Compact / Hardwired / Logic Controller / Twido ... - Schneider Electric

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Compact / Hardwired / Logic Controller / Twido ... - Schneider Electric

Before You BeginDo not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-ofoperationguarding on a machine can result in serious injury to the operator of that machine.WARNINGUNGUARDED MACHINERY CAN CAUSE SERIOUS INJURY Do not use this software and related automation products on equipment which does not havepoint-of-operation protection. Do not reach into machine during operation.Failure to follow these instructions can cause death, serious injury or equipmentdamage.This automation equipment and related software is used to control a variety of industrial processes. The type ormodel of automation equipment suitable for each application will vary depending on factors such as the controlfunction 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 themachine; therefore, only the user can determine the automation equipment and the related safeties and interlockswhich can be properly used. When selecting automation and control equipment and related software for a particularapplication, the user should refer to the applicable local and national standards and regulations. A “National SafetyCouncil’s” Accident Prevention Manual also provides much useful information.In some applications, such as packaging machinery, additional operator protection such as point-of-operationguarding must be provided. This is necessary if the operator’s hands and other parts of the body are free to enterthe pinch points or other hazardous areas and serious injury can occur. Software products by itself cannot protectan operator from injury. For this reason the software cannot be substituted for or take the place of point-ofoperationprotection.Ensure that appropriate safeties and mechanical/electrical interlocks for point-of-operation protection have beeninstalled and are operational before placing the equipment into service. All mechanical/electrical interlocks andsafeties for point-of-operation protection must be coordinated with the related automation equipment and softwareprogramming.NOTE: Coordination of safeties and mechanical/electrical interlocks for point-of-operation protection isoutside the scope of this document.START UP AND TESTBefore using electrical control and automation equipment for regular operation after installation, the system shouldbe given a start up test by qualified personnel to verify correct operation of the equipment. It is important thatarrangements for such a check be made and that enough time is allowed to perform complete and satisfactorytesting.Optimized HW Twido Schneider Electric 3


CAUTIONEQUIPMENT 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 meansused 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 forfuture 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 installedaccording to local regulations (according to the National Electrical Code in the U.S.A, for instance). If high-potentialvoltage testing is necessary, follow recommendations in equipment documentation to prevent accidental equipmentdamage.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 ADJUSTMENTSThe 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 ofcomponents, 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. Alwaysuse the manufacturer’s instructions as a guide for functional adjustments. Personnel who have access to theseadjustments should be familiar with the equipment manufacturer’s instructions and the machinery used with theelectrical equipment. Only those operational adjustments actually required by the operator should be accessible to the operator. Accessto other controls should be restricted to prevent unauthorized changes in operating characteristics.UNEXPECTED EQUIPMENT OPERATIONWARNING 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 equipmentdamage.Optimized HW Twido Schneider Electric 4


IntroductionIntroductionThis document is intended to provide a quick introduction to the described system. It is notintended to replace any specific product documentation, nor any of your own designdocumentation. On the contrary, it offers additional information to the productdocumentation, for installing, configuring and implementing the system.The architecture described in this document is not a specific product in the normalcommercial sense. It describes an example of how Schneider-Electric and third-partycomponents may be integrated to fulfil an industrial application.A detailed functional description or the specification for a specific user application is notpart of this document. Nevertheless, the document outlines some typical applicationswhere the system might be implemented.The architecture described in this document has been fully tested in our laboratories usingall 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 requireadditional and/or different components. In this case, you will have to adapt the informationprovided in this document to your particular needs. To do so, you will need to consult thespecific product documentation of the components that you are substituting in thisarchitecture. Pay particular attention in conforming to any safety information, differentelectrical requirements and normative standards that would apply to your adaptation.It should be noted that there are some major components in the architecture described inthis document that cannot be substituted without completely invalidating the architecture,descriptions, instructions, wiring diagrams and compatibility between the various softwareand hardware components specified herein. You must be aware of the consequences ofcomponent substitution in the architecture described in this document as substitutions mayimpair the compatibility and interoperability of software and hardware.Optimized HW Twido Schneider Electric 5


AbbreviationsAbbreviationACCBDIDODCE-STOPHMII/OILLDPCPSRPMSETVDAVSDWxHxDSignificationAlternating CurrentCircuit BreakerDigital InputDigital OutputDirect CurrentEmergency StopHuman Machine InterfaceInput/OutputInstruction List - a textual IEC-61131 programming languageLadder Diagram – a graphic IEC-61131 programming languagePersonal ComputerPower SupplyRevolutions Per MinuteSchneider ElectricTested, Validated, Documented ArchitecturesVariable Speed DriveDimensions : Width, Height and DepthOptimized HW Twido Schneider Electric 6


GlossaryExpressionAltivar (ATV)HarmonyMagelisMB - SLModbusOsiSensePhaseoPreventaSoMove LiteTeSysUTwidoTwidoSuiteVijeo Designer LiteSignificationSE product name for a family of VSDsSE product name for a family of switches and indicatorsSE product name for a family of HMI-DevicesSE name for a serial Modbus communications protocolA Communications protocolSE product name for a family of sensorsSE product name for a family of power suppliesSE product name for a family of safety devicesAn SE software product for configuring drivesSE product name for motor startersSE product name of a basic range family of PLCsSE product name for a PLC programming softwareAn SE software product for programming Magelis HMI devicesOptimized HW Twido Schneider Electric 7


Application Source CodeIntroductionExamples of the source code and wiring diagrams used through out this document can bedownloaded from our website.The example source code is in the form of configuration, application and import files. Use theappropriate software tool to either open or import the files.Extension File Type Software Tool RequiredCSV Comma Separated Values, Spreadsheet MS ExcelDOC Document file Microsoft WordDOP Project File Vijeo Designer LitePDF Portable Document Format - document Adobe AcrobatPSX Project file SoMove (Lite)SPA Schneider Product Archive TwidoSuiteXPR Project file TwidoSuiteZ13 Project file EPLANOptimized HW Twido Schneider Electric 8


Typical ApplicationsIntroductionHere you will find a list of the typical applications and their market segments, wherethis system or subsystem can be applied:Packaging Recycling machinesTextile Clothing machinesHVac-R Heating and air conditioning systems Refrigerated displayCommercial equipment Automatic washing Ticket vending machines Automatic dispensers Displays scrolling Advertising panels Ice-makersBuilding / services Automated systems for access and entry control (Door, awning, roller blind..)Other Machines Wood working machines Solar energy management Agricultural and fish-farming machinery Ovens and incubators Swimming poolsOptimized HW Twido Schneider Electric 9


ComponentsHardware: Vario disconnect switch VCF (with red and yellow knob) Motor circuit breaker GV2L TeSysD Contactor LC1D Altivar variable speed drive ATV12 Harmony XALK Emergency-Stop switch with rotation release Phaseo power supply unit ABL8 Modicon Twido Compact Logic controller Magelis XBT-N HMI compact operator terminal XBT-N Harmony selector switches, push buttons and indicator lamps, XB5 OsiSense roller limit switches XCK Preventa safety module XPS Multi 9 circuit breaker Standard AC motorSoftware: TwidoSuite 2.20.10 SoMove Lite 1.0.20.0 Vijeo Designer Lite 1.2Quantities ofComponentsFor a complete and detailed list of components, the quantities required and the ordernumbers, please refer to the Detailed Components List in the Appendix.Degree ofProtectionNot all the components in this configuration are designed to withstand the sameenvironmental conditions. Some components may need additional protection, in theform of housings, depending on the environment in which you intend to use them. Forenvironmental details of the individual components please refer to the list in theappendix of this document and the appropriate user manual.CabinetTechnicalDataInputMains voltagePower requirementCable SizeCable Connection400 Vac~ 2 kW5 x 2.5 mm² (L1, L2, L3, N, PE)3 phase + Neutral + GroundNeutral is needed for 230 Vac (Phase and Neutral)Output Motor power ratings 1 asynchronous motors (4 poles:1500 RPM)controlled by ATV12 (0.37 kW)FunctionalSafety Notice(EN ISO13849-1EN IEC62061)The standard and level of functional safety you apply to your application is determinedby your system design and the overall extent to which your system may be a hazard topeople 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 shouldbe ascertained with a proper risk analysis.This document is not comprehensive for any systems using the given architecture anddoes not absolve users of their duty to uphold the functional safety requirements withrespect to the equipment used in their systems or of compliance with either national orinternational safety laws and regulationsEmergencyStopEmergency Stop/Emergency Disconnection functionThis function for stopping in an emergency is a protective measure which complementsthe safety functions for the safeguarding of hazardous zones according toprEN ISO 12100-2.Optimized HW Twido Schneider Electric 11


DimensionsThe compact dimensions of the devices used, for example, the controller and powersupply, mean that the components can be installed inside a small control panel with thefollowing external dimensions: 600 x 600 x 300 mm (WxHxD).The display elements used to indicate “Plant running” and “Safety Acknowledged” canbe built into the door of the control cabinet along with the system master switch andEmergency Stop switch.Optimized HW Twido Schneider Electric 12


InstallationIntroductionThis chapter describes the steps necessary to set up the hardware and configure thesoftware required to fulfill the described function of the application.AssemblyNotes The components designed for installation in a control cabinet, that is, Twido controller,Phaseo power supply unit, Harmony Emergency Stop button, line circuit breaker,contactors and motor circuit breaker, can be snapped onto a 35 mm DIN rail. The Altivar 12 variable speed drive is installed directly on the mounting plate. The Emergency Stop and master switches are installed in the cabinet door. There are two options available for mounting Harmony XB5 push buttons and indicatorlamps:1. Using a 22 mm hole drilled into the front door of the control cabinet in theappropriate position.2. Using XALD housing, this can house up to 5 push buttons or indicator lamps.This XALD is designed for backplane assembly or direct wall mounting. 230 Vac wiring between disconnect switch, motor circuit breaker, load relay andvariable speed drive. 24 Vdc wiring between power supply unit, Twido, push buttons, indicator lamps andvariable speed drive control circuit. 24 Vdc between Emergency Stop, Preventa, and the control circuit of the loadcontactor.Optimized HW Twido Schneider Electric 13


ControllerwiringThe components and I/O points listed below represent a cross-section of the componentsand signals that are a basic necessity for control and display purposes and a number ofoptional inputs and outputs that can be used in conjunction with most typical applications(functional safety/maintenance switches).Twido inputsDC In 0DC In 1DC In 2DC In 3DC In 4DC In 5DC In 6DC In 7DC In 8DC In 9DC In 10DC In 11DC In 12DC In 13Twido outputsRelay Out Q0Relay Out Q1Relay Out Q2Relay Out Q3Relay Out Q4Relay Out Q5Relay Out Q6Relay Out Q7Relay Out Q8Relay Out Q9Twido 24 V supplyComCom 0Com 1Com 2Com 3DescriptionForwardStopReverse--Reserved----Reserved--Limit switch forwardLimit switch reverseMotor circuit breakerMotor alarm--Reserved--Plant ready for Operation--Reserved----Reserved----Reserved--DescriptionMoving active--Reserved--Emergency Stop activatedGeneral alarmMotor forwardMotor reverseSpeed 2Speed 3Moving forwardMoving reverseDescriptionSupply inputs 24 Vdc-+24 Vdc+24 Vdc+24 Vdc+24 VdcATV12 controlcircuit wiringATV12LI1LI2LI3LI4RARCDescriptionTwido relay Out Q4Twido relay Out Q5Twido relay Out Q6Twido relay Out Q7+24 VdcTwido dc In 8Optimized HW Twido Schneider Electric 14


HardwareComponentsDisconnect SwitchVarioVCD0(red/yellow lever)Emergency Stopfor door mountingHarmonyXB5AS844 +XB5AZ141Including EmergencyStopLabelZBY8330Push ButtonHarmonywith indicator lampXB5Emergency StopSafety ModulePreventaXPSAC5121Optimized HW Twido Schneider Electric 15


Motor circuitbreakerTeSysGV2L16ContactorTeSysDLC1D09BDPower supplyPhaseoABL8REM2403024 Vdc, 3 AModicon Twido LogiccontrollerInput:TWDLCDA24DRF14 x 24 Vdc Inputs&10 x Relay OutputsOutput:Optimized HW Twido Schneider Electric 16


Option:Motor starter(alternative)TeSysULU2B12BL&LUCA05BLOptimized HW Twido Schneider Electric 18


SoftwareGeneralTwidoSuite is used for programming the Twido, including the configuration forcommunication and assigning inputs and outputs.The HMI application on the Magelis operator terminal is configured using Vijeo-Designer Lite software.The Altivar 12 variable speed drive can be configured using the front operator’spanel. However, the SoMove software is a more user-friendly option and can beused for configuring the drive, saving data and quickly restoring existing data forservice purposes. The software also allows you to optimize the parameters online.To use the software packages, your PC must have the appropriate MicrosoftWindows operating system installed:Windows XP ProfessionalThe software tools have the following default install paths:TwidoSuiteC:\Program Files\Schneider Electric\TwidoSuiteVijeo-Designer LiteC:\Program Files\Schneider Electric\Vijeo-Designer LiteSoMove LiteC:\Program Files\Schneider Electric\SoMove LiteOptimized HW Twido Schneider Electric 19


CommunicationGeneralA Modbus connection is used to exchange data between the Magelis HMI terminal andthe Modicon Twido Logic controller. The XBTZ9680 communication cable shown belowis needed to connect these two devices. The software driver required for Modbuscommunication is already included in the software packages for the Magelis panel andthe Twido.HMIDownload CablePC HMIXBTZ915Download CablePC HMITSXCUSB485+XBTZ925 (B)To program the HMI, use the cable XBTZ925 (B) with theRS845 Adapters TSXCUSB485 to connect the PC withthe HMI.Verify that the adapter is in switch position 2.Communication CableHMI ControllerXBTZ9680Optimized HW Twido Schneider Electric 20


ControllerCommunication CableWith USB ConnectorPC TwidoTSXCRJMD25+TSXCUSB485To program the Twido, use the cable TSXCRJMD25 withthe RS845 Adapters (TSXCUSB485) to connect the PCwith the Twido.Verify that the adapter is in switch position 2.For the communication to work properly, port 1 must beconfigured on the Twido.Altivar 12Cable set forSoMove LiteTSCMCNAM3M002PUse the USB to RJ45 cableto connect the PC (withSoMove installed) to theAltivar 12. Use the adapteras shown in the diagram.Optimized HW Twido Schneider Electric 21


ImplementationIntroductionThis chapter describes all the steps necessary to initialize, configure, program, and start-upthe system to achieve the application functions as listed below.Function1. All the conditions required to clear the system alarm lamp must be met, that is, motorcircuit breaker, maintenance switch and safety circuit must be ON. The group alarmmessage disappears and the Magelis panel is visible on the main screen.2. In this application the motor can only be controlled in the “Forward” or ”Reverse”direction if the associated limit switch is not pressed and no alarms are pending.3. Forward and reverse can be activated via push buttons. Motion can be stopped bypressing the red stop push button. The motor will stop when the limit switch isengaged.4. Speeds 2 and 3 can only be selected using the HMI device. The selection is retaineduntil it is modified via the HMI or the control panel is switched off.5. The different HMI screens can be selected using the yellow/black left/right arrows onthe text display. Motion can be invoked by setting the parameter FWD or REV to one.The output frequency of the drive can be increased by selecting Speed 2 (SP2) orspeed 3 (SP3).6. The screen “Drive Warning” shows the actual operation status and alarms.7. The screen “PLC Status” indicates whether the controller is in RUN or STOP mode.FunctionalLayoutFieldModbus/RS485FieldOptimized HW Twido Schneider Electric 22


CommunicationIntroductionThis chapter describes the data passed via the communications bus (for example, ModbusRTU) that is not bound directly with digital or analog hardware.The list contains:The device linksDirection of data flowSymbolic nameBus address of the device concerned.Device LinksThis application uses Modbus RTU via RS485 interfaces.The follwing devices are connected via Modbus:- Magelis HMI XBT-N401 as Master- Twido as Slave 1Datalink Device 1 Device 2TwidoHMI XBTN401 (ModBus-Master 0) Twido (ModBus-Slave 1)Address Designation Address Name%M3 Forward %M3 DRV_LEFT_HMI%M4 Reverse %M4 DRV_RIGHT_HMI%M5 Speed 2 %M5 SPEED_2_HMI%M6 Speed 3 %M6 SPEED_3_HMIDatalink Device 1 Device 2Twido->HMI XBTN401 (ModBus-Master 0) Twido (ModBus-Slave 1)Address Designation Address Name%M8 Forward switch %M8 HMI_DRV_DOWN%M9 Reverse switch %M9 HMI_DRV_UP%MW7 Drive status %MW7 HMI_DRV%MW1 PLC status%MW10 Drive alarmOptimized HW Twido Schneider Electric 23


ControllerIntroductionThis chapter describes the steps required for the initialization and configuration and thesource program required to fulfill the functions.The controller program is created with TwidoSuite.RequirementsTo be able to use TwidoSuite and program the the controller you will need to verify that:TwidoSuite is installed on your PCThe example application for this system, TwidoSuite project Example.xpr, is in thestandard project directory (C:\Program Files\Schneider Electric\TwidoSuite\My Projects)The Twido is switched onThe Twido is connected to the PC using the programming cableProcedureSetting up the Twido is done as follows:Create a New ProjectConfigure the TwidoCreate VariablesCreate an Application ProgramOpen an existing projectDownload the Program to the TwidoSave the Program to Memory CardProgram Duplication with Memory CardCreate a NewProject1 To create a new project click onthe arrow next to’’Programming’’ Mode2 Select the Project tab and clickon:Create a new projectOptimized HW Twido Schneider Electric 24


3 Input the project information asrequired:Project nameDirectory path for saveAuthorDepartmentIndexIndustrial PropertyContinue with CreateConfigure theTwido1 To configure the hardware, thecommunication parameters andthe bus system, click on theDescribe tab.2 In the Catalog on the rightselect the Twido type:Bases->Compact->TWDLCDA24DRFClick on Place to see the Twidoshow up in the rack image.3 Again in the Catalog, for thecommunications module select:Serial Adapter->TWDNAC485DClick on Place to see theadapter show up in the rackimageOptimized HW Twido Schneider Electric 25


4 To configure thecommunications port, rightmouse click on the RS485-Portin the graphical image andselect Configuration… in thepop-up menu.5 You can leave the defaultvalues as they are and acceptthem by clicking on OK.Default:Protocol Type: ModbusAddress: 16 The Twido is now configured.In the yellow field above theTwido image you can enter aname.The name Example was givenfor this application.Optimized HW Twido Schneider Electric 26


7 To complete the configurationadd the Magelis HMI.In the Catalog select:Network Elements->Modbus Elements->Magelis8 A right mouse click on theMagelis opens up a pop-upmenu.Select: Configuration…9 In the Configuration dialoggive the device a Name (forexample, XBTN401).Protocol Type: ModbusAddress: MasterConfirm the changes with OK.Optimized HW Twido Schneider Electric 27


10 Move the mouse over theMagelis image until the mousepointer changes to theconnection pointer (a whitecross). Click with the mouseand pull a connection across tothe Modbus port of the Twido.The connection is displayed asa line when you let go of themouse button.A double click on the Mynetwork 1 field opens aconfiguration dialog.11 Input the following parametervalues:Baudrate: 19200Data Bits: 8(RTU)Parity: noneStop Bit: 1Confirm with OK.CreateVariables1 Change to the Program tab.Optimized HW Twido Schneider Electric 28


2 Define the required inputs(%I0.x) and outputs (%Q0.x) inthe tableClick on Apply to take on thechanges.3 Switch to the tab Configureand the sub group Configurethe Data to define the variablesused in the program.4 Use this editor to define theinternal program variables andvariables transferred betweenthe HMI and Twido.Use the Object Categories onthe left to define different typesof variables.Optimized HW Twido Schneider Electric 29


5 Use the Save icon at thebottom of the window to savethe program.Optimized HW Twido Schneider Electric 30


Create aProgram1 Use the Edit Program functionto invoke the program editor.LADDER is the defaultprogramming languageOnce the first rung has beencompleted and analyzed, theprogram can be viewed andprogrammed in LIST mode.2 Start the programming byclicking on the add a sectionicon.This will create a section withempty rungs.3 Clicking on the rung changes itscolor and indicates the currentrung is being edited. Clicking onan icon in the toolbar inserts theselected object at the firstavailable place on the rung.Drag and dropping theelements is also supported.4 Click on the top of a rung to adda rung header or comment.\5 You can also add a sectionheader.Optimized HW Twido Schneider Electric 31


6 Add Coils …7 ..or Compare blocks,Function blocks, Timer orCounter ..8 To add more sections, use:Add a section.Note: a section can be addedeither at the end of the currentprogram or in between existingsections of the current program.9 The editor automaticallyrecognizes whether a rung issyntactically complete andmarks it in yellow.The rung, however, has not yetbeen analyzed.The Analyze program button isin the bottom right hand corner.10 If the analysis is successful, theyellow band changes to green.Rungs with syntax errors areindicated in red.Syntax errors are listed at thebottom of the edit field.The error field can be enlargedby clicking on the button to theleft of the box.Optimized HW Twido Schneider Electric 32


11 Here is the enlarged window.To leave the window just clickon the screen outside theframe.Once the program has beensuccessfully analyzed you candownload it to the Twido.Open anexistingProject1 To open a project use the Openan existing project function inthe Project menu.In the open an existingproject window select themedium :Disk or ControllerGive the file Format (for aproject file: TwidoSuiteProject), select the folder andselect the file you wish to open.Select the project Example andclick on Open to open theproject.Download tothe Twido1 Click on the tab Program in themain menuOptimized HW Twido Schneider Electric 33


2 Select Debug in the sub-menu(upper right) to obtain access tothe connect selection.3 In the sub-menu select theConnect tab (right side).Then the availablecommunication ports areshown.Check that the the USBcommunication cable isconnected, and select USB.Continue with OK.4 A progress bar is visible whileTwidoSuite establishes theconnection.5 After successfully connecting tothe Twido, TwidoSuite comparesthe status of the project and theTwido.The lower section displays thetype of exchange.Select:Transfer PC ==> controllerand click on OK.6 If the Twido is already running itmust be stopped first.Confirm with OK if you wish toproceed.Optimized HW Twido Schneider Electric 34


7 You are notified that thecontents of the Twido are aboutto be over-written.Confirm with OK to continue.8 The download condition isindicated with a progress bar.9 After a successful download,TwidoSuite switchesautomatically to the onlineviewing.10 A control panel appears in theforeground. Here you can startand stop the Twido.The upper button enlarges thecontrol panel, offering moreTwido status information.11 If you start the Twido you will beasked to confirm the action.If you wish to start the Twidoclick on OK.Optimized HW Twido Schneider Electric 35


12 After successfully starting theTwido, the RUN indicatorchanges from yellow to green.Optimized HW Twido Schneider Electric 36


DownloadFirmware1 Ensure you have connected theTwido with the USB cable.Select:PLC firmware update2 You are notified that thefirmware download will deleteany program running on theTwido.Continue by clicking Next >.3 Select the type of connection.(for example, COM1, COM2,USB)In this case select USB.Select the file to be downloadedwith Browse… .Click on Next > to continue.Optimized HW Twido Schneider Electric 37


4 A comparison of the hardwareand existing firmware is shown,as well as the controller state. Ifthe controller is in the runningstate, it must be stopped beforethe firmware can be updated.Click on Stop Controller.5 Confirm the stop with Yes.6 The new Twido status isdisplayed in File and DeviceProperties (green tick inStopped).Continue with Next >.Note: Updating the executiveof your controller will deletethe current controlapplication from thecontroller Memory. You willhave to reload the programafter updating the controller.7 Confirm the notification not tointerrupt the download with YesOptimized HW Twido Schneider Electric 38


8 A progress bar is displayed.9 A message confirms thesuccessful download and asksif you wish to download more.Click on No if you are finished.10 In the progress dialog click onClose.11 Click on Yes to exit the loader.Optimized HW Twido Schneider Electric 39


Save theProgram toMemory Card1 To store the program use the32 kByte EEPROM memorycard:TWDXCPMFK32Remember to turn off the powerto the Twido when removing orreplacing the memory card.2 Connect to the Twido (viaDebug tab and Connect USB).3 SelectAnimate the programand click on Check PLC.Optimized HW Twido Schneider Electric 40


4 Select:See memory informationand click on Save.5 If the Twido is running, click onOK to stop it.6 If you wish to restart thecontroller after storing theprogram on the memory cardclick Yes.7 Once the Twido is runningagain, the save sequence isfinished. You can now removethe memory card and copy theprogram to other Twidos.Remember to switch off theTwido before removing thememory card.Optimized HW Twido Schneider Electric 41


ProgramDuplicationwith MemoryCard1 Turn off the Twido, remove thecover to the card connector andinsert the memory card (makesure the card matches theTwido type and the hardwareconfiguration is the same).2 Turn the Twido on. The programtransfer from EEPROM card toTwido EPROM beginsautomatically.When the transfer is completethe RUN-LED lights up.3 Turn the Twido off to removethe memory card. Replace thecover on the connection andswitch the Twido back on. Itstarts to run automatically.Optimized HW Twido Schneider Electric 42


HMIIntroductionThis application features a compact Magelis XBT-N401 4-line-text-display HMI,which is interfaced with the controller via the Modbus protocol. The Vijeo DesignerLite software is used to program and configure the terminal.The following pages explain this procedure.RequirementsBefore starting work with Vijeo Designer Lite the follwing conditions must be fulfilled:VIJEO-DESIGNER LITE is installed on your PC.The example project has been copied to the Vijeo Designer Lite project storagepath (C:\Program Files\Schneider Electric\VIJEO-DESIGNER LITE\Apps).The Magelis HMI is switched on and connected to the PC with the cableXBTZ915.ProcedureSetting up the HMI is done as follows:Create a new ConfigurationCreate an AlarmCreate an Application screenCreating Variables (Boolean, words, lists)Screen Navigation & Viewing System PagesDownload Program to the HMIDriver-Manager: adding interfacesCreate a newConfiguration1 In the menu bar in VijeoDesigner, selectFile->NewSelect Terminal Type XBT-N401.Select Modbus as TerminalProtocol.Continue by clicking onCreate.Optimized HW Twido Schneider Electric 43


2 The project browser on theleft hand side of the toollists the elementsConfiguration and Design.Configuration is used toset up the HMI parameters.Design offers a breakdownof display screens andalarm panels.3 UnderTerminal – XBT-N401-Controlthe user modus can be setup so that the operator useseither the function keys orthe selector keys for control.Select the selector keys.Optimized HW Twido Schneider Electric 44


4 UnderProtocol – Modbusinput the Communicationparameters:Transmission Speed: 19200Parity Bit: NoneData Length: 8Stop bits: 1The default parameters givenfor Protocol Specific areretained.5 Under Languages thedefault display language forthe operator can be set.Use the Add button to addmore languages so that theoperator can select thelanguage he wishes to use.Optimized HW Twido Schneider Electric 45


6 Under Equipment you candefine the devices thatcommunicate with the HMI.EQPT1 is the default Name,and may be changed.As Address insert the slaveaddress.Use Add to add moreslaves.Use Symbol Variables Fileto import a variable list froma Twido program.After clicking on SymbolVariable File the Opendialog is displayed. Selectthe appropriate controllervariable list.Continue with Open.7 The Communication Tabledefines the data structuresused in communication forexample, memory buffers,alarm lists, function keydefinition, communicationcontrol etc.Right mouse click onCommunication Table anduncheck Disabled in thepop-up menu.8 Click on the correspondingtable (for example, EQPT1or whatever you named theequipment)Optimized HW Twido Schneider Electric 46


9 The Function tableindicates the activatedfunctions for this equipment.To add more Functionsclick on the checkboxbeside the function. It isthen listed in the table onthe right.The Base Address is thestart address of the Dialogtable. The data area ofeach function is shown inthe table beneath.Cycle defines the cycle timefor updating the data.10 Use Security to definepasswords to help protectthe HMI from unauthorizeduse.You can define how long theauthorized access lasts inminutes.The validity of the passwordlevels, A, B, C isconfigurable for individualscreens.Create an Alarm 1 Click on Alarms to open thealarm-list.The function is only availableif it was activated in thefunction list (as shownabove),2 The left column shows theaddress (for example,%MW104).The row shows the individualbits for this memory word.Select a bit with a doubleclick on the representativecell.Optimized HW Twido Schneider Electric 47


3 On the Alarm Settings tab,add the text to be displayedfor this alarm in the AlarmText box.Confirm with Enter.The text is displayed on thescreen should an alarm ofthis type ocurr. The positionof the text on the screen canbe defined under AlarmPanel and viewed in thePanel Preview.4 You can define the actionsof the function keys underStatic Function Keys (onlyavailable if you selectedfunction key mode in theTerminal Configuration)The variables defined in theFunction Setting are usedby the function definedunder Function Name toprovide either impulse ortoggle commands.You can also displayscreens or systeminformation.Create anApplicationscreen1 Design HMI screens todisplay system variablesusing Application Panelsentry.PANEL 1 is the defaultname for the first screen.Optimized HW Twido Schneider Electric 48


2 To create a new screen,select:Application Panels->Add Panel3 Click on the newly createdscreen name in the projectbrowser to display theactual screen.The screen can now bedesigned.Add appropriate text for thescreen.The Security Access isused to apply the passwordlevel required for thisscreen.Creating VariablesBoolean, Word, List1 For Alphanumerical Textvariables (boolean or word)select the icon in the toolbarand position the text box onthe screen.This box is used to displaythe value. The position andsize can be changed later.Optimized HW Twido Schneider Electric 49


Click on the positionedAlphanumerical Textobject to open up theattributes dialog.On the AlphanumericalText – Settings tab, enterthe address of a variable inthe Variable field.You can browse for avariable using the ‘…’ buttonat the end of the Variablefield.2 Define the type of variable(%Mx, %MWx, etc.), thenumber (i:), and the Format(bit, word, etc.).If you have importedvariables from other devices(in Equipment -> SymbolVariables File), a variablecan be selected from theSymbol list for that device.Confirm with OK.3 Use Display Type to definehow the variable should bedisplayed.In the Conversion is itpossible to enter a formulafor processing the variablebefore the value isdisplayed.4 The settings of accessrequirements are on theAccess Mode andSecurity tab.5 For an enumerated listselect the icon in the toolbarand position the text box onthe screen.This box is used to displaythe value. The position andsize can be changed later.Optimized HW Twido Schneider Electric 50


6 Click on the positionedEnumerated List object toopen up the attribute dialog.On the Enumerated List –Settings tab, input theVariable address and FontSize.7 Use the List Value tab toassign different display textsto the various variablevalues. The texts aredisplayed at run-time on thescreen according to thevariable’s actual value.If you selected more thanone language texts have tobe entered for eachlanguage.ScreenNavigation&Viewing SystemPages1 For a navigation symbolselect the icon in the toolbarand position the object onthe screen.This symbol can be used toswitch between the differentHMI screens. The directionof the arrow corresponds tothe arrow keys on the frontof the HMI device.On the tab Link - Settingsunder Link Action selectAccess Application Paneland in Panel Selection,select the screen you wishto have displayed when thekey is pressed.Optimized HW Twido Schneider Electric 51


DownloadProgramTo the HMI1 WithFile->OpenOpen the example fileExample.dop, stored in thepath:C:\Program Files\SchneiderElectric\VIJEO-DESIGNERLITEThe application is openedand the screens aredisplayed.Verify that the HMI isconnected to your PC withthe cable XBT-Z915 oralternatively with the USBadapter TSXCUSB485 andthe cable XBT-Z925 (B).2 Use:Device->Download…to download the applicationto the HMI.3 Select the languages youwish to download to theHMI.Continue with Download.4 You are asked to overwriteany application already inthe HMI.Continue with OK.Optimized HW Twido Schneider Electric 52


5 Note:If the communications drivercannot be activated, you willhave to change the set up inthe Driver Manager - seethe Driver Manager sectionfor this procedure.6 The transfer is started.7 A progress bar is displayed.8 You are informed that thetransfer is successfullycompleted.Continue with OK.Optimized HW Twido Schneider Electric 53


Driver-ManagerAdding interfaces1 The Drive-Manager is aseparate tool used to set upthe communications drivers.Start the tool in Windowswith:Start->All Programs->Schneider Electric ->Communication Drivers ->Driver Managerand go to the UNITELWAYDriver tab.2 Click on Configuration.3 A list of available interfacesis diplayed for example,COM5For the serial interface withthe XBTZ915 cable, youhave to add COM1.Click on Add Station…Optimized HW Twido Schneider Electric 54


4 Select COM1 as COM Port.For the Station ID, enterHMI.Close the dialog with OK.5 The second interface is nowvisible.Close the dialog with OK.6 The drivers are reset andinitialized.7 The reset is confirmed.Continue with OK.Optimized HW Twido Schneider Electric 55


DevicesIntroductionThis chapter describes the steps required to initialize and configure the different devicesrequired to attain the described system function.ATV12GeneralThe initialization and configuration of the ATV12 is done using the SoMove Lite software orusing the integrated operator’s panel.PreparationForCommissioningThe advantages of using the SoMove software are: The data can be stored on the PC Documentation can be printed and The tool supports online optimization of the parameters.Setting up the ATV is done as follows: Configuration using the operator’s panel Set up the Low Set Point Input the nominal power Configuring ATV12 with SoMove Lite Download the configuration Store customer parameter set on ATVNote:If this is not a new drive it is recommended to return to the factory settings. If you needinstructions on how to do this, please read the drive documentation.To speed up the commissioning, first makea note of the motor data found on the motortype labels (see example on the right) Thisdata includes:Nominal voltageNominal powerNominal frequencyPower factor cos At the time of configuration, the VSD mustnot be under Twido control (that is, nocommands are issued from Twido to thedrive).Motor name plateOptimized HW Twido Schneider Electric 56


Configurationusing theOperator’sPanel1 On first start-up of the VSD the displayshows bFr and indicates that the basicfrequency of the motor needs to beinput.Press the key ENT and, using the jogdial, input the nominal frequency. Theinput range is 50 to 60 Hz. Confirm theinput with ENT.Now restart the VSD. The screenshows rdy.2The menus shown here are only thosethat are required to be used for thisarchitecture. See the ATV12 manualfor a full description.The display shows rdy, from here you can jump to the rEF, MOn and COnF – mode bypressing mode and turning the jog dial. To change configuration settings you alwayshave to go through the COnF -mode.3To access the CoS – menu for setting the cos phi – parameter, first you have to switchfrom nPr (nominal power rating) to COS.Optimized HW Twido Schneider Electric 57


Input thenominalmotor values4Go to the menu drC (Drive control) and setup the drive parameters as written on themotor type label.These are:CoS – Rated motor cos phiUnS – Rated motor voltagenCr – Rated motor currentFrS – Rated motor frequencynSP – Rated motor speedThe parameter UnS, is the nominal voltage of the motor (factory setting: 230 Vac).Single phase drives accept a maximum of the mains voltage, so that here the value canonly be reduced. Note that motors with a nominal voltage of 230/400 Vac require adelta connection.The parameter FrS is the nominal frequency of the motor and can usually be left at thedefault value of 50Hz.In the following picture you can see the default values.Optimized HW Twido Schneider Electric 58


Thermalcurrentsetting5Go to ItH press the ENT key and input the nominal power value using the jog dial. Thedefault value is 1.1 Amps.Confirm the input with ENT.Currentlimitation6In the menu CLI you can define the maximum allowed current for the motor.This value should be higher than the nominal power rating to allow a certain amount ofoverload.(for example, CLI = 1.25 * nCr).Optimized HW Twido Schneider Electric 59


Speedsettings7SPL (Speed limit menu) is the menu for the target frequency of the drive when a 24 Vdcsignal is input to the ATV12 via digital input LI1 (FWD) or LI2 (REV).Go to SPL. Now press ENT and go to LSP (Low speed) to modify the value, the defaultvalue is 0.0 Hz.Use the jog dial to input a value of 35.0 Hz.Go to the next entry in the menu, HSP (High speed). Here you can input the maximumallowed speed.This value is normally set to a default value of 50 Hz and can be left as it is.ConfigurationforPS2=SetPointSpeed2(LI3High)Andsetting forSPEED2 (SP2)8Go to the menu PSS (Preset speed menu). Now press ENT and go to PS2 (SetPointSpeed2) and select the Input L3H. If this Input is high, the frequency value from theparameter SP2 (Preset speed 2) is selected as target frequency. Go to PS4 (SetPointSpeed4) and select the Input L4H. If this Input is high, the frequency value from theparameter SP3 (Preset speed 3) is selected as target frequency.Afterwards you can select the parameter SP2 and SP3. Press ENT and use the jog dialto input a value of 35 Hz for the setpoint Speed2 and 50 Hz for the setpoint Speed3.Optimized HW Twido Schneider Electric 60


I/O-settings 9In the menu I_O you can define options regarding the In- and Outputs of the ATV12.Go to tCC and leave the setting on 2C which means that the ATV12 can be driven by 2wires. Then enter to tCt and check if it is set to trn (Transition mode).I/O setting forRRS =Reverse(LI2High)10In the menu FUn you can define application functions of the ATV12.Go to rrS (Reverse) and select the Input LI2High. If this Input is high, the drive runs inReverse-mode.Optimized HW Twido Schneider Electric 61


ConfiguringATV12 withSoMove Lite1 After starting SoMove Lite you willsee the window as shown here on theright – the version is automaticallyshown in english.2 To create a new Project, selectCreate a Project OFF-line andchoose the desired device.Continue with Next.3 In the Device dialog, select aReference-Type and the FirmwareVersion.In this example:Reference: ATV12H037M2Version: V1.1IE01The Version defines a set offunctions.Additional information displayed:- Supply Voltage- Nominal Power- Nominal Current- Max Transient Currentof the VSD.Continue with Create.Optimized HW Twido Schneider Electric 62


4 To save the project useFile–>Save as…Insert the File name (here ATV12)and continue with Save5 Select:Communication->Edit Connectionto go to the connection dialog.6 Select Advanced to check and editthe connection settings.Optimized HW Twido Schneider Electric 63


7 Select the appropriate COM Port,here COM1 is used.Baud Rate: 19200Parity: EvenStop Bits: 1You can also perform a test of theconnection by clicking on TestContinue with OK.8 You can also perform a test of theconnection by clicking on Test.Continue with OK.9 The Main-Window of SoMoveconsists of four tabs. The tab,MyDevice, includes the basicinformation about the device.10 The tab, Parameters, shows a tableof all adjustable parameters.Optimized HW Twido Schneider Electric 64


11 The tab, Fault Detection, shows thecurrent current detected faults.12 The tab Monitoring, is used tomonitor the parameter values of theVSD. Click on the parameter to beobserved and then click again on theplane on the right hand side.13 On the Parameters tab, selectMOTOR CONTROL.Leave the value for BFR at 50Hz.Insert your motor values as found onthe name plate of the motor.Optimized HW Twido Schneider Electric 65


14 Select:FAULT MANAGEMENT MOTOR THERMAL PROT.Modify ITH according to the values foryour motor.15 Select:Application Funct.Set the Input for RRS to LI2 high RAMPChange ACC & DEC to 0.1s PRESET SPEEDSSet the Input for PS2 (2 presetspeeds assign.) -> LI3 high andLI4 high.The Preset speeds can bechosen by setting the appropriateinputs of the drive. Change SP2(Preset Speed 2) to 35Hz andSP3 (Preset Speed 2) to 50Hz. SPEED LOOPSet LSP (Low Speed) to 5 Hz16 Select:INPUTS / OUTPUTS CFGSet TCC to 2 wire.Set TCT to Transition.Optimized HW Twido Schneider Electric 66


17 Select:File-> Saveor use the icon in the toolbar, to saveyour configuration.Download theConfiguration1 Check that the PC is connected to theAltivar drive.For this use the cable setTSCMCNAM3M002P.2 To download the configuration to thedrive click on icon in the toolbar:Store Values to DeviceOptimized HW Twido Schneider Electric 67


3 Before proceeding read thenotification carefully.If you agree to follow theseinstructions, press Alt+F.4 A progress bar is displayed during thedownload.Connect toDevice /Upload theConfiguration1 To connect to the device click theConnect to Device icon in the toolbarOr select:Communication->Connect to Device2 To upload the configuration to the PCanswer the question that follows withYESThe configuration in the PC-File willbe overwritten!Optimized HW Twido Schneider Electric 68


3 You can also upload the configurationfrom the device into PC by clicking onthe Load Values from Device iconAnd answer the question withYES4 A progress bar is displayed during theupload.HMI Personalization1 With SoMove you can configure themain menu of your ATV to make thenavigation easierSelect:Device->ATV12 HMI Personalization2 Tab: MyMenuHere you can customize the mainmenu of the ATV12 by selecting theitems to be shown.3 Tab: VisibilityHere you can select the mostcommon parameters which should beshown in the ATV12 HMIOptimized HW Twido Schneider Electric 69


Store currentconfigurationon ATV121 To permanently store the downloadedconfiguration into the drive, select:Configuration -> Store currentconfigurationYou are asked to store the currentconfiguration in the drive´s memory.Answer the question with YesAfter the configuration has beenstored a message is beeingdisplayed.Confirm with OK.Optimized HW Twido Schneider Electric 70


AppendixDetailed Component ListThe following tables provide a list of the main components for the Optimized HW Twidoarchitecture. The complete bill of materials is included in the EPLAN file for the OptimizedHW Twido.Hardware-ComponentsPos. Qty. Description Part NumberSarel cabinet 1.1 1 Cabinet, 800 x 600 x 400mm (Sarel) 833441.2 1 Fan filter, 230 Vac, 56 m³/h (Sarel) 879011.3 2 Filter unit for ventilation (Sarel) 879111.4 1 Thermostat for Fan, 0..60°C (Sarel) 875621.5 1 Phaseo Power supply 230 Vac / 24 Vdc 3 A ABL8REM24030Pos. Qty. Description Part NumberMain switch 2.0 1 Disconnect switch Harmony Vario VCD0Rev/Vers.Rev/Vers.PLC and I/OmodulesPos. Qty. Description Part Number4.0 1 Twido controller Compact with 24 I/Os TWDLCDA24DRF4.1 1 RS485 Interface adapter for Magelis HMI TWDNAC485DRev/Vers.FW4.20Pos. Qty. Description Part NumberDrives , Servo 5.0 1 ATV12 variable speed drive 0.37 kW ATV12H037M2Drives & Motor 5.1 1 TeSysU Base unit for two directions LU2B12BLStarter 5.2 1 TeSysU Control unit LUCA05BLPos. Qty. Description Part NumberSensor 6.0 2 OsiSense Limit switch XCKP2118P16Pos. Qty. Description Part NumberHMI 7.0 1 HMI Magelis XBT-N XBTN401Rev/Vers.Rev/Vers.Rev/Vers.Emergency-StopPos. Qty. Description Part Number8.0 1 Preventa Emergency Stop safety module XPSAC51218.1 1 Harmony Emergency Stop pushbutton XB5AS8448.2 1 TeSys Motor circuit breaker, 14 A GV2L168.3 1 Auxiliary contacts for circuit breaker 1 NO 1 GVAE11NC8.4 1 Illuminated Push button 1NC, blue XB5AW36B5Rev/Vers.Optimized HW Twido Schneider Electric 71


Pos. Qty. Description Part NumberPushbutton 9.0 1 Harmony Box for 3 button XALD03andTower Light 9.1 1 Harmony Signal lamp LED white XB5AVB19.2 2 Harmony Pushbutton with LED green XB5AVB39.3 1 Harmony Pushbutton with LED red XB5AVB49.4 1 Harmony Tower Light XVBL1B5Rev/Vers.Software-ComponentsPos. Qty. Description Part NumberRev./Vers.Software and 10.0 1 TwidoSuite Software TWDBTFU10M V2.20cable 10.1 1 USB programming adapter TSXCUSB48510.2 1 Communication cable Twido-HMI XBTZ968010.3 1 Vijeo Designer Lite VJDSNDTMSV12M V1.210.4 1 Programming cable PC-HMI XBTZ91510.5 1 SoMove Lite VW3A820010.6 1 Altivar-Set Connection cable for drives TSCMCNAM3M002POptimized HW Twido Schneider Electric 72


Component Protection ClassesCabinetPositioning ComponentIn Field, On SiteFront InsideProtection Class IP54 IP65 IP67 IP55 IP65 IP20Harmony Emergency Stop switch X XVario Disconnect Switch VCD0 X XTeSysD Contactor LC1DXTeSys Motor Circuit breaker GV2LXTeSysU Motor Starter CombinationXAltivar 12 variable speed driveXPhaseo Power Supply ABL8XHarmony Emergency Stop switchXPSACXTwido controllerXIlluminated switches, series ”Harmony“with housingIP66Harmony Compact tower light XVBXOsiSense limit switch XCKXFilter and fanIP40Fan thermostatXOptimized HW Twido Schneider Electric 73


Component FeaturesComponentsTwido controller (TWDLCDA24DRF+ TWDBTUF10EF)The controller used in this example comprises the power base of a Twido compactcontroller and a programming set comprising software and a programming cable 24 Vdc 14 digital inputs 10 digital relay outputs3 programming languages: Ladder Language (LD) Instruction List (IL) Sequential FunctionChart/Grafcet (SFC)Expansions: Up to 4 expansion modules (Fieldbus-, Digital- & Analog-I/O-Modules) Communication adapter RS232/RS485 Back-up function with EEPROM Real time clockPre-defined functions: Drum control Fast Counters up to 5 kHz Very Fast counters up to 20 kHz Frequency measuring 1..20 kHz Reserved Memory for LIFO/FIFO-processing PWM-/PLS-Outputs External PLC-Start PID-controllerPower Supply Phaseo ABL8RPS24030- 100…240 Vac / 24 Vdc- 3.0 A secondary- Short circuit protectedOptimized HW Twido Schneider Electric 74


ComponentsContd.Variable Speed Drive Altivar 0.37 kW, 230 Vac single phase Integrated EMC FilterATV12H037M2 Temperature Range: - 10..+ 50°C Speed range 1 to 20 (0.5..400 Hz) Speed control using Flow Vector Control Drive and motor protections Compact profile, In-row mounting on a DIN railMotor starter combinationTeSysU: LU2B12BL+ LUCA05BL Motor output up to 1.5 kW Reversing contactor control with elect. and mech. interlock Tripping current, adjustable within the range 1.25…5 A Trip feedback via auxiliary contacts Optional activation of a brake using auxiliary contacts Compact dimensions Minimum wiring requirementsPreventa Safety Module: XPSAC5121For monitoringEmergency StopMax. category accord. EN13849-1 3No. of safety circuits3 N/ONo. of additional circuits1 Solid-StateIndicators2 LEDPower supply AC/DC24 VResponse time on input opening< 100 msAC-15 breaking capacityC300DC-13 breaking capacity24 V/2 A - L/R 50msMinimum voltage and current 17 V/10 mADimensions (mm) 114 x 22.5 x 99ConnectionCaptive screw-clamp terminalsDegree of protectionIP20 (terminals)IP40 (casing)Optimized HW Twido Schneider Electric 75


ComponentsContd.TeSys Motor circuit breaker Motor circuit breaker Isolating switch: GV2L16, 14 A 33.5 magnetic activationTeSysD Contactor LC1D09BD Rated current 9 A, AC3 1x NO contact 1x NC contact Positive opening operation 24 Vdc control voltage incl. suppressor circuitMagelis XBTN401LCD-Screen with 3 selectable functions 4 line text display Integrated alarm management Modbus RTU Master 24 Vdc Flat profile, IP65 Quick mounting using spring clampsOptimized HW Twido Schneider Electric 76


ContactPublisherProcess & Machine BusinessOEM Application & Customer SatisfactionSchneider Electric Automation GmbHSteinheimer Strasse 117D - 63500 SeligenstadtGermanyHomepagehttp://www.schneider-electric.com/sites/corporate/en/home.pageAs standards, specifications and designs change from time to time, please ask forconfirmation of the information given in this publication.Optimized HW Twido Schneider Electric 77

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