4BA1 Pushbutton Flush White ZB4BA2 Pushbutton Flush Black ZB4BA3 Pushbutton Flush Green ZB4BA4 Pushbutton Flush Red ZB4BA5 Pushbutton Flush Yellow ZB4BA6 Pushbutton Flush Blue Selector Switch Head ZB4BD2 Selector Switch 2-pos Head ZB4BD3 Selector Switch 3-pos Head ZB4BD4 Selector Switch 2-pos Spring Return Head ZB4BD5 Selector Switch 3-pos Return to Center Head ZB4BD7 Selector Switch 3-pos Return from Left Head ZB4BD8 Selector Switch 3-pos Return from Right Head Contact block for Pushbuttons and Selectors ZB4BZ101 Contact Block c/w collar 1N/O for PB & SS ZB4BZ102 Contact Block c/w collar 1N/C for PB & SS ZB4BZ103 Contact Block c/w collar 2N/O for PB & SS ZB4BZ104 Contact Block c/w collar 2N/C for PB & SS ZB4BZ105 Contact Block c/w collar 1N/O+1N/C for PB&SS ZBE101 Additional Contact Block 1 N/O ZBE102 Additional Contact Block 1 N/C Emergency Stop Pushbutton

ZB4AEQ4021G1 E-Stop Pushbutton Kit, Turn to Release Style Includes: ZB4BS844, ZB4BZ141, ZBZ3605, ZBY9330T

ZB4AEQ4021G2 E-Stop Pushbutton Kit, Push/Pull Style Includes: ZB4BT84, ZB4BZ141, ZBZ3605, ZBY9330T

ZB4BS844 E-Stop pushbutton head 40mm red trigger action turn to release

ZB4BT84 E-Stop pushbutton head 40mm red pull to release ZB4BZ141 Safety rated contact blocks (2) NC (1) NO

ZBZ3605 Padlockable telescopic guard attachment for conformity to Machinery directive 98/37/EC

ZBY9330T "Emergency Stop" circular tag yellow background with black lettering

Cam Switches K1E65SPEC0725 4 pos Cam selector switch (1 pos 2 N/O) + (3 pos 1 N/O) K1D65SPEC0730 3 Pos Com Selector Switch (1 pos 2 N/O) + (2 pos 1 N/O) Lighted Pushbutton Heads ZB4BW3x3 ILL Pushbutton Flush Spring Return Head note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue

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Lighted Pushbutton Body and Contact Block ZB4BW0Bx1 ILL Pushbutton Body & 1 N/O ZB4BW0Bx2 ILL Pushbutton Body & 1 N/C ZB4BW0Bx3 ILL Pushbutton Body & 2 N/O ZB4BW0Bx5 Ill Pushbutton Body & 1 N/O + 1 N/C note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue Pilot Light Head ZB4BW1x3 Pilot Light Head note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue Pilot Light Body (push to test) ZB4BW0Bx5 Pilot Light Body & 1 N/O + 1 N/C note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue 5.5.8 Sensors Inductive Proximity, tubular, extended range XS608B1PAM12 8mm Proximity Switch with Connector, extended range XS612B1PAM12 12mm Proximity Switch with Connector, extended range XS618B1PAM12 18mm Proximity Switch with Connector, extended range XS630B1PAM12 30mm Proximity Switch with Connector, extended range Inductive Proximity, short tubular, extended range XS1N08PA349D 8mm Proximity with Connector, extended range XS1N12PA349D 12mm Proximity with Connector, extended range XS1N18PA349D 18mm Proximity with Connector, extended range XS1N30PA349D 30mm Proximity with Connector, extended range Inductive Proximity, tubular, ferrous only / non-ferrous XS1M18PAS40D 18mm Proximity Switch c/w Connector, ferrous only XS1M18PAS20D 18mm Proximity Switch with Connector, non-ferrous

Photo, tubular XUB2BKSNM12T M18 thru-beam 15 meter emitter XUB2BPANM12R M18 thru-beam 15 meter receiver XUB5BPANM12 M18 diffuse 0.6 meter XUB9BPANM12 M18 polarized reflective 2 meter XUZC50 Reflector for XUB9BPANM12 XUB0BPSNM12 Diffuse with background suppression Photo, compact square body XUK5APANM12 Diffuse photos 1m nominal sensing distance XUK9APANM12 Polarized reflective photos XUZC50 Reflector for XUK9APANM12 XUK2AKSNM12T thru-beam 15 meter emitter XUK2APANM12R thru-beam 15 meter receiver XUK8AKSNM12 diffuse w/ background suppression, focus beam Fiber Optic XUDA1PSMM8 Amplifier unit for fiber sensors XUFNxxx fibers for sensing (various see catalog)

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Mechanical Limit XCKJ161D Limit Switch (2NC + NO) M12, End Plunger XCKJ167D Limit Switch (2NC + NO) M12, Roller Plunger

XCKJ10511D Limit Switch (2NC + NO) M12, Roller Lever XCKJ10541D Limit Switch (2NC + NO) M12, Variable Lever XCKJ10559D Limit Switch (2NC + NO) M12, Rod Lever

9007C54B2D5T Side rotary with M12 connector (single pole)

9007C54FD5T Side plunger with M12 connector (single pole)

9007C54DD5T Top plunger with M12 connector (single pole)

9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)

9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)

9007C54FY140Y35D5T Side plunger, viton seals, epoxy filled with M12 (single pole)

9007C54DY140Y35D5T Top plunger, viton seals, epoxy filled with M12 (single pole)

9007C62B2Y19016 Switch, limit, side rotary with 9-pin (double pole)

9007C62FY19016 Side plunger with 9-pin (double pole)

9007C62DY19016 Top plunger with 9-pin (double pole)

9007C62B2 Y140Y35M9T Side rotary, viton seals, epoxy filled with 9-pin (double pole)

9007C62FY140Y35M9T Side plunger, viton seals, epoxy filled with 9-pin (double pole)

9007C62DY140Y35M9T Top plunger, viton seals, epoxy filled with 9-pin (double pole)

Pressure XMLFM01D2035 Vacuum -1.16 PSI (-0.08 bar) to -14.5 PSI (-1.0 bar) XMLF001D2035 Pressure 1.16 PSI (0.08 bar) to 14.5 PSI (1.0 bar) XMLF002D2035 Pressure 2.9 PSI (0.2 bar) to 36.3 PSI (2.5 bar) XMLF010D2035 Pressure 12 PSI (0.8 bar) to 145 PSI (10 bar) XMLF016D2035 Pressure 19 PSI (1.3 bar) to 232 PSI (16 bar) XMLF025D2035 Pressure 29 PSI (2.0 bar) to 363 PSI (25 bar) XMLF040D2035 Pressure 46 PSI (3.2 bar) to 580 PSI (40 bar) XMLF070D2035 Pressure 81 PSI (5.6 bar) to 1015 PSI (70 bar) XMLF100D2035 Pressure 116 PSI (8.0 bar) to 1450 PSI (100 bar) XMLF160D2035 Pressure 186 PSI (12.8 bar) to 2320 PSI (160 bar) XMLF250D2035 Pressure 290 PSI (20 bar) to 3625 PSI (250 bar) XMLF400D2035 Pressure 464 PSI (32 bar) to 5800 PSI (400 bar) XMLF600D2035 Pressure 696 PSI (48 bar) to 8700 PSI (600 bar) Ultrasonic XX518A3PAM12 18mm ultrasonic tubular body, normally open (0.5-0.5 meters) XX630A1PCM12 30mm ultrasonic tubular body, normally open (0.1-1.0 meters)

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Mounting Brackets XUZA50 Mounting Bracket (Metal), for use with XUM XUZA118 Mounting Bracket (Metal), for use with XU 18mm, XUB XUZA218 Swivel Mounting Bracket (Plastic), for use with XU 18mm, XUB

XUZB2003 3D mounting kit for use with SUB, XU18, SUZC50

XUZM2003 3D mounting kit for use with XUM, SUZC50

XUZK2003 3D mounting kit for use with XUK, XUZC50

XUZX2003 3D mounting kit for with XUX, XUZC50

XUZM2004 Protective 3D mounting kit for XUM XUZK2004 Protective 3D mounting kit for XUK XUZX2004 Protective 3D mounting kit for XUX XUZ2001 M12 stem (75mm), for use with XUZB, XUZM, XUZK, XUZX

XUZ2003 3D mounting base, for use with XUZ2001 Zero Speed Detection XSAV11373LD Motion detector, range 6-150 pulse/min, 9 sec start-up delay XSAV12373LD Motion detector, range 120-3000 pulse/min, 9 sec start-up note: not to be used for safety circuits, use XPS-VN back-emf relay 5.5.9 Cables And Sensor Docks Sensor Docks ABE9C1241C23 4 channel splitter M12/M23 ABE9C1281C23 8 channel splitter M12/M23 ABE9XLA10 Marker labels (lot of 12) FTXCM12B Sealing Plugs for M12 connectors (lot 10) Molded Cables XZCP0766Lx Elbowed M8 female, 3 pin, PUR, with PNP LED XZCP0866Lx Elbowed M8 female, 3 pin, PUR, with NPN LED XZCP1340Lx Elbowed M12 female, 3 pin, PUR, with 2 PNP LEDs XZCP1440Lx Elbowed M12 female, 3 pin, PUR, with 2 NPN LEDs note: for x: 2= 2 meters, 5=5 meters, 10=10 meters XZCC43FCP40B DIN connector for field cable installation XSZEDD1020 Extension M12 to M12, PVR, 1 meter XSZEDD1040 Extension M12 to M12, PVR, 2 meters XZCR1501040G1 Extension M8 to M12, PVR, 1 meter XZCR1501040G2 Extension M8 to M12, PVR, 2 meters XZCR1523062K1 Extension DIN to M12, PVR, 1 meter XZCR1523062K2 Extension DIN to M12, PVR, 2 meters note: many more cable and connector types are available

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5.5.10 Power Supplies Phaseo 110VAC to 24VDC ABL8RPS24030 3 Amp regulated supply ABL8RPS24050 5 Amp regulated supply ABL8RPS24100 10 Amp regulated supply ABL8RPM24200 20 Amp regulated supply Phaseo 480VAC to 24VDC ABL8WPS24200 20 Amp regulated supply ABL8WPS24400 40 Amp regulated supply

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5.6 Circuit Protection and Electrical Distribution 5.6.1 Disconnect Hardware Main Panel Disconnect Mechanism 9422A1 Flange Mount Operating handle (for all mechs) 9422ATCF331 Local Fuse Disconnect to 30 Amp 9422ATDF631 Local Fuse Disconnect to 60 Amp 9422ATEF101 Local Fuse Disconnect to 100 Amp 9422ATF12 Local Fuse Disconnect to 200 Amp 9422CSF50 Flange Disconnect for HJL and JJL breakers 9422CMP50 Flange Disconnect for MJL and PJL breakers Panel Door Interlock hardware 9421… Door interlock hardware note: consult catalog for various part numbers Enclosed Safety Switch HU36xAWK Heavy Duty Enclosed Safety Switch note: for x = 1, 2, 3, or 4 for 30, 60 100, 200 Amps respectively (larger available- catalog) Secondary Disconnect 9421V1A30 10 Amp secondary disconnect 9421V2A30 15 Amp secondary disconnect IEC Style Compact Fusible Disconnect GS1GU3 IEC Fusible Disconnect, 600V, 60 Amp, 3-Pole, Class J GS1JU3 IEC Fusible Disconnect, 600V, 100 Amp, 3-Pole, Class J GS1MU3 IEC Fusible Disconnect, 600V, 200 Amp, 3-Pole, Class J 5.6.2 Circuit Breakers Powerpact Branch Circuits and Main Disconnect HJL36xxxC Molded Case Breaker, 3-pole 150 Amp frame note: for xxx = 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 125, 150 for Amps JJL36xxxC Molded Case Breaker, 3-pole 250 Amp frame note: for xxx = 150, 175, 200, 225, 250 for Amps MJL36xxx Molded Case Breaker, 3-pole 800 Amp frame note: for xxx = 300, 350, 400, 450, 500, 600, 700, 800 for Amps HJL26015C Molded Case Breaker, 2-pole for primary single phase note: larger breakers available

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Secondary Branch Circuits (110/220V) 60100 Circuit Breaker 1 pole (C curve) 0.5 Amp 60101 Circuit Breaker 1 pole (C curve) 1 Amp 60104 Circuit Breaker 1 pole (C curve) 3 Amp 60107 Circuit Breaker 1 pole (C curve) 6 Amp 60110 Circuit Breaker 1 pole (C curve) 10 Amp 60112 Circuit Breaker 1 pole (C curve) 16 Amp 60113 Circuit Breaker 1 pole (C curve) 20 Amp 60114 Circuit Breaker 1 pole (C curve) 25 Amp 60115 Circuit Breaker 1 pole (C curve) 30 Amp 60116 Circuit Breaker 1 pole (C curve) 35 Amp 60118 Circuit Breaker 1 pole (D curve) 1 Amp 60121 Circuit Breaker 1 pole (D curve) 3 Amp 60124 Circuit Breaker 1 pole (D curve) 6 Amp 60127 Circuit Breaker 1 pole (D curve) 10 Amp 60129 Circuit Breaker 1 pole (D curve) 15 Amp 60130 Circuit Breaker 1 pole (D curve) 20 Amp 60131 Circuit Breaker 1 pole (D curve) 25 Amp 60132 Circuit Breaker 1 pole (D curve) 30 Amp 60133 Circuit Breaker 1 pole (D curve) 35 Amp MG26925 Auxiliary Contact for MG Circuit Breaker Supplementary Protectors (24V only) MG24110 Circuit Breaker 1 pole (B curve) 1 Amp MG24112 Circuit Breaker 1 pole (B curve) 3 Amp MG24114 Circuit Breaker 1 pole (B curve) 6 Amp MG24116 Circuit Breaker 1 pole (B curve) 10 Amp MG17411 Circuit Breaker 1 pole (C curve) 0.5 Amp MG24425 Circuit Breaker 1 pole (C curve) 1 Amp MG24427 Circuit Breaker 1 pole (C curve) 3 Amp MG24430 Circuit Breaker 1 pole (C curve) 6 Amp MG24432 Circuit Breaker 1 pole (C curve) 10 Amp MG24434 Circuit Breaker 1 pole (C curve) 16 Amp MG24435 Circuit Breaker 1 pole (C curve) 20 Amp MG24436 Circuit Breaker 1 pole (C curve) 25 Amp MG17421 Circuit Breaker 1 pole (D curve) 1 Amp MG24500 Circuit Breaker 1 pole (D curve) 1 Amp MG24502 Circuit Breaker 1 pole (D curve) 2 Amp MG24504 Circuit Breaker 1 pole (D curve) 6 Amp MG24506 Circuit Breaker 1 pole (D curve) 10 Amp MG24508 Circuit Breaker 1 pole (D curve) 16 Amp MG24509 Circuit Breaker 1 pole (D curve) 20 Amp MG24510 Circuit Breaker 1 pole (D curve) 25 Amp MG26925 Auxiliary Contact for MG Circuit Breaker

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5.6.3 Fuse Blocks & Splitter Blocks CC fuse holder in GV2 form factor LS1D30 CC fuse holder in GV2 form factor for low current 460 circuits DFCC3V CC fuse holder with blown fuse detection Distribution Blocks Square D 9080 Consult Schneider Electric catalog Fuse Blocks Square D 9080 Consult Schneider Electric catalog 5.6.4 Transformers Control Transformers 9070TF500D1 Control Transformer 500VA 240/480V-24V note: other sizes available consult catalog Isolation Transformers, 3-phase xxxTxxxHDIT Isolation transformer note: consult catalog for appropriate voltages and VA ratings Transformer Disconnects 9070SKxxxA2D1E23G1y 480Vx120V electrostatically shielded with duplex note: for x = 250, 500, 750, 1000, 1500, 2000, 3000 for VA rating note: for y = 3 for standard duplex or 4 for GFI receptacle

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6 Revision Log Home

6.1 Version 2.0 Revision Detail 3.1 Removed the “Mixed Architecture”

Changed the order of the architecture presentations Removed presentation of Twido PLC as part of assembly station Home

3.3 Added representation of Twido for simple standalone machines 4.1.2 Removed XBT-N display

Added IPC with note that Chrysler approval is required 6.1 Updated drawing of standard PDP 8.1.1 Corrected M340 CPU part numbers

Added more powerful M340 power supply 8.1.3 Removed XBT-N 8.2.1 Corrected switch part numbers 8.4.2 Updated part number for safety controller 8.5.4 Updated part numbers for higher amperage MCPs 8.5.8 Updated ultrasonic sensor part numbers 8.5.10 Updated power supply part numbers 8.6.4 Corrected transformer disconnect part number

6.2 Version 3.0 Revision Detail 2 Removed Home 2.1 Removed 2.2 Moved to new section 2 Scope of Supply 2.3 Removed 2.4 Moved to new section 2.1.3 Networks 3 Architectures moved to new section 3.1 Changed “Anything In Between” to “Hybrid” 3.1.1 Updated graphic 3.1.2 Updated graphic 3.1.4 Updated graphic 3.1.7 Updated graphic and changed to “Hybrid” 3.2.1 Updated graphic 3.2.2 Updated graphic for gantry 3.3 Removed graphic showing Twido for simple machine 4,5,6 Moved to new section 2 Scope of Supply 4.1.1 (now 2.1.1) Removed Twido and added Quantum 4.1.2 (now 2.1.2) Added Factorycast HMI and Citect Scada 4.2 Moved to 2.1.3 and rearranged 5 Moved to 2.2 Control Products and revised 5.2 Moved to 2.1.4 Motion Control and Drives and revised 6 Split into 2.1.5 Safety and 2.3 Power Distribution and revised New Added section 2.4 System Capabilities 7 Becomes section 4 8 Becomes section 5, added web and product links, corrected links throughout section 8.1.1 (now 5.1.1) Added memory card, removed Twido processor and memory card 8.1.2 (now 5.1.2) Removed Twido modules New Added 5.1.3 PLC programming software New Added 5.1.4 PLC programming cables 8.1.3 (now 5.1.5) Removed 5.7” HMIs, added HMI software, added XBTGK keypad HMI 8.2.1 (now 5.2.1) Added several Connexium switches

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8.3.1 (now 5.3.1) Removed Twido I/O modules 8.3.2 (now 5.3.2) Added Twido I/O modules to be used with OTB as remote I/O 8.3.3 (now 5.3.3) Added Asi 4 input module w/ dual M12 8.5.4 (now 5.5.4) Added higher range contactors, added mounting hardware, added GV7 part

numbers, revised Asi motor starter part numbers 8.5.5 (now 5.5.5) Added RUM series relays, deleted RUX 8.5.6 (now 5.5.6) Changed Beacon lens to LED type 8.5.7 (now 5.5.7) Added e-stop pushbutton and padlock guard, added additional contact blocks 8.5.8 (now 5.5.8) Corrected XS5 part numbers to XS6, added larger ultrasonic sensors, added

mounting brackets, updated zero speed detection part numbers, replaced 9007 limits with XCKJ

8.6.1 (now 5.6.1) Revised disconnect part numbers to reflect type A1 8.6.2 (now 5.6.2) Added 110V circuit breakers for D curve 8.6.3 (now 5.6.3) Added fuse holder w/ blown fuse detection

6.3 Version 4.0 Revision Detail All Removed Daimler name Home 1 Updated contact information 2.3.1 – 2.3.5

Removed sections relating to power distribution

2.4.2 Removed turn key systems information 5.1.1 Added Premium PL7 single slot L3 CPU 5.5.4 Added D-line overload relays 5.5.7 Added part numbers for e-stop pb 5.5.8 Added part numbers for 9007 series limit switches 5.6 Changed name to Circuit Protection and Electrical Distribution 5.6.1 Added part numbers for GS1 compact fusible disconnect switches 5.6.5 Removed Busway components

6.4 Version 5.0 Revision Detail 4-66 Renumbered pages Home 4 Updated contact information with contacts for Mexico & India 66 Added revision detail sheet

6.5 Version 6.0 Revision Detail 1 Added link to brand information & added contact information for Italy

Home 2.1.2 Added Smart iPC, updated graphics 2.1.3 Updated Connexium graphic, added Ethernet/IP 2.2.1 Added ETB graphic 2.2.2 Added Tesys T motor management system graphic 5 Updated links 5.1.1 Added 600 series processor, updated M340 part number for BMXP3420302 processor, added

128 M memory card 5.1.2 Added TSXETC100 and BMXNOE0110, updated part number BMXEIA0100 5.1.3 Updated part numbers for Unity Pro to reflect latest version and PL7 Pro typo 5.1.5 Updated part numbers for Vijeo Designer for latest version, updated Magelis Compact part

numbers, added Magelis Smart iPC 5.2.1 Added 3-port unmanaged switch, updated part number for 5-port unmanaged switch 5.2.3 Updated part number for cable tee TCSATN011F 5.3.1 Updated part numbers for M340 input and output modules (typos) 5.3.1 Added STBNIC2212 Ethernet/IP interface module, changed STB I/O modules to connection

kits instead of individual parts for easier ordering, updated part numbers for OTB IP20 I/O to new numbers

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5.3.3 Updated part numbers for FTB modules for typo, updated typo in ASI67FFP43EY, added ETB modules and accessories

5.4.1 Updated XPSVNE1142P, removed XPSN3440 standstill monitoring relay due to obsolescence 5.5.2 Corrected typo in Lexium Network Interface modules AM0… 5.5.3 Replaced ATV31 with ATV312 (direct replacement), corrected part number ATV71HU55N4,

added ATV71 Ethernet/IP module, added ATS22 softstart 5.5.4 Updated part numbers LC2D40ABD, LC2D50ABD, LC2D65ABD now with Everlink, updated

GV2AF4 for typo, added Tesys-T motor management system part numbers 5.5.6 Added XVC stack lights. 5.5.8 Updated part number XUB0BPSNM12 due to obsolescence, corrected part number XUZA50 5.5.9 Replaced Elbowed molded cables with new part numbers due to obsolescence