Compact / Hardwired / HMI Controller / XBTGC ... - Schneider Electric

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Compact / Hardwired / HMI Controller / XBTGC ... - Schneider Electric

This document is based on European standards and is not valid for use in U.S.A.

Compact / Hardwired /

HMI Controller / XBTGC

System User Guide

EIO0000000287

MAY 2010


Contents

Important Information ................................................................................................................2

Before You Begin..................................................................................................................3

Introduction ................................................................................................................................5

Abbreviations........................................................................................................................6

Glossary ................................................................................................................................7

Application Source Code .....................................................................................................8

Typical Applications.............................................................................................................9

System ......................................................................................................................................10

Architecture.........................................................................................................................10

Installation...........................................................................................................................13

Hardware ..........................................................................................................................................................16

Software ...........................................................................................................................................................32

Communication ...............................................................................................................................................33

Implementation ...................................................................................................................34

Controller .........................................................................................................................................................36

HMI....................................................................................................................................................................64

Devices ................................................................................................................................72

Altivar 12 ..........................................................................................................................................................73

Altivar 312 ........................................................................................................................................................76

Lexium 32C ......................................................................................................................................................79

Appendix...................................................................................................................................83

Detailed Component List....................................................................................................83

Component Protection Classes.........................................................................................86

Component Features..........................................................................................................87

Contact......................................................................................................................................92

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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.

The addition of this symbol to a Danger or Warning safety label indicates that an

electrical hazard exists, which will result in personal injury if the instructions are not

followed.

This is the safety alert symbol. It is used to alert you to potential personal injury

hazards. Obey all safety messages that follow this symbol to avoid possible injury or

death.

DANGER

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation, which, if not avoided, can result in

death, serious injury, or equipment damage.

CAUTION

CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in

injury or equipment damage.

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 the installation, and has received safety

training to recognize and avoid the hazards involved

© 2008 Schneider Electric. All Rights Reserved.

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Before You Begin

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-ofoperation

guarding on a machine can result in serious injury to the operator of that machine.

WARNING

UNGUARDED MACHINERY CAN CAUSE SERIOUS INJURY

Do not use this software and related automation products on equipment which does not have

point-of-operation protection.

Do not reach into machine during operation.

Failure to follow these instructions can cause 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 the user can be aware of all the conditions and factors present during setup, operation and maintenance of

the machine; therefore, only the user 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, the user should refer to the applicable local and national standards and regulations. A

“National Safety Council’s” Accident Prevention Manual 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 by itself cannot protect

an operator from injury. For this reason the software cannot be substituted for or take the place of point-ofoperation

protection.

Ensure that appropriate safeties and mechanical/electrical interlocks for point-of-operation protection have been

installed and are operational before placing the equipment into service. All mechanical/electrical interlocks and

safeties for point-of-operation protection must be coordinated with the related automation equipment and software

programming.

NOTE: Co-ordination of safeties and mechanical/electrical interlocks for point-of-operation protection is

outside the scope of this document.

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.

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CAUTION

EQUIPMENT OPERATION HAZARD

Verify that all installation and set up procedures have been completed.

Before operational tests are performed, remove all blocks or other temporary holding means

used for shipment from all component devices.

Remove tools, meters and debris from equipment.

Failure to follow these instructions can result in injury or equipment damage.

Follow all start up tests recommended in the equipment documentation. Store all equipment documentation for

future reference.

Software testing must be done in both simulated and real environments.

Verify that the completed system is free from all short circuits and grounds, except those grounds installed

according to local regulations (according to the National Electrical Code in the U.S.A, for instance). If high-potential

voltage testing is necessary, follow recommendations in equipment documentation to prevent accidental

equipment damage.

Before energizing equipment:

• Remove tools, meters, and debris from equipment.

• Close the equipment enclosure door.

• Remove ground from incoming power lines.

• Perform all start-up tests recommended by the manufacturer.

OPERATION AND ADJUSTMENTS

The following precautions are from NEMA Standards Publication ICS 7.1-1995 (English version prevails):

Regardless of the care exercised in the design and manufacture of equipment or in the selection and rating of

components, there are hazards that can be encountered if such equipment is improperly operated.

It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always

use the manufacturer’s instructions as a guide for functional adjustments. Personnel who have access to these

adjustments should be familiar with the equipment manufacturer’s instructions and the machinery used with the

electrical equipment.

Only those operational adjustments actually required by the operator should be accessible to the operator. Access

to other controls should be restricted to prevent unauthorized changes in operating characteristics.

UNEXPECTED EQUIPMENT OPERATION

WARNING

Only use software tools approved by Schneider Electric for use with this equipment.

Update your application program every time you change the physical hardware configuration.

Failure to follow these instructions can cause death, serious injury or equipment

damage.

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Introduction

Introduction

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 might be implemented.

The architecture described in this document has been fully tested in our laboratories using

all the specific references you will find in the component list near the end of this document.

Of course, 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.

It should be noted that 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. You must 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.

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Abbreviations

Abbreviation

AC

CB

CFC

DI

DO

DC

E-STOP

FBD

HMI

I/O

IL

LD

PC

POU

PS

RMS

RPM

SE

SFC

ST

TVDA

VSD

WxHxD

Signification

Alternating Current

Circuit Breaker

Continuous Function Chart – a programming language based on

function chart

Digital Input

Digital Output

Direct Current

Emergency Stop

Function Block Diagram – an IEC-61131 programming language

Human Machine Interface

Input/Output

Instruction List - a textual IEC-61131 programming language

Ladder Diagram – a graphic IEC-61131 programming language

Personal Computer

Programmable Object Unit, Program Section in SoMachine

Power Supply

Root Mean Square

Revolution Per Minute

Schneider Electric

Sequential Function Chart – an IEC-61131 programming language

Structured Text – an IEC-61131 programming language

Tested, Validated and Documented Architecture

Variable Speed Drive

Dimensions : Width, Height and Depth

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Glossary

Expression

Altivar (ATV)

Harmony

Lexium (LXM)

Magelis

Magelis XBTGC HMI

controller

Modbus

OsiSense

Phaseo

Preventa

SoMachine

TeSys

Vijeo Designer

Signification

SE product name for a family of VSDs

SE product name for a family of switches and indicators

SE product name for a family of servo drives

SE product name for a family of HMI-Devices

SE product name for a HMI controller

A Communications protocol

SE product name for a family of sensors

SE product name for a family of power supplies

SE product name for a family of safety devices

SE product name for an integrated software tool

SE product name for a family for motor protection devices and

load contactors

An SE software product for programming Magelis HMI devices

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Application Source Code

Introduction

Examples of the source code and wiring diagrams used to attain the system function as

described in this document can be downloaded from our website (registration is required,

contact your Schneider Electric Application Design Expert).

The example source code is in the form of configuration, application and import files. Use the

appropriate software tool to either open or import the files.

Extension File Type Software Tool Required

CSV Comma Separated Values, Spreadsheet MS Excel

DWG Project file AutoCAD

DOC Document file Microsoft Word

PDF Portable Document Format - document Adobe Acrobat

PROJECT Project file SoMachine

RTF Rich Text File - document Microsoft Word

VDZ Project file Vijeo Designer

Z13 Project archive file EPLAN

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Typical Applications

Introduction

Here you will find a list of the typical applications and market segments, where this

system or subsystem can be applied:

Textile

Opening and closing machines

Circular knitting machines

Plucker machines

Blending machines

Pumping

Booster stations

Compressors

Vacuum pumps

HVAC-R

Compressors

Other Machines

Wood working machines

Cutting machines

Sanding machines

Sawing machines

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System

Introduction

The system chapter describes the architecture, the dimensions, the quantities and different

types of components used within this system.

Architecture

General

The controller in this application is a Magelis XBTGC HMI controller. The user can control

and monitor the application using the HMI display of the controller. The motor drives, which

are hardwired to the controller, are of the type Altivar 12, Altivar 312 and servo drive Lexium

32C.

The example application includes two functional safety options according to

EN ISO 13849-1 standards: an Emergency Stop function supervised by a Preventa safety

module (see the appropriate hardware manual), plus a second Preventa safety module to

evaluate protective door sensors.

Layout

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Components

Hardware:















Compact NSX100F main switch

Phaseo ABL8 power supply unit 230 Vac / 24 Vdc

Magelis XBTGC HMI controller

Motor circuit breaker GV2L (Short Circuit protected) for the motor drives

TeSysD load contactors LC1D

Altivar 12 and Altivar 312 variable speed drives

Lexium 32C servo drive

BMH servo motor

Multi9 circuit breaker

Emergency Stop switch with rotation release XALK

Harmony illuminated push buttons XB5

OsiSense limit switches

Preventa guard switch

Preventa safety module

Software:

SoMachine V2.0

Quantities of

Components

For a complete and detailed list of components, the quantities required and the order

numbers, please refer to the components list at the rear of this document.

Degree of

Protection

Not all the components in this configuration are designed to withstand the same

environmental conditions. Some components may need additional protection, such as

housings, depending on the environment in which you intend to use them. For

environmental details of the individual components please refer to the list in the appendix of

this document and the corresponding user manual.

Cabinet

Technical

Data

Input

Mains voltage

Power requirement

Cable size

Cable connection

400 Vac

~ 3 kW

5 x 2.5 mm² (L1, L2, L3, N, PE)

3 phase + Neutral + Ground

Neutral is needed for 230 Vac (Phase and Neutral)

Output

Motor power ratings

1 asynchronous motor controlled by ATV12 (0.37 kW)

1 asynchronous motor controlled by ATV312 (0.37

kW)

1 servo motor (BMH type without brake) controlled

by LXM32C (continuous output current : 6 A RMS at

6000 RPM)

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Functional

Safety Notice

(EN ISO13849-1

EN IEC62061)

The standard and level of functional safety you apply to your application is determined by

your system design and the overall extent to which your system may be a hazard to people

and machinery.

As there are no moving mechanical parts in this application example, category 1 (according

to EN13849-1) has been selected as an optional safety level.

Whether or not this functional safety category should be applied to your system should be

ascertained with a proper risk analysis.

This document is not comprehensive for any systems using the given architecture and does

not absolve users of their duty to uphold the functional safety requirements with respect to

the equipment used in their systems or of compliance with either national or international

safety laws or regulations.

Emergency

Stop

Safety

Functions

Emergency Stop / Emergency Disconnection function

This function for stopping in an emergency is a protective measure which compliments the

safety functions for the safeguarding of hazardous zones according to prEN ISO 12100-2.

Door guarding :

up to Performance Level (PL) = b, Category 1, Safety Integrity Level (SIL) = 1

Dimensions

The dimensions of the individual devices used; controller, drive, power supply, etc. require

a housing cabinet size of at least 1000 x 800 x 400 mm (WxHxD).

The HMI display, illuminated indicators such as “SYSTEM ON“, “SYSTEM OFF“ or

“ACKNOWLEDGE EMERGENCY STOP“ as well as the Emergency Stop switch itself, can

be built into the door of the cabinet.

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Installation

Introduction

This chapter describes the steps necessary to set up the hardware and configure the

software required to fulfill the described function of the application.

Assembly

Main cabinet

front

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Main cabinet

interior

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Notes

The components designed for installation in a cabinet, i.e. safety module, circuit breakers,

contactors, motor circuit breakers, power supply can be mounted on a 35 mm DIN rail.

The Magelis XBTGC HMI controller is mounted in the panel door.

TM2 IO modules are plugged on XBTGC base.

Main switches, Lexium 32C servo drives and Altivar 12, Altivar 312 variable speed drives

are screwed directly onto the mounting plate. Alternatively, if an adapter is used, the Altivar

312 can be mounted on a DIN rail.

The Emergency Stop button, the door guard switches and the pushbutton housing for the

display and acknowledgement indicators are designed for on-wall mounting in the field. All

switches (except the door guard switch) can also be installed directly inside a control

cabinet (e.g., in a cabinet door) without special housings.

There are two options for installing XB5 pushbuttons or indicator lamps:

These pushbuttons or switches can be installed either in a 22 mm hole, e.g., drilled

into the front door of the control cabinet,

or in an XALD-type housing suitable for up to 5 pushbuttons or indicator lamps.

The XALD pushbutton housing is designed for backplane assembly or direct wall

mounting.

400 Vac 3-phase wiring between the main circuit breaker, drives and motors.

230 Vac 1-phase wiring between the main circuit breaker and Lexium 32C drive.

230 Vac 1-phase wiring between the main circuit breaker and primary side of the 24 Vdc

power supply.

24 Vdc wiring for control circuits and the controller, I/O modules and the HMI power supply.

The individual components must be interconnected in accordance with the detailed circuit

diagram in order to ensure that they function correctly.

The modules and I/O listed here are a representative cross section of the modules and

indicators required to implement the application as defined in this document and will

without doubt differ from your own specific application.

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Hardware

General

General description of the hardware.

Main switch

Compact NSX100F

LV429003

36 kA 380/415 Vac

Main Switch

Compact NSX100F

LV429035

Trip unit TM32D

Thermal-magnetic 32 A

Ir - Thermal protection

Im - Magnetic protection

Main Switch

Compact NSX100F

Rotary handle

LV429340

Terminal shield

LV429515

Rotary handle with red

handle on yellow front

Terminal shield short

Emergency Stop

Switch

Harmony

XB5AS844 +

XB5AZ141

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Power Supply

Phaseo

ABL8RPS24050

Primary 200…500 Vac,

Secondary 24 Vdc,

120 W, 5 A

Magelis XBTGC

HMI controller

XBTGC2230T

16 Digital Inputs incl.

4 Fast Inputs,

16 Digital Outputs incl.

4 Fast Outputs

24 Vdc Input, STN Color

5.7” LCD, 320 x 240

Pixels, 4096 Colors, 16

MB Application Flash

EPROM with Built-in

Ethernet

HMI controller

Magelis

XBTGC2230T

Parts Description

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HMI Controller

Magelis

XBTGC2230T

Digital I/O Interface

(connector)

HMI Controller

Magelis

XBTGC2230T

Input circuit

The dotted line shows

the connection to the

sink output type

HMI Controller

Magelis

XBTGC2230T

Output circuit

(source type)

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TM2 I/O Expansion

Module

TM2DDI16DT

16 Digital Inputs, 24 Vdc

Sink/Source, Removable

Screw Terminal Block

(a) Source inputs

(b) Sink inputs

TM2 I/O Expansion

Module

TM2AVO2HT

2 Analog Outputs

(-10…+10 Vdc)

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TM2 I/O Expansion

Module

TM2AMM6HT

4 Analog Inputs

(0…10 Vdc / 4…20 mA)

2 Analog Output

(0..10 Vdc / 4..20 mA)

Motor Circuit Breaker

(Short Circuit

Protected)

GV2L07

and

GV2L14

Used together with

auxiliary contact

GVAE11

Contactor

TeSysD

LC1D09BD

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Circuit Breaker

Multi9

23726, 23728, 23747,

24517 and 23756

Variable Speed Drive

Altivar 12

ATV12H037M2

1-phase

230 Vac, 0.37 kW

External 0…10 Vdc

Analog Signal as

Speed Reference

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Variable Speed Drive

Altivar 312

ATV312H037N4

3-phase

400 Vac, 0.37 kW

External 0…10 Vdc

Analog Signal as

Speed Reference

1. Line choke, if used

2. Detected fault relay contacts, for remote

indication of the drive status

3. Braking resistor, if used

Variable Speed Drive

Altivar 312

ATV312H037N4

Terminal connection

The following is

mandatory to ensure

that the logic inputs can

be energized using

XBTGC transistor

outputs:

Toggle the logic input

configuration switch to

CLI position

Connect the CLI

terminal to the 0 Vdc

reference potential

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Servo Drive

Lexium 32C

LXM32CD18M2

1-phase

230 Vac,

Continuous output

current :

6 A RMS at 6000 RPM.

Servo Drive

Lexium 32C

LXM32CD18M2

Embedded Human

Machine Interface

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Servo Drive

Lexium 32C

LXM32CD18M2

Control Panel Overview

of the Signal Connectors

Servo Drive

Lexium 32C

LXM32CD18M2

Power Connection CN1

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Servo Drive

Lexium 32C

LXM32CD18M2

Connection to the

controller supply

Voltage and STO

CN2

The controller supply

voltage (24 Vdc) must

be connected for all

operating modes

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Servo Drive

Lexium 32C

LXM32CD18M2

Signal Connector

CN3

A: Encoder Cable

Connection to Motor

(Length 3 m)

VW3M8102R30

Servo Drive

Lexium 32C

LXM32CD18M2

Motor Connection

Power Cable

Connection to Motor

(Length 3 m)

VW3M5101R30

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Servo Drive

Lexium 32C

LXM32CD18M2

Signal Connector

CN5

Servo Drive

Lexium 32C

LXM32CD18M2

Wiring diagram holding

brake

Servo Drive

Lexium 32C

LXM32CD18M2

Parallel connection of DC

bus.

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Servo Drive

Lexium 32C

LXM32CD18M2

Connecting the external

braking resistor

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Servo Drive

Lexium 32C

LXM32CD18M2

Wiring diagram, digital

inputs/outputs

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Servo Motor

BMH0702T06A2A

Connected to Motor

Terminals and CN3 of

LXM32 using the cables

VW3M5101R30 and

VW3M8101R30

respectively.

Safety Module

Preventa

XPSAC5121

Guard Switch

Preventa

XCSPA792

with actuator

XCSZ02

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Limit Switch

OsiSense

XCKP2118P16

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Software

General

The main programming work lies in programming the Magelis XBTGC HMI controller and

creating the screens for the HMI display.

Programming the Magelis XBTGC HMI controller is done using SoMachine.

Programming the HMI display of the Magelis XBTGC HMI controller is done by using Vijeo

Designer which is integrated into SoMachine.

Configuration of the drives (ATV12, ATV312 and LXM32C) is done using the control panel

on the drive.

To use the software packages, your PC must have the appropriate Microsoft Windows

operating system installed:


Windows XP Professional

The software tools have the following default install paths:

SoMachine

C:\Program Files\Schneider Electric\SoMachine

Vijeo Designer (Installed with SoMachine)

C:\Program Files\Schneider Electric\Vijeo Designer

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Communication

General

The Magelis XBTGC HMI controller is a combination of controller and HMI display.

The download from the PC to the controller and to the HMI display is done using a single

connection.

The local control panel is used to configure the ATV312, the ATV71 and the LXM32A.

PC ↔ XBTGC

The download direction

is from the PC to the

XBTGC HMI Controller

using the transfer cable

XBTZG935.

PC ↔ XBTGC

connection cable

XBTZG935

1. PC

2. XBTGC HMI controller

3. USB to USB cable XBTZG935

Cable for the connection

between a SoMachineequipped

PC and

XBTGC

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Implementation

Introduction

The implementation chapter describes all the steps necessary to initialize, to configure, to

program and start-up the system to achieve the application functions as listed below.

Function

Functional

Layout

Start up and functional description

1. Verify all motor circuit breakers and Multi9 circuit breakers are in the ON position.

2. Verify that the mains switch is in the ON position.

3. Press the "ACKN E-STOP" blue illuminated pushbutton on the main cabinet door

to acknowledge the system is energized. The blue illuminated pushbutton will turn

OFF if the system is energized.

4. Ensure that all machine interlocks are engaged (i.e. the door guard switches)

5. Press the "ACKN DOOR-READY" blue illuminated pushbutton on the main cabinet

door to acknowledge the system is ready for operation. The blue illuminated

pushbutton will turn OFF if the system is ready for operation.

6. Use Magelis XBTGC HMI to control/monitor the system.

a. Manual Mode: Using the screens ATV12, ATV312 and LXM32C you can

control the drives individually by touching the buttons FWD, REV, STOP

and RESET. You can also individually adjust their manual speeds here.

b. Local Mode: Control the drives from the selector switch located outside the

cabinet. Reset drive faults by acknowledging the red illuminated push

button. Use the screens ATV12, ATV312 and LXM32C, individually adjust

their automatic speeds here.

c. Use the XBTGC screen to configure the HMI.

d. The “BUS”, “ALARM”, “SAFETY” screens can be used to monitor the

network, system status and alarm messages.

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Course of

Action

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Controller

Introduction

Preconditions

The controller chapter describes the steps required for the initialization and configuration

and the source program required to fulfill the functions.

In order to proceed you require the following:




SoMachine V2 is installed on your PC

The Magelis XBTGC HMI controller is switched on and running

The Magelis XBTGC HMI controller is connected to the PC via the cable

XBTZG935

Setting up the controller is done as follows:


















Create a new project

Add the controller

Add I/O expansion modules

Configure I/O expansion modules

Configure PTO function for LXM32C

Map I/O module variables to existing variables

Add Toolbox Library

Add POU

Add Symbol configuration

Configure Task

Configure controller ↔ HMI Data Exchange

Communication settings controller ↔ PC

Save the Project

Build Application

Download the controller and HMI project

Login to the controller

Application overview

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Create a new

project

1 To create a new project select

Create new machine.

2 Select Start with empty

project.

3 In the Save Project As

dialog enter a File name and

click on Save.

NOTE:

As default the project is saved

under My Documents.

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4 The SoMachine User

Interface opens.

5 Select the Program tab

6 The Program window appears

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Add the

Controller

1 In the Devices browser, right

click on

Optimized_HW_XBTGC.

Select

Add Device…

in the pop up menu.

2 Select Schneider Electric as

Vendor. Then select:

HMI Controller

XBTGC2230

as device.

Click on Add Device.

Click on Close.

3 The Devices browser now

displays the new controller

Add I/O

expansion

modules

1 To add expansion modules to

the controller, right click on

XBTGC2230 in the devices

browser and select:

Add Device….

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2 In the Add Device dialog,

select the required I/O

expansion modules and click

on Add Device.

This project requires the

following modules:

1x TM2DDI16DT

1x TM2AVO2HT

1x TM2AMM6HT

3 After adding the third module, the

device list shows now only the

Expert Expansion Modules

for CANbus-

Click on Close.

Note:

A Magelis XBTGC2000 Series

HMI controller can be expanded

with up to three I/O expansion

modules depending on the

module combination. Please

refer to SoMachine Help under

the Help menu or the HMI

controller’s user manual for more

information.

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4 The added expansion modules

can now be seen in the device

list.

Note:

The sequence of the modules

have to be consistent with the

sequence of the actual

hardware, i.e. in this

application, the TM2DDI16DT

module is attached to the

expansion module interface

EXT 1 of the controller and

theTM2AVO2HT module to the

expansion interface of the

TM2DDI16DT module.

Configure I/O

expansion

modules

1 To configure an expansion

module, double click on it.

Here we will configure the

analog output of the expansion

module TM2AVO2HT.

2 In the I/O Configuration tab,

the Value of the Enumeration

of BYTE for the Type of QW0

is changed to -10..10 V.

After selecting, press Enter to

accept the new selection.

The Value of the Enumeration

of BYTE for the Scope of QW0

can be set to Normal (fixed

min and max values) or

Customized.

For this project, it is set to

Normal.

After selecting, press Enter to

accept the new selection.

Output QW1 is not configured

in this project.

Optimized HW XBTGC Schneider Electric 41


Configure

PTO function

for LXM32C

1 To configure the PTO function,

double click on

Embedded Functions →

PTO_PWM

in the Device list.

2 In the I/O Configuration tab the

Value of the Enumeration of

BYTE for the Mode of PTO00 is

changed to PTO.

3 The library that manages the

PTO of the XBTGC controller is

located inside the Library

Manager.

Double click on Library Manager

in the Device browser to open

the Library Manager editor.

4 The Library Manager editor has

the following components:

1. Libraries currently included

in the project

2. Modules (for example: FBs)

of the currently selected

library showed in the lower

part of the Library Manager

3. Information of the module

currently selected in the

lower part of the Library

Managed

The library XBTGC PTOPWM is

directly loaded into the project

when a XBTGC2230 HMI

controller is used in the

application.

Optimized HW XBTGC Schneider Electric 42


5 When you select the XBTGC

PTOPWM library from the list,

the PTO modules are displayed

in the lower left part of the editor.

6 In the lower right part of the

editor, the following tabs are

displayed:

Inputs/Outputs tab

7 Graphical tab

8 Documentation tab

Optimized HW XBTGC Schneider Electric 43


9 More information on the

XBTGC libraries and the PTO

function can be found inside

the Online Help.

To open the Online Help

window left click on

Help →

Contents

Optimized HW XBTGC Schneider Electric 44


Map I/O

Module

variables to

existing

variables

1 On the Extension Bus I/O

Mapping tab it is possible to map

the data of QW0 to a variable.

There are two ways of Mapping:

Create a new variable

Mapping to an existing

variable

In this project, Map to existing

variable was used, i.e. the

output is mapped to an existing

variable that is located in the

folder Application→GVL.

GVL stands for Global Variables

List which can be accessed

throughout the Application

folder.

The GVL is opened by double

clicking on GVL in the Devices

browser.

In this application,

q_wAtv312SpdRef is declared

as a WORD variable in the

Application’s GVL

(Application.GVL.q_wAtv312

SpdRef) prior to mapping the

data QW0 to it.

2 To map the Outputs to an

existing variable, double click on

the output Variable field then

click on the … button that

appears at the end of the field.

In the Input Assistant dialog

that opens, locate the variable

inside the Global Variables

category and select it.

Then click OK.

Optimized HW XBTGC Schneider Electric 45


3 The analog module’s output

WORD, QW0, will now maps

itself to

Application.GVL.q_wAtv312

SpdRef.

To update the status of all the

I/O variables in every cycle with

the newest I/O data, check the

Always update variables box.

If left unchecked, only the

status of the I/O variables that

are called in the POUs are

updated.

Note:

The status of the mapped I/O

variables that are used in the

HMI but are not called by any

POU are not updated if the

Always update variables box is

unchecked.

Add TeSys

Library

1 In this application, the function

block MOT2D1S were used to

manage the forward and

reverse control of the ATV12,

ATV312 and LXM32C drives.

2 The current libraries in the

project are located in the

Library Manager.

Double click on Library

Manager in the Devices

browser to open the Library

Manager editor.

3 To add the library, click on Add

library… in the Library

Manager editor.

Optimized HW XBTGC Schneider Electric 46


4 In the Add library dialog,

Placeholder tab, select:

Placeholder name: SE_TeSys

select:

Devices →

select:

→ TeSys Library 2.0.0.5

And click on OK to insert the

TeSys Library into the Library

Manager.

5 The new library can now be

seen in the Library Manager

editor list.

Optimized HW XBTGC Schneider Electric 47


6 More information on the TeSys

library, its modules and other

Schneider Electric libraries can

be found in the SoMachine

Online Help under the Help

menu by click on Contents.

7 Information on System libraries

and their modules can be found

in the Online Help under the

folder CoDeSys -> Libraries

8 Repeat steps 2 through 4 to add more libraries.

Add POU 1 To add a POU to the project,

right click on:

Application

in the Devices browser and

select:

Add Object…

in the pop-up menu.

Optimized HW XBTGC Schneider Electric 48


2 In the Add Object dialog,

select POU and enter a Name

e.g. ATV_CONTROL.

Select Program as the Type

and CFC as the

Implementation language.

It is possible to select any of

the IEC languages and to

generate functions and

function blocks.

Click on Open to exit the

dialog.

3 The new POU ATV_CONTROL

is now visible in the Devices

browser under the Application

folder.

4 The tab ATV_CONTROL is

opened in the Editor. It is

divided in the following sections:

1. Declaration section

2. Programming section

3. ToolBox – use drag and

drop to place programming

elements in the

programming section

5 Begin by placing a box element

in the programming section.

Click on ???.

6 Type in a name for the

function or function block. As

you start to type, a hint list

opens.

In this project, the MOT2D1S

FB was used for controlling

the forward and reverse

commands of the drives.

Select MOT2D1S from the list

and press Enter twice.

Optimized HW XBTGC Schneider Electric 49


7 To instantiate the FB, click on

??? and type in a name (for

example fbAtv312Ctrl) and

press Enter.

8 The Auto Declare dialog

opens.

A variable comment can be

added in the Comment box.

Click OK to create the instance.

9 The new FB MOT2D1S is

instantiated in the declaration

section of the ATV_CONTROL.

Optimized HW XBTGC Schneider Electric 50


10 To connect a variable to an

input, place an input element

from the ToolBox on the input

side of the FB and connect

the input box to a FB input by

clicking on the red end and

dragging it to the input of the

FB.

Click on ??? in the input box

and insert the variable name:

i_xSelSwcLocFwd

In the Auto Declare dialog that

opens, select the Scope and

Type and confirm the variable

Name.

In this example, select

VAR_GLOBAL and BOOL from

the Scope and Type list box

respectively.

11 Connecting a variable to an

output is done similar to the

input, but here, a new variable

is created.

Click on the ??? in the output

field, type in a name for the

variable and then press Enter.

In the Auto Declare dialog that

opens, select the Scope and

Type and confirm the variable

Name.

In this example, select

VAR_GLOBAL and BOOL from

the Scope and Type list box

respectively.

When finished, click on OK.

Optimized HW XBTGC Schneider Electric 51


12 The VAR_GLOBAL variables

are located in the GVL folder.

All variables located in this

folder can be accessed

throughout the Application

folder. If the variables are

located in the POU, they can

only be accessed by the POU

(local variables).

Global Variables (Application Specific)

Local Variables (POU Specific)

Task

configuration

1 The Task Configuration in the

Devices browser defines one or

several tasks for controlling the

processing of an application

program.

To start working with a new

POU, it has to be called within

a Task.

In this application, all POUs are

implemented by the POU

Application_Main, which is

added to the MAST task.

To do this, first add a POU

called Application_Main and

call the POUs from here. In this

application, the POU called is

ATV_CONTROL.

2 Double click on MAST task.

Optimized HW XBTGC Schneider Electric 52


3 In the MAST tab, click on Add

POU.

4 In the Input Assistant dialog,

select Programs (Project)

from the Categories list and

select the new POU from the

Items list.

In this application, the new

POU is Application_Main.

Click on OK to confirm.

Note:

POUs that are added to the

MAST task are called every

cycle.

5 The POU is now included in the

MAST task.

The Type of task can be

modified.

For this project, select

Freewheeling.

Optimized HW XBTGC Schneider Electric 53


Configure

controller ↔

HMI Data

Exchange

1 To link the variables between

the controller and the HMI, the

object Symbol configuration is

used. To add a Symbol

Configuration, right click on

Application and select Add

Object… from the pop-up

menu.

2 Select Symbol configuration

in the Add Object dialog.

Click on Open.

3 In the opened Symbol

configuration tab, click on

Refresh.

The refresh automatically

starts a compilation.

4 Check the Messages box for

the compilation results and

correct the compilation errors.

To locate the compilation error

cause, double click on the

compilation error message.

There are no compilation errors

and compilation warnings in this

project.

Note:

The Symbol configuration

cannot be refreshed when there

are compilation errors in the

program.

Optimized HW XBTGC Schneider Electric 54


5 All Variables created in the

user program are shown in

the Variables list.

In this project, as all variables

are global variables, they are

located in the GVL folder.

To link the variables from the

Controller to the HMI, select

GVL and click on >.

6 The right frame now lists the

Selected variables that have

been linked and can be used

in the HMI.

7 To export the selected

variables to Vijeo Designer

right click on HMI Application

and select Export Symbols

to Vijeo-Designer.

Communication

settings

controller ↔ PC

1 To configure the

communication gateway,

double click on XBTGC2230

in the Devices browser.

2 On the tab Communication

Settings click on:

Add gateway...

Optimized HW XBTGC Schneider Electric 55


3 Keep the default settings and

click on OK.

4 Select Gateway-1 and click

on Scan network.

Note:

Confirm that the graphics

controller is connected to the

PC using XBTZG935.

5 During the scan, the Scan

network button is inactive.

When the scan is finished, the

Scan network button

becomes active again and the

devices that have been

detected are listed under

Gateway-1.

Select the graphics controller

that is being used and click on

Set active path.

Optimized HW XBTGC Schneider Electric 56


6 The XBTGC is now indicated

in bold text and marked

(active).

7 NOTE:

If you would like to change the

default name of your

controller:

Click on Edit…

In the displayed pop-up

window go to the

Device Name field and enter

the new unique name for your

controller.

In our example we keep the

factory setting name.

Save the

Project

1 To save the project, click

File→Save Project

To save the project under a

different name, click

File→Save Project As…

Optimized HW XBTGC Schneider Electric 57


2 If you use Save Project As…,

in the Save Project dialog

that opens enter the new File

name and click on Save.

Build

Application

1 To build the application, click

on

Build →

Build ‘Application

[XBTGC2230: PLC Logic]’

Note:

To build the whole project

(both HMI and Controller) click

Build all.

2 After the build, the Messages

box indicates whether the

build was successful or not.

If the build was not

successful, the compilation

errors are listed in the

Messages box.

Download

the controller

and HMI

Applications

1 Note

If it is the initial download of an application to the HMI display, a download of the

latest runtime version to the HMI using Vijeo Designer will be required prior to

downloading the application file.

This first download is described in the following steps.

If this is not the first download, go directly to step 7.

Optimized HW XBTGC Schneider Electric 58


2 In Vijeo Designer, select the

target name in the Navigator

to display its properties in the

Property Inspector. In this

application,

in the Property Inspector,

select Download via USB.

Note:

The PC must be connected to

the XBTGC via the cable

XBTZG935.

3 Select:

Build→Download all

4 The VDPLoad dialog indicates

that the runtime version does

not match. Start the download

of the new version by clicking

on Yes.

5 The actual state of the

download is displayed in a

progress bar.

Optimized HW XBTGC Schneider Electric 59


6 Once the runtime download is

complete, change the

Download connection in the

Property Inspector back to

SoMachine.

7 To download the application

to the controller and the HMI

click

Online → Multiple

Download…

8 Check the boxes for the

controller:

XBTGC2230: Application

XBTGC2230: HMI Application

and

Always perform a full

download

and click on OK.

Optimized HW XBTGC Schneider Electric 60


9 Before the download starts, a

build of the complete project is

done.

The result of the build is

displayed in the Messages

box.

10 The results of the download to

the controller are displayed in

the Multiple Download –

Result window.

Here are two examples:

In the first dialog, there was

no change.

And in the second dialog, the

application was downloaded.

Click on Close to close the

results window.

11 Once the download to the

controller is finished, the HMI

download starts.

12 The result of the HMI

download is displayed in the

Messages window.

Login to

controller

1 To login to the controller click

Online→

Login

Optimized HW XBTGC Schneider Electric 61


2 SoMachine will display a

message according to the

state of the controller you are

trying to login to.

Here are two examples:

In the first dialog, there is no

program in the device.

And in the second dialog, the

controller program is different

from the program on the PC.

In both cases, you are asked

to confirm whether to proceed

with the download of the PC

program into the controller.

If you do not wish to overwrite

the controller program, skip to

step 4, otherwise click Yes to

confirm the download.

3 The actual download status is

displayed at the bottom left of

the main window.

4 To start running the

application in the controller,

select:

Online →

Start

Optimized HW XBTGC Schneider Electric 62


5 If there are no detected errors,

the devices and folders are

marked in green otherwise

they are marked in red.

Application

overview

1 The picture on the right shows

the structure of the program.

Optimized HW XBTGC Schneider Electric 63


HMI

Introduction

This application uses a Magelis XBTGC2230T HMI controller. The HMI display is programmed

using the software tool Vijeo Designer (integrated in SoMachine) and is described briefly in

the following pages.

Setting up the HMI is done as follows:







Open the HMI Application

Main Window

HMI display Communication Settings

Create a Switch

Create a Numeric Display

Example Screens

Open the HMI

Application

1 To open the HMI application of

in SoMachine double click on

XBTGC2230 →

HMI Application

2 A new window is opened in

Vijeo-Frame in the Vijeo

Designer environment.

Note:

When a project is created with

a Magelis HMI controller, the

programming software Vijeo

Designer opens in a new

window and you can start

programming.

Optimized HW XBTGC Schneider Electric 64


Main Window 1 After creating a Vijeo Designer

HMI program in SoMachine the

main Window of Vijeo Designer

is displayed.

Vijeo Designer has the

following components:

1. Navigator

2. InfoViewer

3. Toolchest

4. Property Inspector

5. Feedback Zone

6. Graphic List

HMI display

Communication

Settings

2 When an XBTGC HMI

controller is used, Vijeo

Designer automatically creates

an equipment called

SOM_XBTGC2230 under

SoMachineCombo01 for the

communication with its

integrated controller.

Create a

Switch

1 Click on the Switch icon in the

toolbar.

2 Click on the panel where you

wish to position the switch and

then drag the cursor to size it.

Then click again or press enter.

Optimized HW XBTGC Schneider Electric 65


3 In the Switch Settings dialog,

under the General tab, click on

the bulb icon at the end of the

Destination field to select the

variable that should be linked

to the switch.

4 In the Variables List dialog that

opens, select tab

SoMachine,…

the appropriate variable and

click on OK.

Optimized HW XBTGC Schneider Electric 66


5 After the variable has been

selected as the switch’s

Destination, click on Add >.

6 In the tab Label, select Static

as the Label Type and enter a

name that the switch would be

labeled with, e.g. FWD.

If you wish, you can modify the

label’s Font attributes (Style,

Width, Height and Alignment).

When you are satisfied with the

switch settings, click on OK.

7 The new switch is now on the

Work frame.

Optimized HW XBTGC Schneider Electric 67


Create a

Numeric

Display

1 Click on the Numeric Display

icon in the toolbar.

2 Click on the panel where you

wish to position the numeric

display and then drag the

cursor to size it.

Then click again or press enter.

3 In the Numeric Display

Settings dialog, under the tab

General, click on the bulb icon

at the Variable field to select

the variable that should be

linked to the display.

In Display Digits, the

maximum number of digits to

be displayed for the integral

and fractional part of the value

can be set.

Optimized HW XBTGC Schneider Electric 68


4 The new numeric display is

now on the work frame.

Example

Screens

1 The Home page of the HMI

shows a picture of the

complete architecture.

2 The System page has two

functions:

1. To show the overall status

for all devices

2. To select between LOCAL

or MANUAL operation

mode

Optimized HW XBTGC Schneider Electric 69


3 The Alarm page shows the

status of the system alarms

and logs them chronologically.

4 The “Safety” page shows the

status of the Emergency Stop

relay.

5 The ATV12 page is for setting

the speed references of the

ATV12 drive and controlling the

drive when the system is

operating in Manual mode. It

also displays the status of the

drive.

6 The ATV312 page is for setting

the speed references of the

ATV312 drive and controlling

the drive when the system is

operating in Manual mode. It

also displays the status of the

drive.

Optimized HW XBTGC Schneider Electric 70


7 The LXM32 page is for setting

the speed references of the

LXM32 drive and controlling the

drive in either speed or position

mode when the system is

operating in Manual mode. It also

displays the status of the drive

8 The XBTGC page allows to

access to the HMI system

configuration and shows the

status of the XBTGC onboard

I/O.

Optimized HW XBTGC Schneider Electric 71


Devices

Introduction

General

Note

This chapter describes the steps required to initialize and configure the different

devices required to attain the described system function.

Altivar 12, Altivar 312 and Lexium 32C drives are configured by using the local

control panel.

If this is not a new drive it is recommended to return to the factory settings. If you

need instructions on how to do this, please read the drive documentation.

It is recommended that the controller is in stop mode before parameterizing the

drives.

Optimized HW XBTGC Schneider Electric 72


Altivar 12

Introduction

Note

The ATV12 parameters can be entered or modified via the local control panel on the

front of the device.

If this is not a new drive it is recommended to return to the factory settings. If you need

instructions on how to do this, please read the drive documentation.

Jog dial that is a part of the local control panel and can be used for navigation by

turning it clockwise or counter-clockwise. Pressing the jog dial enables the user to

make a selection or confirm information.

Control panel

1

The configuration of the Altivar can be done by using the buttons and the jog dial on

the control panel of the Altivar.

List of

modified

paramters

1

► Allt → 10U

► r1 → FLt

► LO1 → SrA

► rrS → L2H

► rsF → L3H

Optimized HW XBTGC Schneider Electric 73


Inputs /

Outputs

configuration

1 To assign the inputs and outputs:

Press MODE

Select COnF and press enter

Select FULL and press enter

Select I_O- [INPUTS /

OUTPUTS CFG] and press

enter

Select AII- and press enter

Select AIIt (Analog input

1)and press enter

Select 10U (0-10V) and

press enter

Return to AIIt with ESC

Return to AII- with ESC

Select r1 (relay output 1)

and press enter

Select FLt (No Fault) and

press enter

Return to r1 with ESC

Select LO1- and press enter

Select LO1 (Logic output 1)

and press enter

Select SrA (Speed reached)

and press enter

Return to LO1 with ESC

Return to LO1- with ESC

Return to I_O- with ESC

Return to FULL with ESC

Return to COnF with ESC

Return to rdy with ESC

Set Input for

reverse

function

1 To assign the input for the reverse

function input:

Press MODE

Select COnF and press enter

Select FULL and press enter

Select FUn- [APPLICATION

FUNCT.] and press enter

Select rrS (Reverse input)

and press enter

Select L2H (Logic input 2)

and press enter

Return to rrS with ESC

Return to FUn- with ESC

Return to FULL with ESC

Return to COnF with ESC

Return to rdy with ESC

Optimized HW XBTGC Schneider Electric 74


Fault

management

1 To assign the settings for Fault

management:

Press MODE

Select COnF and press enter

Select FULL and press enter

Select FLt- [FAULT-

MANAGEMENT] and press

enter

Select rSF (Reset Fault) and

press enter

Select L3H (Logic input 3)

and press enter

Return to rSF with ESC

Return to FLt- with ESC

Return to FULL with ESC

Return to COnF with ESC

Return to rdy with ESC

Optimized HW XBTGC Schneider Electric 75


Altivar 312

Introduction

Note

The ATV312 parameters can be entered or modified via the local control panel on the

front of the device.

If this is not a new drive it is recommended to return to the factory settings. If you need

instructions on how to do this, please read the drive documentation.

Jog dial that is a part of the local control panel and can be used for navigation by

turning it clockwise or counter-clockwise. Pressing the jog dial enables the user to

make a selection or confirm information.

Control panel

1

The configuration of the Altivar can be done by using the buttons and the jog dial on

the control panel of the Altivar.

Optimized HW XBTGC Schneider Electric 76


Inputs /

Outputs

configuration

1 To assign the inputs and outputs:

Press MODE

Select I_O- [INPUTS /

OUTPUTS CFG] and press

enter

Select rrS (Reverse input

assignment) and press enter

LI2 (factory setting)

Return to rrS with ESC

Select r1 (relay output 1) and

press enter

FLt (No Drive Fault, factory

setting)

Return to r1 with ESC

Select r2 (relay output 2) and

press enter

Select SrA (Speed Reached)

and press enter

Return to r2 with ESC

Select SCS (Save

configuration) and press enter

Select StrI and press enter for

2 seconds

SCS automatically switches to

nO as soon as the as the save

has been performed.

Return to SCS with ESC

Return to I_O- with ESC

Return to rdy with ESC

Optimized HW XBTGC Schneider Electric 77


Change

settings for

Preset Speeds

1 To assign the settings for Preset

Speeds:

Press MODE

Select FUn- [APPLICATION

FUNCT.] and press enter

Select PSS and press enter

Select PS2 and press enter

Select nO and press enter

Return to PS2 with ESC

Select PS4 and press enter

Select nO and press enter

Return to PS4 with ESC

Return to PSS with ESC

Return to FUn- with ESC

Return to rdy with ESC

The reason for this modification is: in

this Application we do not use the

Preset Speeds and we use the Input

LI3 for RSF (Fault Reset)

Fault

management

1 To assign the settings for Fault

management:

Press MODE

Select FLt- [FAULT-

MANAGEMENT] and press

enter

Select rSF (Reset Fault) and

press enter

Select LI3 and press enter

Return to rSF with ESC

Return to FLt- with ESC

Return to rdy with ESC

Optimized HW XBTGC Schneider Electric 78


Lexium 32C

Introduction

The LXM32C parameters can be entered or modified via using the local control panel

of the device.

Note:

If this is not a new drive it is recommended to return to the factory settings. If you need

instructions on how to do this, please refer to the drive documentation.

If the drive is being started for the first time, the FSu (First Setup) is invoked.

Operation

Mode

1

Selection of the operating mode: GEAr (Electronic Gear).

The parameter “IOdefaultMode” (io-M) is used to set the desired operating mode.

The selected operating mode is starting by enabling the power stage.

► Set the operating mode with the parameter “IOdefaultMode” (io-M).

Optimized HW XBTGC Schneider Electric 79


Settings for

the gear ratio

and PTIsignal

1

Selection of the gear ratio (500) and signal type for PTI interface: (Pd).

The parameter “GEARratio” (GFAc) is used to set the gear ratio. The parameter

“PTI_signal_type” (ioPi) is used to set the signal type for the PTI interface.

► Set the signal type with the parameter “GEARratio” (GFAc).

► Set the signal type with the parameter “PTI_signal_type” (ioPi).

Optimized HW XBTGC Schneider Electric 80


Inputs /

Outputs

configuration

1

Configuration of the digital inputs di0, di1 and digital outputs do0, do1.

► di0 → EnAb Enables the power stage

► di1 → FrES Fault reset after error

► do0 → nFLt Ready to switch on

► do1 → Acti Operation Enable

The digital inputs di2 – di5 are not used. It is required to set this inputs to nonE.

► di2 → nonE

► di3 → nonE

► di4 → nonE

► di5 → nonE

Optimized HW XBTGC Schneider Electric 81


Power cycle 1 In case of display “nrdy” instead of “rdy”, a power cycle (on, off, on) is required.

Optimized HW XBTGC Schneider Electric 82


Appendix

Detailed Component List

Hardware-Components

Pos. Qty. Description Part Number

Sarel Cabinet 1.1 1 Switch cabinet and mounting plate NSYS3D10840P

1000 x 800 x 400 mm

1.2 1 Cabinet light NSYLAM75

1.3 1 Wiring diagram pocket NSYDPA4

1.4 1 Thermostat 1NC 0-60 °C NSYCCOTHO

1.5 1 Fan with filter 230 Vac, 0.12 A NSYCVF85M230PF

1.6 1 Air filter for cabinet, 250 x 250 mm NSYCAG125LPF

Rev./

Vers.

Hardware-Components

Pos. Qty. Description Part Number

Mains Switch 2.1 1 Main switch 36 A 3pin LV429003

2.2 1 Contact block TM32D LV429035

2.3 1 Terminal cover LV429515

2.4 1 Rotary drive with door interface LV429340

Rev./

Vers.

Hardware-Components

Pos. Qty. Description Part Number

Power Supply 3.1 1 Power supply 230 Vac / 24 Vdc, 5 A, ABL8REM24050

120 W

3.2 3 Circuit breaker C60 1P ; 2 A ; C 23726

3.3 1 Circuit breaker C60N 2P ; 2 A ; C 23747

3.4 1 Circuit breaker C60L 2P ; 2 A ; D 24517

3.5 2 Circuit breaker C60N 1P ; 3 A ; C 23728

3.6 1 Circuit breaker C60N 2P ; 10 A ; C 23756

3.7 1 Earth disconnect terminal 5711016550

Rev./

Vers.

Hardware-Components

Pos. Qty. Description Part Number

HMI Controller 4.1 1 Magelis XBTGC 5.7“ HMI controller

terminal

XBTGC2230T

Rev./

Vers.

V5.1.1

Optimized HW XBTGC Schneider Electric 83


Automation

Components

Hardware-Components

Pos. Qty. Description Part Number

5.1 1 Digital input extension module, 16

inputs, 24 Vdc

5.2 1 Analog extension module 2 OUT,

-10… +10 Vdc

5.3 1 Analog extension module 4 IN/

2 OUT 0…10 Vdc / 4 – 20 mA

5.4 1 Expansion module securing hook –

used to secure 3 expansion modules

to the XBTGC2000 series

TM2DDI16DT

TM2AVO2HT

TM2AMM6HT

XBTZGCHOK

Rev./

Vers.

Drives and

Power

Hardware-Components

Pos. Qty. Description Part Number

Rev./

Vers.

6.1 1 ATV12 variable speed drive

ATV12H037M2 V1.1

0.37 kW, 200/240 Vac

IE01

6.2 1 ATV 312 variable speed drive

ATV312H037N4 V5.0

0.37 kW, 380/500 Vac

IE50

6.3 1 Lexium 32C servo drive 200/240 Vac, LXM32CD18M2 V01.

6 A RMS at 6000 RPM

03.17

6.4 1 Servo motor without brake, 0.5 Nm, BMH0702T06A2A

6000 RPM, 1.1 kW

6.5 2 Motor circuit breaker 2.5 A GV2L07

6.6 1 Motor circuit breaker 10 A GV2L14

6.7 3 Auxiliary contacts 1 NO + 1 NC for GVAE11

circuit breaker

6.8 1 Load contactor 4 kW LC1D09BD

6.9 1 Power cable for Lexium 32C, 3 m VW3M5101R30

6.10 1 Encoder cable for Lexium 32C, 3 m VW3M8102R30

6.11 1 Signal cable for connecting PTI VW3M8223R30

6.12 1 Coupling relay as an interface module ABS2EC01EB

between ATV12 and HMI controller,

24 Vdc

Hardware-Components

Pos. Qty. Description Part Number

Sensor 7.1 2 OsiSense Limit Switch XCKP2118P16

Rev./

Vers.

Hardware-Components

Pos. Qty. Description Part Number

Safety E-Stop 8.1 2 Preventa safety module XPSAC5121

8.2 1 Emergency Stop pushbutton, red XB5AS844

yellow

8.3 1 Auxiliary contacts for Emergency ZB5AZ141

Stop

8.4 1 Circular legend for Emergency Stop ZBY8330

mushroom head pushbutton, 90 mm

diameter

8.5 1 Guard Switch XCSPA792

Rev./

Vers.

Optimized HW XBTGC Schneider Electric 84


Display and

Indicators

Hardware-Components

Pos. Qty. Description Part Number

9.1 2 Assembly housing XALD01

9.2 1 Assembly housing for 2 Style 5 XALD02

buttons

9.3 1 Three position selector switch XB5AD33

9.4 1 Signal lamp white LED XB5AVB1

9.5 1 Illuminated pushbutton with red LED XB5AW34B5

1NC/1NO

9.6 3 Illuminated pushbutton with blue LED XB5AW36B5

1 NC

9.7 1 Tower Light bank (red, green, blue,

white)

XVBC

Rev./

Vers.

Software-Components

Pos. Qty. Description Part Number

Rev./

Vers.

Software Tools 10.1 1 SoMachine (includes Vijeo Designer) MSDCHNSFUV20 V2.0

10.2 1 PC→XBTGC Programming cable,

USB to USB

XBTZG935

Optimized HW XBTGC Schneider Electric 85


Component Protection Classes

Positioning Component In Field, On Site

Cabinet

Front Inside

Protection Class IP54 IP65 IP67 IP55 IP65 IP20

Main switch NSX

X

Emergency Stop switch housing

XALK

X

Preventa safety module

XPSAC5121

X

Preventa guard switch XCSPA792

X

Single/Double switch housing,

complete

X

Control switch, 3 positions

X

Indicator buttons

X

Buttons with LED + 1 switch(1S),

all colors

X

Labels 30x40

X

Positions switch Universal

X

Contactor, all types

X

Phaseo Power Supply

24 Vdc / 5 A

X

TM2 I/O Expansion Modules

X

Magelis XBTGC HMI controller X X

Lexium 32C servo drive

X

BMH servo motor

X

shaft

end

IP40

Altivar 312 variable speed drive

X

Altivar 12 variable speed drive

X

Optimized HW XBTGC Schneider Electric 86


Component Features

Components

Compact NSX main switch

Compact NSX rotary switch disconnections from 12 to 175 A

are suitable for on-load making and breaking of resistive or

mixed resistive and inductive circuits where frequent operation

is required. They can also be used for direct switching of

motors in utilization categories AC-3 and DC-3 specific to

motors.




3-pole rotary switch disconnectors, 12 to 175 A

Pad lockable operating handle (padlocks not supplied)

Degree of protection IP65

Phaseo power supply: ABL8RPS24050







1 or 2-phase connection

100...120 Vac and 200...500 Vac input

24 Vdc output

5 A output

Diagnostic relay

Protected against overload and short circuits

Optimized HW XBTGC Schneider Electric 87


Preventa safety module: XPSAC5121

Main technical characteristics:

For monitoring

Emergency Stop

Max. Category accord. EN954-1 3

No. of safety circuits

3 N/O

No. of additional circuits

1 Solid-State

Indicators

2 LED

Power supply AC/DC

24 V

Response time on input opening < 100 ms

AC-15 breaking capacity

C300

DC-13 breaking capacity

24 Vdc / 2 A - L/R

50ms

Minimum voltage and current 17 V / 10 mA

Dimensions (mm) 114 x 22.5 x 99

Connection

Captive screw-clamp

terminals

Degree of protection

IP20 (terminals)

IP40 (casing)

Safety modules XPS AC are used for monitoring Emergency

Stop circuits conforming to standards EN ISO 13850 and EN

60204-1 and also meet the safety requirements for the

electrical monitoring of switches in protection devices

conforming to standard EN 1088 ; ISO 14119. They provide

protection for both the machine operator and the machine by

immediately stopping the dangerous movement on receipt of a

stop instruction from the operator, or on detection of a fault in

the safety circuit itself.

Magelis XBTGC HMI controller: XBTGC2230

The Magelis XBTGC HMI controller offers:





Expansion interface to attach M238 CANopen Master

module

16 x 24 Vdc inputs including 4 fast inputs, dedicated to

special functions such as HSC high-speed counting

16 x 24 Vdc solid state outputs including 4 fast outputs,

dedicated to special functions such as counting, PWM and

PTO

Expansion interface to increase the number of I/O by the

addition of up to 3 modules maximum* to the back of the

Controller that can be the following types:

o

o

Discrete TM2DDI/DDO/DMM/DRA/DAI

Analog TM2AMI/ALM/ARI/AMO/AVO/AMM

*Depends on the XBT GC model, the combination of the

expansion modules and the use of the hook XBTZGCHOK.

The Magelis XBTGC HMI controller is powered with 24 Vdc.

The XBTGC HMI Display has the following features:

Brightness and Contrast adjustment

16MB Flash for Application (HMI + Control)

One USB port host, Ethernet and one serial port multiprotocol

Sub-D9 RS232/ RS422-485 on specific models

Temperature range: 0..+ 50°C

Optimized HW XBTGC Schneider Electric 88


Altivar 12 variable speed drive: ATV12H037M2

100 Vac to 120 Vac 1- phase, 0.18 kW to 0.75 kW

200 Vac to 240 Vac 1-phase, 0.18 kW to 2.2 kW

200 Vac to 240 Vac 3-phase, 0.18 kW to 4 kW

Integrated EMC Filter

Temperature Range: - 10..+ 50°C

Speed range 1 to 20 (0...200 Hz)

Speed control using Flow Vector Control

Drive and motor Protection

Compact profile, In-row mounting on a DIN rail

Altivar 312 variable speed drive: ATV312H037N4

The Altivar 312 drive is a variable speed drive for 3-phase

squirrel cage asynchronous motors. The Altivar 312 is robust,

compact, easy to use and conforms to EN 50190, IEC/EN

61800-2, IEC/EN 61800-3 standards UL/CSA certification and

to CE marking.

Altivar 312 drives communicate on Modbus and CANopen

industrial buses. These two protocols are integrated as

standard.

Altivar 312 drives are supplied with a heat sink for normal

environments and ventilated enclosures. Multiple units can be

mounted side by side to save space.

Drives are available for motor ratings between 0.18 kW and 15

kW, with four types of power supply:

- 200 Vac to 240 Vac 1-phase, 0.18 kW to 2.2 kW

- 200 Vac to 240 Vac 3-phase, 0.18 kW to 15 kW

- 380 Vac to 500 Vac 3-phase, 0.37 kW to 15 kW

- 525 Vac to 600 Vac 3-phase, 0.75 kW to 15 kW

Optimized HW XBTGC Schneider Electric 89


Lexium 32 servo drive: LXM32CD18M2

Voltage range:

1-phase 100 – 120 Vac or 200 – 240 Vac

3-phase 200 – 240 Vac or 380 – 480 Vac

Power: 0.4 to 6 kW

Rated torque: 0.5 to 36 Nm

Rated speed: 1500 to 8000 RPM

The compact design allows for space-saving installation of

the drive in control cabinets or machines.

Features the "Power Removal" (Safe Stop) functional

safety function, which prevents the motor from being

started accidentally. Category 3 with machine standard EN

954-1

Lexium 32 servo amplifiers are fitted with a brake resistor

as standard (an external brake resistor is optional)

Quick control loop scan time: 62.5 µs for current control

loop, 250 µs for speed control loop and 250 µs for position

control loop

Operating modes: Point-to-point positioning (relative and

absolute), electronic gears, speed profile, speed control

and manual operation for straightforward setup.

Control interfaces:

CANopen, Modbus or Profibus DP

Analog reference inputs with ± 10 Vdc

Logic inputs and outputs

Optimized HW XBTGC Schneider Electric 90


SoMachine OEM Machine Programming Software:

MSDCHNSFUV20

SoMachine is the OEM solution software for developing,

configuring and commissioning the entire machine in a single

software environment, including logic, motion control, HMI and

related network automation functions.

SoMachine allows you to program and commission all the

elements in Schneider Electric’s Flexible and Scalable Control

platform, the comprehensive solution-oriented offer for OEMs,

which helps you achieve the most optimized control solution for

each machine’s requirements.

Flexible and Scalable Control platforms include:

Controllers:

HMI controllers:

Magelis XBTGC HMI controller

Magelis XBTGT HMI controller

Magelis XBTGK HMI controller

Logic controllers:

Modicon M238 Logic controller

Modicon M258 Logic controller

Motion controller

Modicon LMC058 Motion controller

Drive controller:

Altivar ATV-IMC Drive controller

HMI:

HMI Magelis graphic panels:

XBTGT

XBTGK

SoMachine is a professional, efficient, and open software

solution integrating Vijeo Designer.

It integrates also the configuring and commissioning tool for

motion control devices.

It features all IEC 61131-3 languages, integrated field bus confi

gurators, expert diagnostics and debugging, as well as

outstanding capabilities for maintenance and visualization.

SoMachine integrates tested, validated, documented and

supported expert application libraries dedicated to Packaging,

Hoisting and Conveying applications.

SoMachine provides you:

One software package

One project file

One cable connection

One download operation

Optimized HW XBTGC Schneider Electric 91


Contact

Publisher

Process & Machine Business

OEM Application & Customer Satisfaction

Schneider Electric Automation GmbH

Steinheimer Strasse 117

D - 63500 Seligenstadt

Germany

Homepage

http://www.schneider-electric.com/sites/corporate/en/home.page

As standards, specifications and designs change from time to time, please ask for

confirmation of the information given in this publication.

Optimized HW XBTGC Schneider Electric 92

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