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CHRYSLER

Project Book Version 6.0

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Project Book
Version 6.0

Revision Information

Revision Version Revised


Date Number Document Name Revision Affected Sections By
11-1-06 1.0 Project Book V1 First Release All
1-1-07 2.0 Project_Book_- Various part number 3.1, 3.3, 4.1, 6.1, 8.1, 8.2, McGinn/
_Telemecanique_v2 and architecture 8.4, 8.5, 8.6 Dollins
corrections (detail)
7-1-07 3.0 Project_Book_- Rearranged sections 2, 2.1, 2.2, 2.3, 2.4, 3, 3.1, McGinn/
_Telemecanique_v3 and various part 3.2, 3.3, 4, 4.1, 4.2, 5, 5.2, Dollins
number changes 6, 7, 8, 8.1, 8.2, 8.3, 8.5,
(detail) 8.6
1-1-08 4.0 Project_Book_- Removed Daimler 1, 2.3.1-2.3.5, 5.1.1, 5.5.4, Perez/
_Schneider_Electric name and various 5.5.7, 5.5.8, 5.6.1, 5.6.5 Dollins
_v4 part number changes
(detail)
1-1-09 5.0 Project_Book_- Added Contacts in Perez
_Schneider_Electric India & Mexico
_v5 (detail)
1-1-10 6.0 Project_Book_- Various part number 1, 2.1.2, 2.1.3, 2.2.1, Perez
_Schneider_Electric additions and 2.2.2, 5, 5.1.1, 5.1.2,
_v6 changes, contact in 5.1.3, 5.1.5, 5.2.1, 5.2.3,
Italy added 5.3.1, 5.3.1, 5.3.3, 5.4.1,
(detail) 5.5.2, 5.5.3, 5.5.4, 5.5.6,
5.5.8, 5.5.9

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Index/Contents
1 Supplier Information / Contact information ............................................................... 4
2 Scope of Supply ....................................................................................................... 5
2.1 Automation ......................................................................................................... 7
2.1.1 PLC Equipment .......................................................................................... 7
2.1.2 HMI Equipment .......................................................................................... 8
2.1.3 Networks .................................................................................................. 10
2.1.4 Motion Control and Drives........................................................................ 13
2.1.5 Safety ....................................................................................................... 14
2.2 Control Products............................................................................................... 16
2.2.1 I/O Devices............................................................................................... 16
2.2.2 Other Machine Control Products .............................................................. 17
2.2.3 Network I/O & Devices ............................................................................. 18
2.3 Power Distribution ............................................................................................ 19
2.4 Engineering Services........................................................................................ 20
2.4.1 Program Management ............................................................................. 20
2.4.2 Integration Services ................................................................................. 20
3 Architecture ............................................................................................................ 21
3.1 Assembly Architecture ...................................................................................... 21
3.1.1 Assembly Architecture: Auto and Semi-Auto Stations.............................. 22
3.1.2 Assembly Zone Architecture: Line Layout ................................................ 23
3.1.3 Assembly Distributed Architecture: Line Layout ....................................... 24
3.1.4 Assembly Conveyor Controller: Separate Conv Control / Sta Control..... 25
3.1.5 Assembly Manual Station in Zone Architecture........................................ 26
3.1.6 Assembly Manual Station in Distributed Architecture............................... 27
3.1.7 Hybrid: Example showing three grouped manual stations........................ 28
3.2 Machining Architecture: .................................................................................... 29
3.2.1 Transfer Machine Architecture ................................................................. 30
3.2.2 Flexible Machining Cell Architecture ........................................................ 32
3.3 Architecture for General Machines ................................................................... 35
4 Software Approach................................................................................................. 36
4.1 Logic Structure ................................................................................................. 37
4.1.1 Integrated Diagnostics and HMI paging ................................................... 37
4.1.2 System Reporting..................................................................................... 38
4.1.3 Object Based............................................................................................ 38
4.1.4 Configuration versus Programming.......................................................... 38
4.1.5 Model Management ................................................................................. 39
4.1.6 Alternative approaches (PL7 vs. Unity) .................................................... 39
4.2 Device Interfaces.............................................................................................. 39
4.3 HMI Screens..................................................................................................... 40
4.4 Programming Software ..................................................................................... 40
4.5 Flex Cell Agent Technology.............................................................................. 40

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5 Program Components ............................................................................................ 41


5.1 Automation Controls ......................................................................................... 42
5.1.1 PLC Equipment ........................................................................................ 42
5.1.2 Intelligent Modules ................................................................................... 43
5.1.3 PLC Programming Software..................................................................... 44
5.1.4 PC to PLC Programming Cables.............................................................. 44
5.1.5 Operator Interface .................................................................................... 44
5.2 Networking........................................................................................................ 45
5.2.1 Ethernet Hardware ................................................................................... 45
5.2.2 CanOpen Hardware ................................................................................. 46
5.2.3 ASi Hardware ........................................................................................... 46
5.3 Inputs/Outputs .................................................................................................. 47
5.3.1 I/O (Racks and Telefast) .......................................................................... 47
5.3.2 Network I/O (Flex IP20)............................................................................ 48
5.3.3 Network I/O (Field IP65/67)...................................................................... 49
5.3.4 Terminals ................................................................................................. 52
5.4 Safety ............................................................................................................... 53
5.4.1 Safety Relays ........................................................................................... 53
5.4.2 Asi Safety ................................................................................................. 53
5.4.3 Programmable Safety .............................................................................. 53
5.5 Devices............................................................................................................. 54
5.5.1 RF Tag System ........................................................................................ 54
5.5.2 Servo Motors And Drives ......................................................................... 54
5.5.3 Frequency Drives And Soft Starts ............................................................ 55
5.5.4 Motor Control ........................................................................................... 56
5.5.5 Control Relays.......................................................................................... 58
5.5.6 Beacons, Horns & Stack Lights................................................................ 58
5.5.7 Pushbuttons & Pilot Lights ....................................................................... 59
5.5.8 Sensors .................................................................................................... 60
5.5.9 Cables And Sensor Docks ....................................................................... 62
5.5.10 Power Supplies ........................................................................................ 63
5.6 Circuit Protection and Electrical Distribution ..................................................... 64
5.6.1 Disconnect Hardware ............................................................................... 64
5.6.2 Circuit Breakers........................................................................................ 64
5.6.3 Fuse Blocks & Splitter Blocks................................................................... 66
5.6.4 Transformers............................................................................................ 66
6 Revision Log .......................................................................................................... 67
6.1 Version 2.0 Revision Detail............................................................................... 67
6.2 Version 3.0 Revision Detail............................................................................... 67
6.3 Version 4.0 Revision Detail............................................................................... 68
6.4 Version 5.0 Revision Detail............................................................................... 68
6.5 Version 6.0 Revision Detail............................................................................... 68

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1 Supplier Information / Contact information


Schneider Electric is the corporate manufacturing entity. Schneider Electric products
carry different brand names. Most common are the Telemecanique, Square D, Modicon
and Merlin-Gerin brands. There are other less common ones as well. See Schneider
Electric Brands for more information.

Contact Information:

Name Role Phone Mobile


International
Manny Perez Account Manager +1 248 457 4162 +1 248 835 5824
Armando Martinez Liaison Mexico 5804 5162 044 55 1069 3511
Horst Kuhn Liaison Germany +49 711790887521 +49 1722131456
Imad Siddiqui Liaison India +912240170000/12 +91 9323736111
Masakazu Kase Liaison Japan 81 3 52 932 8000
Alfredo Longhitano Liaison Italy +39112281211 +393299020745

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

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

Automation  Control Transformers & Power


 PLCs & PACs Supplies
 HMIs (dedicated, PC, web server,  Sensors (proximity, photo, ultrasonic,
SCADA) limit, pressure)
 Motion Control & Drives  RFID Systems
 Industrial Networks Power Distribution
 Safety Control  Substations (LV/MV Switchgear)
System Capabilities  Panelboards
 Network Design  Motor Control Centers
 Production Monitoring Systems  Lighting Control
 Industrial Performance Services  Power Monitoring and Metering
Building Automation  Power Factor Correction and
 HVAC Transient Suppression
 Access Control Power Equipment Services
Machine Control  Maintenance and Repair
 Motor Control and Soft starts  Refurbishment (Retrofit/Retrofill)
 Relays, Terminal Blocks  Arc Fault and Current Fault Potential
 Pushbuttons, Pilot Lights Analysis
 Stack Lights, Beacons  Enterprise Monitoring
 Circuit Breakers, Disconnects,
Safety Switches

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

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

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2.1 Automation

2.1.1 PLC Equipment

There are three PLC options, depending on the architecture chosen, including the
Premium, M340 and Quantum. Processor capability may determine the architecture
chosen. The Premium range can be programmed with Unity or PL7 software while the
M340 range is programmed with Unity only and the Quantum is programmed with Unity,
Concept or Proworx software.

The M340 will be the primary controller for distributed systems with Premium for more
central systems and stations requiring complex motion control. The Quantum may be
used if process control or PID loops are required. Each system will include Ethernet
Modbus TCP/IP as the primary network with options for additional networks to support
varied device strategies.

Detailed information on each of these processor ranges can be found in Schneider


Electric technical documentation. Below is a quick reference of the three CPU ranges.

PREMIUM M340 QUANTUM


Unity, Concept,
Unity, PL7 Unity
Programming Software Proworx
2048 discrete 1024 discrete limited only by memory
Max I/O Configuration 512 analog 256 analog 1024/1024 local
Performance
Boolean Instruction
Execution Time
.0375 µs .06 µs 0375 µs
Typical Machine
Application (65% Boolean)
14 K instr/ms 6.9 K instr/ms 14 K instr/ms
Memory Capacity
Code 7168 Kbytes 70 K instructions 7.1 Mbytes
User Data 896 Kbytes plus file 256 Kbytes plus file 768Kbytes plus file
Ethernet Modbus Ethernet Modbus Ethernet Modbus
Networks TCP/IP TCP/IP TCP/IP
CanOpen, AS-i CanOpen CanOpen, AS-i
Interbus, Profibus, Fip,
Interbus, Profibus, MB+
MB+

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2.1.2 HMI Equipment

The primary HMI used will be the XBTGT family. This is a scalable family with systems
of various sizes all programmed using Vijeo Designer Software. Templates will be
provided per the Chrysler specification with options to support the proposed logic
strategy.

The use of PCs is generally discouraged and requires special approval from Chrysler.
However, PCs still can still provide valuable functionality. Care should be taken to apply
them in ways that allow production to continue while PCs are in maintenance. The
Compact IPC and Smart IPC ranges can provide integrated PC and HMI functionality
using similar templates as developed for the XBTGT and using the same Vijeo Designer
programming software.

Below is a quick reference for these HMI families.

XBT-GT Magelis IPC Web Browser SCADA


Smart, Compact, Vijeo Citect
Catalog Numbers XBTGTxxxx Factory Cast HMI
Modular SCADA
Programming Web tool or Vijeo Web tool or Vijeo
Software
Vijeo Designer Vijeo Citect SCADA
Designer Designer
from 3.8” to 15”
Screen Size 12” or 15” Any Any
available
Display Type STN or TFT TFT, 16K colors Any Any
Data Entry Touch or Keypad Touch or Keypad Any Any
Ethernet, Serial, Ethernet, serial,
Communication Simatic, Melsec, Simatic, Melsec, Any Any
etc. etc.

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

These systems are typically built on our modular “Tego” enclosure offer. This is a line of
customizable enclosure equipment directed to smaller systems.

Schneider also has designs for integrated material handling control systems that can be
adapted to meet many assembly needs: ConveyorPak.

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2.1.3 Networks

One of the architecture goals is to make greater use of network I/O and devices while
also reducing the number of networks. The core network for the complete Schneider
Electric system will be Ethernet using Modbus TCP/IP protocol. A second device level
network will be available and shown for most system options to provide modularity and
reduced cost for I/O and devices.

The network strategy is based on using Ethernet as the primary network with ASi or
other network of choice as required to provide a complete and effective installation.

At the machine level, devices and I/O typically rest on a device level network, which,
depending upon the system, will be Ethernet, ASi or other network of choice. Controllers
will rest on the department level Ethernet network. This network will provide machine
interlocking, HMI connection and can serve system data as well. There can be another
segregated Ethernet network for systems if preferred, but it is not technically required.
HMIs and third party devices such as robots, nut-runners, etc. can rest on either the
device network or the department network.

Below is a department level view of the network architecture

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

A complete range of Ethernet networking hardware is described in this section. For


more detail and for specific detail on other networks (ASi, CanOpen, etc.), follow the
links in the product list sections.

Schneider’s line of Connexium Ethernet hardware includes a full range of switch and
cabling equipment to support a variety of industrial Ethernet networks from simple to
highly complex systems. The offer includes:

 Basic 3 and 5-port


industrial switches
 Hardened IP67 5-port
switches with M12
connections
 Managed switches
from 4 to 24 ports
(copper or fiber uplink)
 Transceivers for media
conversion
 Industrial Cat-5e
cables (RJ45 and/or
M12 terminations)
 Hardware for field
termination of
industrial Ethernet cable
 Support for redundant networks

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As for the network masters, the Premium, M340 and Quantum controllers have Ethernet
interfaces as options built in to the CPUs or as a slot module. Services supported by
these networks include: global data, I/O scanning, broadcast with IGMP/GMRP filtering,
time-synch with SNTP/PTP, VLAN, BootP, SNMP, DHCP.

The Connexium network diagnostic software (ConnexView) provides a great deal of


features to support the configuration and troubleshooting of industrial Ethernet
networks. This includes configuration, backup, topology discovery, traffic optimization,
alarm reporting, port security and many more features.

Similarly, CanOpen and ASi master modules are available for all three offers as well as
supporting hardware, power supplies, cabling and devices (see device section and
product list).

As a matter of connectivity, where third party equipment is required, additional interface


modules are available (i.e. Profibus, Interbus, DeviceNet). And the Ethernet system can
be adapted to support third party protocols via Schneider’s TCP-Open Technology.

In 2007 Schneider Electric became a principal member of the


ODVA, the standards organization that governs EtherNet/IP and
other protocols belonging to the CIP family.

Schneider Electric is committed to expanding our Transparent


Ready architecture by supporting both Modbus/TCP and
EtherNet/IP protocols and services. As a result, we can now offer
several Ethernet/IP compatible products, with more to come.
Additionally, our Magelis HMIs and VijeoCitect SCADA software
already support Ethernet/IP communication along with many more
3rd party communication protocols.

Schneider Electric’s commitment to open communications ensures our customers can


integrate Schneider Electric products into a wide array of product architectures. This
benefits our customers by enabling them to maintain a single network for multiple
automation components from various vendors, which simplifies network maintenance
and lowers the cost of ownership.

Products Now Available:


Premium Ethernet/IP Module TSX ETC 100
Advantys STB Ethernet/IP Module STB NIC 2212
Advantys ETB IP67 I/O Modules ETB 1EI *****
Altivar 71 VFD Communications Card VW3A3316

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2.1.4 Motion Control and Drives

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

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

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

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2.1.5 Safety

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

● Traditional safety relay systems


● Configurable multi-function safety
relays
● ASi network safety relays
● Safety controllers without safety
network
● Safety controllers with safety
network

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

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

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Schneider Electric can also provide power distribution panels with the safety system
integrated.

Below is a functional view of a sample PDP design that incorporates safety functions. It
provides switched power controlled by the safety circuit as well as control power that
can be switched and unswitched. A variation provides only 460V and 110V to a
secondary bus (24V is generated in the plugs – see below)

The power distribution concept incorporates safety at the source. Safety inputs are
brought into a PDP (power distribution panel) via ASi-Safe (alternatively by a classical
safety relay dual channel circuit). The output controlled is the actual power source so no
further consideration of safety is required downstream. The full system is protected to
Category 4.

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2.2 Control Products

2.2.1 I/O Devices

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

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

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2.2.2 Other Machine Control Products

The machine control product offer itself extends to the following additional areas:

 Sensors
o Mechanical Limit
o Inductive Proximity
o Photo
o Pressure
 Relays
o Control
o Protection
 Terminal Strips
o Fuse Holders
o Distribution Blocks
 Pushbutton, Pilot Lights
 Frequency Drives
 Motor Control
o Contactors
o Starters
o Motor Circuit Protectors
o Motor Management
System
o Soft starts
 Alarm Beacons
o Stack Lights
o Horns
 Safety Disconnects
 Control Transformers
 Transformer Disconnects
 Panel Main Disconnects
 Power Supplies
 Circuit Breakers
o Molded Case
o Compact
o Automatic Switch

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2.2.3 Network I/O & Devices

What is shown in the architecture drawings in section 3 is meant to leave some


interpretation for OEMs regarding exact topology and the mix of devices that connect
discretely or over a network. More than one option exists for many devices. Connectivity
to other networks is also an option.

Examples of devices that can be connected to the ASi


network

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

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2.3 Power Distribution

Contact Square D/Schneider Electric for any power distribution needs. Power
distribution is not covered in this document. However, Schneider Electric provides a
complete range of industrial power products and technologies for distributing and
monitoring power. For example, I-Line Busway, Bus225, PowerLogic monitoring
systems, harmonic filtering and power factor correction equipment, and power system
engineering services.

Additionally, the new UL508A and NEC409 regulations may warrant a closer look at
engineered MCCs (motor control centers) and panelboards on the floor level for
machine power distribution.

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2.4 Engineering Services

2.4.1 Program Management

Depending on the Schneider Electric product content, a typical powertrain


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

2.4.2 Integration Services

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

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

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

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

3.1 Assembly Architecture

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

 More of a system than a collection of machines


 Simple manual stations in addition to more complex systems
 Low power requirements compared to machining systems
 Greater use for enclosed equipment to reduce/eliminate custom panels

For these reasons the approach differs from other parts of the complete Powertrain
manufacturing process. Also, subassembly systems and some simple automation might
use more of the assembly architecture than the machining architecture.

There are numerous possibilities, but examples shown here are for 3 types of
architectures. If these architectures do not suit a specific OEM design, Schneider
Electric will consult with the OEM to customize an architecture that best suits their
needs.

1) Zone Architecture – The line will be broken up into zones and each zone will
have a zone controller which will control the transport, stops, manual stations,
manual back-up stations, and lifts and rotates that are not included in automatic
stations. Each Automatic station will have its own controller.
2) Distributed Architecture – There are no zone controllers. Every manual station,
lift, rotate and automatic station will have its own controller. There may be
additional conveyor controllers to handle sections of conveyor with stops and any
other device not associated with a specific station.
3) Hybrid – The Chrysler specification limits an area system to five stations. Any
combination of equipment from fully distributed to this is acceptable.
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3.1.1 Assembly Architecture: Auto and Semi-Auto Stations

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3.1.2 Assembly Zone Architecture: Line Layout

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3.1.3 Assembly Distributed Architecture: Line Layout

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3.1.4 Assembly Conveyor Controller: Separate Conv Control / Sta Control

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3.1.5 Assembly Manual Station in Zone Architecture

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3.1.6 Assembly Manual Station in Distributed Architecture

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3.1.7 Hybrid: Example showing three grouped manual stations

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3.2 Machining Architecture:

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

1) Transfer Machine Architecture – For the purpose of this approach, the station
architecture and the transfer architecture are the same with console functionality
available at any station through “virtual console”. Both the station detail and a
machine operation overview are shown.
2) Flexible Machining Cell Architecture – An overall operation overview is shown
as well as a gantry system detail. A potential architecture using similar
technology with an OEM specified CNC is shown for the machine tools
themselves.

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

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3.2.1 Transfer Machine Architecture

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

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

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3.2.2 Flexible Machining Cell Architecture

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

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3.3 Architecture for General Machines

Machines that are not specifically part of the architectures described above can be
accommodated in a similar manner. If a device I/O structure is preferred then machines
in the assembly areas should use ASi in a manner similar to the rest of the assembly
line architecture and those in machining departments should use automation islands
with a network structure similar to the rest of the department.

For the case of some general systems (esp. simple equipment, HVAC and filtration
equipment) a classical discrete I/O approach may be more suitable than using a device
network exclusively. Both the TSX Premium and M340 systems support complete offer
of standard discrete I/O to support this need.

For facilities equipment, OEMs can make use of custom turn-key Square D equipment
from Schneider such as PDPs (power distribution panels) and MCCs (motor control
centers).

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4 Software Approach
There are two approaches to software design, traditional ladder logic and structured
programming. Since traditional ladder logic is familiar to all OEMs, only the structured
programming approach will be discussed here. That said, varied approaches may be
considered.

For the structured programming approach, Schneider Electric has developed a set of
software modules that provide necessary control and diagnostic functions for any
application. This document will provide an overview of the tools available, but in-depth
training on this software approach is available on an as-needed basis. Please contact
Schneider Electric for more information.

Following is a brief comparison of the two software approaches.

Traditional Ladder Logic Structured Programming


Generally easy to follow Integrated Diagnostic
Lower memory usage Common approach across program
Virtual console functionality
Easier to re-order machine sequence
Handles non/multi-sequence applications
HMI applications are standard
Easy to make online message changes
Consistent program look and feel
No guarantee on diagnostic Uses more memory
HMI applications specific to each PLC Initial learning curve is High
No consistency across PLC programs Training required to efficiently modify the program
Very difficult to validate

The goals of the structured programming approach include:

 Integrated Diagnostics and HMI paging


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

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4.1 Logic Structure

4.1.1 Integrated Diagnostics and HMI paging

Standard logical elements integrate these functions with the basic logic. Manual Control,
Auto Control, HMI paging, Machine Interlocking and Diagnostic Reporting are all
together. This prevents machine creep over time where the basic logical control is not
matched by corresponding fault handling. The system cannot stop without a
corresponding fault.

HMI Reporting

The HMI function for discrete control is fully integrated with the logic. No changes are
required to the HMI application to add or modify control functions. Console and zone
control functionality is available at all stations with access controlled (request/accept)
based on a “Virtual Console” implementation

Root Cause Diagnostics

The system fault reporting is “root cause”, that is the fault reported is not the action that
failed to occur but the condition that prevented it. Below is an example map of the
methodology:

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4.1.2 System Reporting

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

4.1.3 Object Based

The strategy employs a building block approach to programming. Common structures


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

4.1.4 Configuration versus Programming

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

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4.1.5 Model Management

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

4.1.6 Alternative approaches (PL7 vs. Unity)

As the purpose of the Project Book effort from the Chrysler perspective is to allow for
OEM best practices, this system allows for existing software strategies used on
previous programs to continue to be used. By using the Premium controller exclusively,
every aspect of the hardware architectures presented can be realized by using PL7 in
lieu of Unity programming software.

Also, Unity could still be utilized but with a more generic programming approach than
that described above. In fact, PL7 applications can be imported into Unity allowing
OEMs to maintain past programming practices and migrate to the Unity platform. This
also allows OEMs to use their current programming practices and use the more cost
effective M340 controller.

4.2 Device Interfaces


(reference to component section where appropriate)

Wherever possible standard interfaces will be written to interface to devices in a


common way. This interface will include logic (probably in the form of a function block)
and supporting documentation. Combined with software standards this will provide for a
common and validated method of implementing that device within the system.
Examples of standard interfaces might include:

 Motor Starter  Valve Stack


 RFID Tag  Nutrunner
 VFD Drive  Robot Interface
 Servo Drive  Machine Stop
 Stack Light  others as needed…

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4.3 HMI Screens

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

4.4 Programming Software

Programming software as described in this document breaks out as follows (please


follow links for more detailed product information):

 Unity: This is the common programming software for the Premium and M340
PLC ranges. It also supports the Quantum range and future Schneider offers.
 PL7: This platform is also available to program the Premium range. Applications
developed in PL7 can be imported and converted to Unity
 Vijeo Designer: This is the programming software for the XBTGT HMIs
 Vijeo Citect: This is the programming software for the SCADA system.
 Powersuite: VF Drive and Softstart configuration software
 Connexview: Ethernet network configuration and diagnostic software
 Safety Suite: Safety controller configuration software
 ASi Design: ASi design software
 Unilink: Servo drive configuration software
 TCP-Open: 3rd Party Ethernet protocol configuration utility

4.5 Flex Cell Agent Technology

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

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

NOTE: All components listed in the Project Book are UL approved.

Links to Component List Sections in this Project Book:


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

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

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

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

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5.1 Automation Controls


5.1.1 PLC Equipment
Premium Processors
TSXP576634M Premium Processor, 600 Series, Unity, Ethernet embedded
TSXP575634M Premium Processor, 500 Series, Unity, Ethernet embedded
TSXP574634M Premium Processor, 400 Series, Unity, Ethernet embedded
TSXP573634M Premium Processor, 300 Series, Unity, Ethernet embedded
TSXP572634M Premium Processor, 200 Series, Unity , Ethernet embedded
TSXP571634M Premium Processor, 100 Series, Unity , Ethernet embedded
TSXP574823AM Premium Processor, 400 Series, PL7, Ethernet embedded
TSXP573623AM Premium Processor, 300 Series, PL7, Ethernet embedded
TSXP572623M Premium Processor, 200 Series, PL7, Ethernet embedded
Premium Processor, 300 Series, PL7, Single Slot, Fipio
TSXP57353LAM * To be used for retools, upgrading from L1 or L2 single slot
CPUs or Atrium replacements
Premium Memory Cards
TSXMRPC768K SRAM Memory Card 128K (PL7) / 768K (Unity)
TSXMRPC001M SRAM Memory Card 1.0M (Unity)
TSXMRPC01M7 SRAM Memory Card 256K (PL7) / 1.7M (Unity)
TSXMRPC002M SRAM Memory Card 384K (PL7) / 2.0M (Unity)
TSXMRPC003M SRAM Memory Card 512K (PL7) / 3.0M (Unity)
TSXMRPC007M SRAM Memory Card 992K (PL7) / 7.0M (Unity)
Premium Racks
TSXRKY6EX 6 slot standard rack extensible
TSXRKY8 8 slot standard rack
TSXRKY12 12 slot standard rack
TSXRKY8EX 8 slot standard rack extensible
TSXRKY12EX 12 slot standard rack extensible
TSXCBYxxxK Rack Extension Cables
note: xxx = 010, 030, 050, 120, 280, 380 for 1, 3, 5 12, 18, 28, 38 meters respectively
TSXTLYEX Rack Terminators (Qty 2)
TSXRKA02 Empty Slot Covers (Qty 5)
Premium Power Supplies
TSXPSY1610M Power Supply 24Vdc 30 w non isolated
TSXPSY3610M Power Supply 24Vdc 50 w non isolated
TSXPSY2600M Power Supply 110Vac 26 w isolated
TSXPSY5500M Power Supply 110Vac 50 w isolated
TSXPSY8500M Power Supply 110Vac 77 w isolated

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M340 PLC CPUs


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

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5.1.3 PLC Programming Software


UNYSPUEFUCD41 Unity Pro V4.1 PLC Programming Software, Single License
UNYSPUEFGCD41 Unity Pro V4.1 PLC Programming Software, 3 License
UNYSPUEFTCD41 Unity Pro V4.1 PLC Programming Software, 10 License
UNYSPUEFFCD41 Unity Pro V4.1 PLC Programming Software, Site License
TLXCDPL7PP45 PL7 Pro V4.5 PLC Programming Software, Single License
TLXCD3PL7PP45 PL7 Pro V4.5 PLC Programming Software, 3 License
TLXOTPL7PP45M PL7 Pro V4.5 PLC Programming Software, 10 License
TLXOSPL7PP45M PL7 Pro V4.5 PLC Programming Software, Site License
5.1.4 PC to PLC Programming Cables
USB – RS485 external adapter cable Note: must also order
TSXCUSB485
TSXCRJDB25
Mini-DIN junction cable for PLC, (Premium, TSX Micro,
TSXCRJDB25
Twido)1.5 m Note: must also order TSXCUSB485
UNYXCAUSB033 USB port on a PC terminal, 3.3m
5.1.5 Operator Interface
Magelis Graphical Operator Interface, Ethernet
XBTGT7340 15" color touchscreen HMI with Ethernet
XBTGT6330 12" color touchscreen HMI with Ethernet
XBTGT5330 10.4” color touchscreen HMI with Ethernet
XBTZGM128 128 MB CF Memory Card for XBTG
XBTGK5330 10.4" color touchscreen HMI with Keypad and Ethernet
XBTZ9780 Serial connection cable for PLC or tap box
note: consider Tego mounting hardware for HMI/pushbutton panels
note: smaller HMIs are available but require a deviation to use from Chrysler
HMI Software (Vijeo Designer)
VJDSNDTGSV50M Vijeo Designer HMI Programming Software – single license
VJDGNDTGSV50M Vijeo Designer HMI Programming Software – 3 license
VJDTNDTGSV50M Vijeo Designer HMI Programming Software – 10 license
VJDFNDTGSV50M Vijeo Designer HMI Programming Software – Site license
Compact and Smart IPC/HMI (with approval only)
Magelis Compact iPC 15” PC based HMI (Windows XP Pro
MPCKT55NAX20H
with VijeoDesigner RT)
MPCYN00CF100N 1 GB Compact Flash card
MPCYK05RAM512 512M RAM option for Compact iPC
Magelis Smart iPC 15” PC based HMI (Windows XPe with
MPCST52NAJ20H
Vijeo Designer RT), with 1GB Compact Flash card included
note: many different configurations are available in the IPC range consult Schneider Electric

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

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5.2.2 CanOpen Hardware


Accessories and Cables
TSXCANCBx CanOpen Trunk Cable
note: x =50,100, 300r meters of length
TSXCANKCDF90T CanOpen SubD Connector 90o
TSXCANTDM4 Tap Box 4 x 9-pin Sub-D
TSXCANCBDDx Preassembled Drop Cables 9-pin Sub-D
note: x =03 for 0.3m, and 1, 3 or 5 for meters of length
VW3CANTAP2 Tap Box 3 x RJ45
VW3CANCARRx CanOpen RJ45 cables x = 03 for 30cm and 1 for 1m
IP65/67 Network Cabling
See section for IP67 Network I/O
5.2.3 ASi Hardware
see relevant sections for additional devices and safety monitors
System & Device Cabling
XZCB11001H 100m Yellow TPE Cable (Signal)
XZCB11002H 100m Black TPE Cable (Power)
TCSATN011F Cable tee with micro connector
XZCE40 Bulkhead gland for ASi cables
Power Supplies
ASIABLB3004 ASi Bus Power Supply (110/240AC Input)
TSXSUPSPEC0734 ASi Bus Power Supply (24VDC Input)
Repeater
ASIRPT01 ASi Network Repeater
Programmer Unit and Connection Kit
ASITERV2SET ASi Addressing Kit (incl. programmer and cables)

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

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5.3.2 Network I/O (Flex IP20)


Advantys STB Interface
STBNIP2212 Ethernet Modbus TCP Network Interface Module
STBNIC2212 Ethernet/IP Network Interface Module
STBNCO2212 CanOpen Network Interface Module
note: Interbus, Profibus, Devicenet and FipIO NIMs are also available, see link
Advantys STB Virtual Backplane
STBXBA1000 Backplane mounting for 13.9mm I/O modules
STBXBA2000 Backplane mounting for 18.4mm I/O modules and CAN ext.
STBXBA2200 Backplane mounting for power supply modules
STBXBE2100 CanOpen field network “Island” extension
STBXMP7700 Keying pins for backplane modules (Qty 60)
Advantys STB I/O Modules
STBDDI3420K 4pt. Input Module, 24VDC Sink Connection Kit
STBDDO3410K 4pt. Output Module, 24VDC, 0.5A Connection Kit
STBDDO3600K 6pt. Output Module, 24VDC, 0.5A Connection Kit
STBDDO3230K 2pt. Output Module, 24VDC, 2A Connection Kit
STBDRC3210K 2pt. Output Module, Relay 7A Connection Kit
STBXMP6700 customizable label sheets (Qty 25)
note: Connection Kits include a suitable backplane/base (STBXBAxxx), the I/O module, and
terminal block (STBXTSxxx). Individual I/O modules may also be ordered separately by
eliminating the K at the end of the part number.
note: for analog, counting and high-density parallel interface modules, see link
Advantys STB Terminals
STBXTS1100 Terminal block for DDI and DDO modules (Qty 20, 2 per unit)
STBXTS1110 Terminal block for DRC modules (Qty 20, 2 per unit)
STBXTS1130 Terminal block for power supply modules (Qty 10, 2 per unit)
STBXMP7800 Keying pins for terminal modules (Qty 96)
Advantys STB Power Modules
STBPDT3100 24VDC power module
STBPDT2100 115/230VAC power module
Advantys OTB IP20 I/O (low cost STB alternative)
OTB1E0DM9LP Ethernet Module 12in, 8out (2ss, 6 relay) expandable
TM2DDI16DT 16pt Input Module 24V sink
TM2DDO8TT 8pt Output Module 24V
TM2DRA8RT 8pt Output Module Relays
TM2DMM8DRT Combo I/O module: 4in 24V sink, 4out relay
TM2DMM24DRF Combo I/O module: 16in 24V sink, 8out relay
ASI IP20 I/O
ASI20MT4I4OSA 4I4O, external 24V, no extended addressing
ASI20MT4I3OSAE 4I3O, external 24V, extended addressing
ASI20MT4I4OS 4I4O, powered from network, no extended addressing

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5.3.3 Network I/O (Field IP65/67)


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

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


Advantys ETB IP67 Block I/O Module, 16 Configurable I/O
ETB1EM16CP00 Points, Dual Port Ethernet Modbus TCP/IP
Advantys ETB IP67 Block I/O Module, 16 Inputs, PNP, Dual
ETB1EM16EPP0 Port Ethernet Modbus TCP/IP
Advantys ETB IP67 Block I/O Module, 12 Inputs / 4 Outputs,
ETB1EM12E04SPP0 PNP, Dual Port Ethernet Modbus TCP/IP
Advantys ETB IP67 Block I/O Module, 8 Inputs / 8 Outputs,
ETB1EM08E08SPP0 PNP, Dual Port Ethernet Modbus TCP/IP
Advantys ETB IP67 Block I/O Module, 16 Configurable I/O
ETB1EI16CP00 Points, Dual Port EtherNet/IP
Advantys ETB IP67 Block I/O Module, 16 Inputs, PNP, Dual
ETB1EI16EPP0 Port EtherNet/IP
Advantys ETB IP67 Block I/O Module, 12 Inputs / 4 Outputs,
ETB1EI12E04SPP0 PNP, Dual Port EtherNet/IP
Advantys ETB IP67 Block I/O Module, 8 Inputs / 8 Outputs,
ETB1EI08E08SPP0 PNP, Dual Port EtherNet/IP
Advantys ETB Power Cables for Modbus TCP/IP Modules
ETXPC511M400020 5 Pin Power Cable, 90° Female connector, single ended, 2m
ETXPC511M400040 5 Pin Power Cable, 90° Female connector, single ended, 4m
ETXPC511M300040 5 Pin Power Cable, Female straight conn., single ended, 4m
ETXPC512M1M3010 5 Pin Power Cable, Female straight connectors, 1m
ETXPC512M1M3020 5 Pin Power Cable, Female straight connectors, 2m
ETXPC512M1M3050 5 Pin Power Cable, Female straight connectors, 5m
ETXPC512M2M4006 5 Pin Power Cable, 90°connectors, 0.6m
ETXPC512M2M4010 5 Pin Power Cable, 90°connectors, 1m
ETXPC512M2M4020 5 Pin Power Cable, 90°connectors, 2m
Advantys ETB Power Cables for EtherNet/IP Modules
ETXPC411M400020 4 Pin Power Cable, 90° Female connector, single ended, 2m
ETXPC411M400040 4 Pin Power Cable, 90°connector, single ended, 4m
ETXPC411M300040 4 Pin Power Cable, straight Female conn., single ended, 4m
ETXPC412M1M3010 4 Pin Power Cable, Female straight connectors, 1m
ETXPC412M1M3020 4 Pin Power Cable, Female straight connectors, 2m
ETXPC412M1M3050 4 Pin Power Cable, Female straight connectors, 5m
ETXPC412M2M4006 4 Pin Power Cable, 90°connectors, 0.6m
ETXPC412M2M4010 4 Pin Power Cable, 90°connectors, 1m
ETXPC412M2M4020 4 Pin Power Cable, 90°connectors, 2m
ETXPC412M2M4050 4 Pin Power Cable, 90°connectors, 5m

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CHRYSLER
Project Book Version 6.0

Advantys ETB Sensor Cables


ETXSC412M1M3010 I/O Cable - M12 Connectors – 1m
ETXSC412M1M3020 I/O Cable - M12 Connectors – 2m
ETXSC412M1M3050 I/O Cable - M12 Connectors – 5m
ETXSC412U1M3010 I/O Cable – Ultra Lock™ Connectors -1m
ETXSC412U1M3020 I/O Cable – Ultra Lock™ Connectors -2m
ETXSC412U1M3050 I/O Cable – Ultra Lock™ Connectors -5m
ETXSC412U2M3010 I/O Cable – 90° Ultra Lock™ Connectors -1m
ETXSC412U2M3020 I/O Cable – 90° Ultra Lock™ Connectors -2m
ETXSC412U2M3050 I/O Cable – 90° Ultra Lock™ Connectors -5m
I/O Splitter cable – Ultra Lock™ connector 1 end, 2 M12
ETXSC413U1M3003 connectors at other end - 30 CM Long
Advantys ETB Accessories
ETXPA513M Auxiliary Power Tee, 5 Pins for Modbus TCP/IP
ETXPA413M Auxiliary Power Tee, 4 Pins for EtherNet/IP
ETXPA511M3 Auxiliary Power Receptacle, 5 Pins for Modbus TCP/IP
ETXPA411M3 Auxiliary Power Receptacle, 4 Pins for EtherNet/IP
ETXSA12B Sealing plug for M12 connectors - 10 per package
ETXPA78BE Sealing plug for 7/8 external thread connectors - 1 per pkg.
ETXPA78BI Sealing plug for 7/8 internal thread connectors - 1 per pkg.
ETXADRJM12 Adapter RJ 45 to M12 connectors, for panel mounting
ETXPA5M1 Field Attachable Power Connector 5 Pin Male
ETXPA5M3 Field Attachable Power Connector 5 Pin Female
ETXPA4M1 Field Attachable Power Connector 4 Pin Male
ETXPA4M3 Field Attachable Power Connector 4 Pin Female

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CHRYSLER
Project Book Version 6.0

5.3.4 Terminals
IEC Terminal Strip Hardware
AB1VV435Ux Screw Terminal 4mm2, 6mm spacing (100 p/pck)
AB1VV635Ux Screw Terminal 6mm2, 8mm spacing(100 p/pck)
AB1VVN1035Ux Screw Terminal 10mm2, 10mm spacing (100 p/pck)
AB1VVN1635Ux Screw Terminal 16mm2, 12mm spacing (100 p/pck)
AB1VVN3535Ux Screw Terminal 35mm2, 16 mm spacing (100 p/pck)
AB1VVN7035Ux Screw Terminal 70mm2, 24mm spacing (100 p/pck)
note: for x blank=grey, BL=blue, GE-orange, RO=red (435/635 only), VE=green (435 only),
BLA=white (435 only), UNO=black (435 only)
AB1ET435U Double Screw Term., 6mm spacing, 2 in 2 out, grey (100)
AB1ET435U2 Double Screw Term., 6mm spacing, 4 wire, black (100)
AB1ET435UTP Double Screw Term., 6mm spacing, Earth, green/yellow (100)
AB1ET435UBRO Double Screw Term., 6mm spacing, 24V LED, red (100)
AB1ET435UBVE Double Screw Term., 6mm spacing, 24V LED, green (100)
note: see catalog for additional numbers: end stops partitions, labels, etc.

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CHRYSLER
Project Book Version 6.0

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

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CHRYSLER
Project Book Version 6.0

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

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CHRYSLER
Project Book Version 6.0

5.5.3 Frequency Drives And Soft Starts


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

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CHRYSLER
Project Book Version 6.0

5.5.4 Motor Control


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

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CHRYSLER
Project Book Version 6.0

Motor Circuit Protectors


GV2P01 0.1 to 0.16 A
GV2P02 0.16 to 0.25 A
GV2P03 0.25 to 0.4 A
GV2P04 0.4 to 0.63 A
GV2P05 0.63 to 1 A
GV2P06 1 to 1.6 A
GV2P07 1.6 to 2.5 A
GV2P08 2.5 to 4 A
GV2P10 4 to 6.3 A
GV2P14 6.3 to 10 A
GV3P13 9 to 13 A
GV3P18 12 to 18 A
GV3P25 17 to 25 A
GV3P32 23 to 32 A
GV3P40 30 to 40 A
GV3P50 37 to 50 A
GV3P65 48 to 65 A
GVAD0110 GV aux. block 1 N/O state & 1 N/C fault (side mount)
GVAE11 GV aux. block 1 N/O, 1 N/C state (front mount)
LA4DE3E Varistor Coil Suppressor for D40 … D80
TeSys T Motor Management System
LTMR08xBD Motor Management Controller, 8 A
LTMR27xBD Motor Management Controller, 27 A
LTMR100xBD Motor Management Controller, 100 A
note: x = M for Modbus, C for CANopen, D for DeviceNet, P for Profibus, E for Ethernet
LTM EV40BD Extension Module with voltage measurement on the 3 phases
LTMCU Operator control unit
note: consult catalog for additional accessories and information
ASi enclosed motor starters
LF3MPxxDU Non-reversing ASi motor starter
LF4MPxxDU Reversing ASi motor starter
note: xx= 02 for .16-.25A, 03 for .25-.4A, 04 for .4-.63A, 05 for .63-1A, 06 for 1-1.6A, 07 for 1.6-
2.5A, 08 for 2.5-4A, 10 for 4-6.3A, 14 for 6-10A, 16 for 9-14A

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CHRYSLER
Project Book Version 6.0

5.5.5 Control Relays


IEC Control Relays
CAD32BD Relay 24Vdc instantaneous 3NO+2NC
CAD50BD Relay 24Vdc instantaneous 5NO
LADN20 2 N/O Front Mount Aux module
LADN11 1 N/O 1 N/C Front Mount Aux module
LADN40 4 N/O Front Mount Aux module
LADN22 2 N/O, 2 N/C Front Mount Aux module
Miniature IEC Control Relays
CA3KN40BD Relay 24Vdc instantaneous 4NO
CA3KN22BD Relay 24Vdc instantaneous 2NO+2NC
LA1KNxx Aux modules (various consult catalog)
Ice Cube Relays
Tele RUM Series Control Relay Equipment
Timers
note: per Chrysler spec all non-safety timing functions should be in PLC
5.5.6 Beacons, Horns & Stack Lights
XVC Complete Pre-wired Indicating Banks
XVC4Bx 40mm, support tube mount, w/out buzzer, steady light only
XVC4Bx5S 40mm, support tube mount, w/ buzzer, steady or flashing light
XVC4BxK 40mm, base mount, w/out buzzer, steady light only
XVC6Bx 60mm, support tube mount, w/out buzzer, steady light only
XVC6Bx5S 60mm, support tube mount, w/ buzzer, steady or flashing light
XVC6BxK 60mm, base mount, w/out buzzer, steady light only
XVC6Bx5SK 60mm, base mount, w/ buzzer, steady or flashing light
XVC1BxK 100mm, base mount, w/out buzzer, steady light only
XVC1BxSK 100mm, base mount, w/ buzzer, steady or flashing light
note: for x (number of lights):
Signaling colors: R: Red, G: Green, O: Orange, B: Blue, C:
1=R
Clear. The colors are listed in the same order as the mounting
2=R,O
order of the illuminated units (from top to bottom).
3=R,O,G
Flashing function is selected/programmed by wiring.
4=R,O,G,B
For XVC Stack Light accessories see catalog.
5=R,O,G,B,C
XVB Stack Lights
XVBC2Bx Stack Light Beacon Lens
note: for x: 3=green, 4=red, 5=orange, 6=blue, 8=yellow
DL1BDBx Stack Light Base 24 volt LED Module
note: for x: 1= white (clear), 3=green, 4=red, 5=orange, 6=blue, 8=yellow
XVBC21 Standard Beacon Stack Light Base and Cap
XVBC21A ASI Beacon Stack Light Base and Cap
Beacon Lights
XVBL3x Beacon Light
XVBL8Bx High Intensity Flasher
note: for x: 3=green, 4=red, 5=orange, 6=blue, 7=clear, 8=yellow
Audible Horn
XVSB1 Standalone 24V Alarm Horn
XVBC9B Sounder Unit 24V as part of stack light

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CHRYSLER
Project Book Version 6.0

5.5.7 Pushbuttons & Pilot Lights


Pushbutton Head
ZB4BA1 Pushbutton Flush White
ZB4BA2 Pushbutton Flush Black
ZB4BA3 Pushbutton Flush Green
ZB4BA4 Pushbutton Flush Red
ZB4BA5 Pushbutton Flush Yellow
ZB4BA6 Pushbutton Flush Blue
Selector Switch Head
ZB4BD2 Selector Switch 2-pos Head
ZB4BD3 Selector Switch 3-pos Head
ZB4BD4 Selector Switch 2-pos Spring Return Head
ZB4BD5 Selector Switch 3-pos Return to Center Head
ZB4BD7 Selector Switch 3-pos Return from Left Head
ZB4BD8 Selector Switch 3-pos Return from Right Head
Contact block for Pushbuttons and Selectors
ZB4BZ101 Contact Block c/w collar 1N/O for PB & SS
ZB4BZ102 Contact Block c/w collar 1N/C for PB & SS
ZB4BZ103 Contact Block c/w collar 2N/O for PB & SS
ZB4BZ104 Contact Block c/w collar 2N/C for PB & SS
ZB4BZ105 Contact Block c/w collar 1N/O+1N/C for PB&SS
ZBE101 Additional Contact Block 1 N/O
ZBE102 Additional Contact Block 1 N/C
Emergency Stop Pushbutton
E-Stop Pushbutton Kit, Turn to Release Style
ZB4AEQ4021G1 Includes: ZB4BS844, ZB4BZ141, ZBZ3605, ZBY9330T
E-Stop Pushbutton Kit, Push/Pull Style
ZB4AEQ4021G2 Includes: ZB4BT84, ZB4BZ141, ZBZ3605, ZBY9330T
E-Stop pushbutton head 40mm red trigger action turn to
ZB4BS844 release
ZB4BT84 E-Stop pushbutton head 40mm red pull to release
ZB4BZ141 Safety rated contact blocks (2) NC (1) NO
Padlockable telescopic guard attachment for conformity to
ZBZ3605 Machinery directive 98/37/EC
"Emergency Stop" circular tag yellow background with black
ZBY9330T lettering
Cam Switches
K1E65SPEC0725 4 pos Cam selector switch (1 pos 2 N/O) + (3 pos 1 N/O)
K1D65SPEC0730 3 Pos Com Selector Switch (1 pos 2 N/O) + (2 pos 1 N/O)
Lighted Pushbutton Heads
ZB4BW3x3 ILL Pushbutton Flush Spring Return Head
note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue

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CHRYSLER
Project Book Version 6.0

Lighted Pushbutton Body and Contact Block


ZB4BW0Bx1 ILL Pushbutton Body & 1 N/O
ZB4BW0Bx2 ILL Pushbutton Body & 1 N/C
ZB4BW0Bx3 ILL Pushbutton Body & 2 N/O
ZB4BW0Bx5 Ill Pushbutton Body & 1 N/O + 1 N/C
note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue
Pilot Light Head
ZB4BW1x3 Pilot Light Head
note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue
Pilot Light Body (push to test)
ZB4BW0Bx5 Pilot Light Body & 1 N/O + 1 N/C
note: for x: 1= white, 3=green, 4=red, 5=yellow, 6=blue
5.5.8 Sensors
Inductive Proximity, tubular, extended range
XS608B1PAM12 8mm Proximity Switch with Connector, extended range
XS612B1PAM12 12mm Proximity Switch with Connector, extended range
XS618B1PAM12 18mm Proximity Switch with Connector, extended range
XS630B1PAM12 30mm Proximity Switch with Connector, extended range
Inductive Proximity, short tubular, extended range
XS1N08PA349D 8mm Proximity with Connector, extended range
XS1N12PA349D 12mm Proximity with Connector, extended range
XS1N18PA349D 18mm Proximity with Connector, extended range
XS1N30PA349D 30mm Proximity with Connector, extended range
Inductive Proximity, tubular, ferrous only / non-ferrous
XS1M18PAS40D 18mm Proximity Switch c/w Connector, ferrous only
XS1M18PAS20D 18mm Proximity Switch with Connector, non-ferrous
Photo, tubular
XUB2BKSNM12T M18 thru-beam 15 meter emitter
XUB2BPANM12R M18 thru-beam 15 meter receiver
XUB5BPANM12 M18 diffuse 0.6 meter
XUB9BPANM12 M18 polarized reflective 2 meter
XUZC50 Reflector for XUB9BPANM12
XUB0BPSNM12 Diffuse with background suppression
Photo, compact square body
XUK5APANM12 Diffuse photos 1m nominal sensing distance
XUK9APANM12 Polarized reflective photos
XUZC50 Reflector for XUK9APANM12
XUK2AKSNM12T thru-beam 15 meter emitter
XUK2APANM12R thru-beam 15 meter receiver
XUK8AKSNM12 diffuse w/ background suppression, focus beam
Fiber Optic
XUDA1PSMM8 Amplifier unit for fiber sensors
XUFNxxx fibers for sensing (various see catalog)

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Project Book Version 6.0

Mechanical Limit
XCKJ161D Limit Switch (2NC + NO) M12, End Plunger
XCKJ167D Limit Switch (2NC + NO) M12, Roller Plunger
XCKJ10511D Limit Switch (2NC + NO) M12, Roller Lever
XCKJ10541D Limit Switch (2NC + NO) M12, Variable Lever
XCKJ10559D Limit Switch (2NC + NO) M12, Rod Lever
9007C54B2D5T Side rotary with M12 connector (single pole)
9007C54FD5T Side plunger with M12 connector (single pole)
9007C54DD5T Top plunger with M12 connector (single pole)
9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)
9007C54B2Y140Y35D5T Side rotary, viton seals, epoxy filled with M12 (single pole)
9007C54FY140Y35D5T Side plunger, viton seals, epoxy filled with M12 (single pole)
9007C54DY140Y35D5T Top plunger, viton seals, epoxy filled with M12 (single pole)
9007C62B2Y19016 Switch, limit, side rotary with 9-pin (double pole)
9007C62FY19016 Side plunger with 9-pin (double pole)
9007C62DY19016 Top plunger with 9-pin (double pole)
9007C62B2 Y140Y35M9T Side rotary, viton seals, epoxy filled with 9-pin (double pole)
9007C62FY140Y35M9T Side plunger, viton seals, epoxy filled with 9-pin (double pole)
9007C62DY140Y35M9T Top plunger, viton seals, epoxy filled with 9-pin (double pole)
Pressure
XMLFM01D2035 Vacuum -1.16 PSI (-0.08 bar) to -14.5 PSI (-1.0 bar)
XMLF001D2035 Pressure 1.16 PSI (0.08 bar) to 14.5 PSI (1.0 bar)
XMLF002D2035 Pressure 2.9 PSI (0.2 bar) to 36.3 PSI (2.5 bar)
XMLF010D2035 Pressure 12 PSI (0.8 bar) to 145 PSI (10 bar)
XMLF016D2035 Pressure 19 PSI (1.3 bar) to 232 PSI (16 bar)
XMLF025D2035 Pressure 29 PSI (2.0 bar) to 363 PSI (25 bar)
XMLF040D2035 Pressure 46 PSI (3.2 bar) to 580 PSI (40 bar)
XMLF070D2035 Pressure 81 PSI (5.6 bar) to 1015 PSI (70 bar)
XMLF100D2035 Pressure 116 PSI (8.0 bar) to 1450 PSI (100 bar)
XMLF160D2035 Pressure 186 PSI (12.8 bar) to 2320 PSI (160 bar)
XMLF250D2035 Pressure 290 PSI (20 bar) to 3625 PSI (250 bar)
XMLF400D2035 Pressure 464 PSI (32 bar) to 5800 PSI (400 bar)
XMLF600D2035 Pressure 696 PSI (48 bar) to 8700 PSI (600 bar)
Ultrasonic
XX518A3PAM12 18mm ultrasonic tubular body, normally open (0.5-0.5 meters)
XX630A1PCM12 30mm ultrasonic tubular body, normally open (0.1-1.0 meters)

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Project Book Version 6.0

Mounting Brackets
XUZA50 Mounting Bracket (Metal), for use with XUM
XUZA118 Mounting Bracket (Metal), for use with XU 18mm, XUB
XUZA218 Swivel Mounting Bracket (Plastic), for use with XU 18mm, XUB
XUZB2003 3D mounting kit for use with SUB, XU18, SUZC50
XUZM2003 3D mounting kit for use with XUM, SUZC50
XUZK2003 3D mounting kit for use with XUK, XUZC50
XUZX2003 3D mounting kit for with XUX, XUZC50
XUZM2004 Protective 3D mounting kit for XUM
XUZK2004 Protective 3D mounting kit for XUK
XUZX2004 Protective 3D mounting kit for XUX
XUZ2001 M12 stem (75mm), for use with XUZB, XUZM, XUZK, XUZX
XUZ2003 3D mounting base, for use with XUZ2001
Zero Speed Detection
XSAV11373LD Motion detector, range 6-150 pulse/min, 9 sec start-up delay
XSAV12373LD Motion detector, range 120-3000 pulse/min, 9 sec start-up
note: not to be used for safety circuits, use XPS-VN back-emf relay
5.5.9 Cables And Sensor Docks
Sensor Docks
ABE9C1241C23 4 channel splitter M12/M23
ABE9C1281C23 8 channel splitter M12/M23
ABE9XLA10 Marker labels (lot of 12)
FTXCM12B Sealing Plugs for M12 connectors (lot 10)
Molded Cables
XZCP0766Lx Elbowed M8 female, 3 pin, PUR, with PNP LED
XZCP0866Lx Elbowed M8 female, 3 pin, PUR, with NPN LED
XZCP1340Lx Elbowed M12 female, 3 pin, PUR, with 2 PNP LEDs
XZCP1440Lx Elbowed M12 female, 3 pin, PUR, with 2 NPN LEDs
note: for x: 2= 2 meters, 5=5 meters, 10=10 meters
XZCC43FCP40B DIN connector for field cable installation
XSZEDD1020 Extension M12 to M12, PVR, 1 meter
XSZEDD1040 Extension M12 to M12, PVR, 2 meters
XZCR1501040G1 Extension M8 to M12, PVR, 1 meter
XZCR1501040G2 Extension M8 to M12, PVR, 2 meters
XZCR1523062K1 Extension DIN to M12, PVR, 1 meter
XZCR1523062K2 Extension DIN to M12, PVR, 2 meters
note: many more cable and connector types are available

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CHRYSLER
Project Book Version 6.0

5.5.10 Power Supplies


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

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CHRYSLER
Project Book Version 6.0

5.6 Circuit Protection and Electrical Distribution


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

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CHRYSLER
Project Book Version 6.0

Secondary Branch Circuits (110/220V)


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

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CHRYSLER
Project Book Version 6.0

5.6.3 Fuse Blocks & Splitter Blocks


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

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CHRYSLER
Project Book Version 6.0

6 Revision Log
Home
6.1 Version 2.0 Revision Detail
3.1 Removed the “Mixed Architecture”
Changed the order of the architecture presentations
Removed presentation of Twido PLC as part of assembly station Home
3.3 Added representation of Twido for simple standalone machines
4.1.2 Removed XBT-N display
Added IPC with note that Chrysler approval is required
6.1 Updated drawing of standard PDP
8.1.1 Corrected M340 CPU part numbers
Added more powerful M340 power supply
8.1.3 Removed XBT-N
8.2.1 Corrected switch part numbers
8.4.2 Updated part number for safety controller
8.5.4 Updated part numbers for higher amperage MCPs
8.5.8 Updated ultrasonic sensor part numbers
8.5.10 Updated power supply part numbers
8.6.4 Corrected transformer disconnect part number
6.2 Version 3.0 Revision Detail
2 Removed Home
2.1 Removed
2.2 Moved to new section 2 Scope of Supply
2.3 Removed
2.4 Moved to new section 2.1.3 Networks
3 Architectures moved to new section
3.1 Changed “Anything In Between” to “Hybrid”
3.1.1 Updated graphic
3.1.2 Updated graphic
3.1.4 Updated graphic
3.1.7 Updated graphic and changed to “Hybrid”
3.2.1 Updated graphic
3.2.2 Updated graphic for gantry
3.3 Removed graphic showing Twido for simple machine
4,5,6 Moved to new section 2 Scope of Supply
4.1.1 (now 2.1.1) Removed Twido and added Quantum
4.1.2 (now 2.1.2) Added Factorycast HMI and Citect Scada
4.2 Moved to 2.1.3 and rearranged
5 Moved to 2.2 Control Products and revised
5.2 Moved to 2.1.4 Motion Control and Drives and revised
6 Split into 2.1.5 Safety and 2.3 Power Distribution and revised
New Added section 2.4 System Capabilities
7 Becomes section 4
8 Becomes section 5, added web and product links, corrected links throughout section
8.1.1 (now 5.1.1) Added memory card, removed Twido processor and memory card
8.1.2 (now 5.1.2) Removed Twido modules
New Added 5.1.3 PLC programming software
New Added 5.1.4 PLC programming cables
8.1.3 (now 5.1.5) Removed 5.7” HMIs, added HMI software, added XBTGK keypad HMI
8.2.1 (now 5.2.1) Added several Connexium switches

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CHRYSLER
Project Book Version 6.0

8.3.1 (now 5.3.1) Removed Twido I/O modules


8.3.2 (now 5.3.2) Added Twido I/O modules to be used with OTB as remote I/O
8.3.3 (now 5.3.3) Added Asi 4 input module w/ dual M12
8.5.4 (now 5.5.4) Added higher range contactors, added mounting hardware, added GV7 part
numbers, revised Asi motor starter part numbers
8.5.5 (now 5.5.5) Added RUM series relays, deleted RUX
8.5.6 (now 5.5.6) Changed Beacon lens to LED type
8.5.7 (now 5.5.7) Added e-stop pushbutton and padlock guard, added additional contact blocks
8.5.8 (now 5.5.8) Corrected XS5 part numbers to XS6, added larger ultrasonic sensors, added
mounting brackets, updated zero speed detection part numbers, replaced 9007 limits with
XCKJ
8.6.1 (now 5.6.1) Revised disconnect part numbers to reflect type A1
8.6.2 (now 5.6.2) Added 110V circuit breakers for D curve
8.6.3 (now 5.6.3) Added fuse holder w/ blown fuse detection
6.3 Version 4.0 Revision Detail
All Removed Daimler name Home
1 Updated contact information
2.3.1 – Removed sections relating to power distribution
2.3.5
2.4.2 Removed turn key systems information
5.1.1 Added Premium PL7 single slot L3 CPU
5.5.4 Added D-line overload relays
5.5.7 Added part numbers for e-stop pb
5.5.8 Added part numbers for 9007 series limit switches
5.6 Changed name to Circuit Protection and Electrical Distribution
5.6.1 Added part numbers for GS1 compact fusible disconnect switches
5.6.5 Removed Busway components
6.4 Version 5.0 Revision Detail
4-66 Renumbered pages Home
4 Updated contact information with contacts for Mexico & India
66 Added revision detail sheet
6.5 Version 6.0 Revision Detail
1 Added link to brand information & added contact information for Italy
Home
2.1.2 Added Smart iPC, updated graphics
2.1.3 Updated Connexium graphic, added Ethernet/IP
2.2.1 Added ETB graphic
2.2.2 Added Tesys T motor management system graphic
5 Updated links
5.1.1 Added 600 series processor, updated M340 part number for BMXP3420302 processor, added
128 M memory card
5.1.2 Added TSXETC100 and BMXNOE0110, updated part number BMXEIA0100
5.1.3 Updated part numbers for Unity Pro to reflect latest version and PL7 Pro typo
5.1.5 Updated part numbers for Vijeo Designer for latest version, updated Magelis Compact part
numbers, added Magelis Smart iPC
5.2.1 Added 3-port unmanaged switch, updated part number for 5-port unmanaged switch
5.2.3 Updated part number for cable tee TCSATN011F
5.3.1 Updated part numbers for M340 input and output modules (typos)
5.3.1 Added STBNIC2212 Ethernet/IP interface module, changed STB I/O modules to connection
kits instead of individual parts for easier ordering, updated part numbers for OTB IP20 I/O to
new numbers

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CHRYSLER
Project Book Version 6.0

5.3.3 Updated part numbers for FTB modules for typo, updated typo in ASI67FFP43EY, added ETB
modules and accessories
5.4.1 Updated XPSVNE1142P, removed XPSN3440 standstill monitoring relay due to obsolescence
5.5.2 Corrected typo in Lexium Network Interface modules AM0…
5.5.3 Replaced ATV31 with ATV312 (direct replacement), corrected part number ATV71HU55N4,
added ATV71 Ethernet/IP module, added ATS22 softstart
5.5.4 Updated part numbers LC2D40ABD, LC2D50ABD, LC2D65ABD now with Everlink, updated
GV2AF4 for typo, added Tesys-T motor management system part numbers
5.5.6 Added XVC stack lights.
5.5.8 Updated part number XUB0BPSNM12 due to obsolescence, corrected part number XUZA50
5.5.9 Replaced Elbowed molded cables with new part numbers due to obsolescence

SCHNEIDER ELECTRIC Page 69 of 69