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Magelis, TeSysU and Preventa

System User Guide
[source code]
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SEP 2006
Contents

Application Source Code................................................................................................... 4

Typical Applications .......................................................................................................... 5
System................................................................................................................................ 6
Architecture ....................................................................................................................... 6
Installation ....................................................................................................................... 10
Hardware...............................................................................................................................................12
Software................................................................................................................................................19
Communication ......................................................................................................................................20
Implementation ................................................................................................................ 23
PLC.......................................................................................................................................................24
AS-Interface Configuration......................................................................................................................46
HMI .......................................................................................................................................................49
Safety Monitor........................................................................................................................................67
Data Exchange ......................................................................................................................................79
Appendix .......................................................................................................................... 82
Detailed Component List .................................................................................................. 82
Component Protection Classes ........................................................................................ 85
Component Features ....................................................................................................... 86
Contact ............................................................................................................................. 90

Introduction This document is intended to provide a quick introduction to the described System.
It is not intended to replace any specific product documentation. On the contrary, it offers
additional information to the product documentation, for installing, configuring and starting up the
system.

A detailed functional description or the specification for a specific user application is not part of
this document. Nevertheless, the document outlines some typical applications where the system
might be implemented.

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 Abbreviations
Word / Expression Signification
AC Alternating Current
Advantys SE product name for a family of I/O modules
Altivar (ATV) SE product name for a family of VSDs
CANopen Name for a communications maschine bus system
CB Circuit Breaker
CoDeSys Hardware-independant IEC 61131-3 programming software
ConneXium SE product name for a Family of Transparent Factory devices
DC Direct Current
EDS Electronic Data Sheet
E-OFF, E-STOP Emergency Off switch
Harmony SE product name for a family of switches and indicators
HMI Human Machine Interface
I/O Input/Output
IclA (ICLA) SE product name for a compact drive
Lexium/Lexium05/LXM SE product name for a family of servo-drives
Magelis SE product name for a family of HMI-Devices
MB - SL SE name for a serial Modbus communications protocol
Micro SE product name for a middle range family of PLCs
NIM SE product name for a Network Interface Module
Osiswitch SE product name for a family of position switches
PC Personal Computer
Phaseo SE product name for a family of power supplies
PLC Programmable Logic Computer
Powersuite An SE software product for configuring drives
Premium SE product name for a middle range family of PLCs
Preventa SE product name for a family of safety devices
PS1131 (CoDeSys) SE Product name for PLC programming software with CoDeSys
PS Power Supply
SE Schneider Electric
Sycon SE product name of a Field bus programming software
Telefast SE product name for a series of distributed I/O devices
TesysU SE product name for a decentralised I/O System
Twido SE product name of a middle range family of PLCs
TwidoSoft SE product name for a PLC programming software
TwidoSoft SE product name for a PLC programming software
Unity (Pro) SE product name for a PLC programming software
Vijeo Designer An SE software product for programming Magelis HMI devices
VSD Variable Speed Drive
WxHxD Dimensions : Width, Height and Depth
XBT-L1000 An SE software product for programming Magelis HMI devices
Zelio SE product name for a low range PLC family
ZelioSoft SE product name for a PLC programming software

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 Application Source Code

Introduction Examples of the source code used to attain the system function as described in this document
can be downloaded under this online link.

The example source code is in the form of configuration, application and import files. Use the
appropriate software tool to either open or import the files.

Extension File Type Software Tool Required

AIW Configuration file Advantys
CNF Configuration file Sycon
CO CANopen definitions file Sycon
CSV Comma Seperated Values, Spreadsheet Twidosoft
CTX Unity
DCF Device Configuration File Advantys
DIB Device Independent Bitmap Sycon
DOC Document file Microsoft Word
DOP Project file Magelis XBTL
EDS Electronic Data Sheet – Device Definition Industrial standard
FEF Export file PL7
GSD EDS file (Geraete Stamm Datei) Profibus
ISL Island file, project file Advantys
PB Profibus definitions file Sycon
PDF Portable Document Format - document Adobe Acrobat
PRO Project file PS1131 - CoDeSys
PS2 Export file Powersuite export file
RTF Rich Text File - document Microsoft Word
STU Project file Unity Pro
STX Project file PL7
TLX Project file Twinline control tool
TWD Project file TwidoSoft
VDZ Project file Vijeo Designer
XEF Export file Unity Pro
XPR Project file TwidoSuite
ZM2 Project file Zeliosoft

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 Typical Applications

Introduction Here you will find a list of the typical applications, and their market segments, where
this system or subsystem can be applied:

Industrial

 Small to middle sized automated machines

 De-centralised automated sub systems serving as components in large or middle
sized machines

Building/Services

 Material elevators, e.g. in cafeterias or hospitals

 Climate control in greenhouses

Application Description Image

 Industry The example shows a small
 conveying & conveying system.
handling
The control elements are:
 moving walkway
 machinery  operator interface
automation  peripheral motor control
systems, with low  AS-Interface
complexity

 Building / services The example shows a lift control

 lift system.

 escalator The control elements are:

 Lighting
management  operator interface
 central motor control
 Access, control and  AS-Interface on each floor
surveillance
 AS-Interface in the shaft
management
 AS-interface in the car
 Heating and air
conditioning
management

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 System

Introduction The system chapter describes the architecture, the dimensions, the quantities and different
types of components used within this system.

Architecture

General The architecture comprises three main-function groups:

 Control cabinet with operator interface

 Remote cabinet with motor control
 Subsystem for the field installation

Each of the three groups is described separately.

Layout

Central
Cabinet

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Control The control cabinet comprises the following main components:
Cabinet
 Premium PLC with AS-Interface master module
 Magelis XBT-GT display terminal (graphical monochrom display)
 3 TeSysU motor starters with AS-Interface (TeSysU)
 Optional: AS-Interface safety monitor, AS-Interface emergency-off switch
with redundant load contactors for disconnecting the 400 V AC power
supply

The central devices in this control cabinet include the Twido PLC, the Magelis HMI
and the optional safety provided in the event of an emergency-off, by means of
which the load is disconnected via an AS-Interface safety monitor with assigned
contactors.

As well as the distribution board for the load power supply for the load
components (400/230 V AC), this control cabinet also houses the conventional 24
V and AS-Interface power supplies, along with three TeSysU type motor starters.

Layout

Remote Cabinet
and Field
installation

Remote The remote cabinet comprises the following main components:

Cabinet
 3 TeSysU motor starters with AS-Interface (TeSysU)
 4 digital IP20 I/O modules with AS-Interface (ASI20MT)
 Optional: AS-Interface safety monitor, AS-Interface emergency-off switch with
redundant load contactors for disconnecting the 400 V AC power supply.

The TeSysU motor starters can be installed side-by-side and supplied with power via
busbars in order to minimize requirements in respect of space and wiring. The IP20 I/O
modules can also be installed side-by-side to save space. Furthermore, an AS-Interface
safety monitor with associated redundant load contactors for implementing an optional
Optional safety guard function is also assigned to this cabinet.
Safety
Function The AS-Interface emergency-off switch is connected to the shared yellow AS-Interface
cable (this means that it does not have to be wired separately). Although the emergency-
off switches on the main cabinet and on the remote cabinet will trigger both safety
monitors, if the door safety function (which is controlled by the roller limit switches) is
cancelled, only the safety monitor in the remote cabinet will be disconnected.

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Field The field installation essentially comprises 3+2 ASI67FMP digital IP67 I/O modules. The
Installation last two modules are optional field devices and can be used for remote control (start/error
unlatching) of the safety monitors.
As the IP67 modules and their connection adapters do not require enclosures, their
installation location and type can be selected in accordance with requirements. Field
installations can, therefore, be set up anywhere and in any configuration using cables and
sensors with the appropriate degree of protection.

Components Hardware for the control cabinet:

 Vario VCF master switch (with red and yellow knob) (MS) - optional
 GV2ME motor circuit breaker (MCB)
 Multi 9 circuit breaker, 1- and 2-pole (CB)
 Phaseo power supply, 30V (PS) for AS-Interface
 Modular Premium PLC with Ethernet interface and AS-Interface-Master (PLC)
 Magelis XBT-GT display terminal (graphical monochrom display)
 3 x TeSysU-Motor starter with AS-Interface (TeSysU)

Optional: Devices required for safety in the control cabinet

 ASISAFEMON1 safety module for AS-Interface Safety@Work
 ASISSLB4 with mushroom pushbutton attachment (tamper-proof)
 2 x LC1D load contactors

Hardware for the remote cabinet:

 3 x TeSysU motor starters with AS-Interface (TeSysU)
 1 x GV2G busbar with GV1G terminal blocks
 3 x taps for connection to the AS-Interface bus
 4 x ASI20MT digital IP20 I/O blocks (4 transistor inputs/3 transistor outputs) with
AS-Interface (IP20 I/O)
 4 x ASI20MACC IDCs (IDC = Insulation Displacement Connector) for connection to the
AS-Interface bus

Optional: Devices required for safety in the remote cabinet

 ASISAFEMON1 safety module for AS-Interface Safety@Work
 ASISSLB4 with mushroom pushbutton attachment (tamper-proof)
 2 x LC1D load contactors

Hardware for field installation:

 3(5) x ASI67FMP digital IP67 I/O blocks (4 transistor inputs/3 transistor outputs) with
AS-Interface (IP67 I/O)
 3(5) x ASIDCMP for connection to the AS-Interface bus
 XZCP1564x jumper cable for connection to machines or similar
 AS-Interface cable, yellow and black (yellow: bus; black: 24 V aux. power)

Optional: Safety components in the field

 ASISAFEMON1 safety module for AS-Interface Safety@Work
 ASISSLC2 safe AS-Interface slave for 2 safe inputs
 XCS39M15xx roller limit switches for safety door supervision
 XB5AW illuminated pushbutton in XALD housing

Software:
 Unity Pro 2.2 XL
 Vijeo-Designer 4.3
 ASISWIN 2 V2.0.3 (optional)

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Quantities of For a complete and detailed list of components, the quantities required and the order
Components numbers, please refer to the components list at the rear of this document.

Degree of Not all the components in this configuration are designed to withstand the same
Protection environmental conditions. Some components may need additional protection, in the form of
housings, depending on the environment in which you intend to use them. For
environmental details of the individual components please refer to the list in the appendix of
this document and the appropriate user manual.

Technical Mains Voltage 400 VAC

Data Power Requirement ~ 5 kW
Drive Power Rating <= 0,75 kW
Motor brake none
Connection 5 x 2,5 mm² (L1, L2, L3, N, PE)
Safety Level category 3 (optional)

Safety Notice The standard and level of safety you apply to your application is determined by your
system design and the overall extent to which your system may be a hazard to
people and machinery.

In this application example, category 3 has been selected for the safety level.
Category 3 is the second highest safety level according to EN954-1.

Whether or not the above safety category should be applied to your system should
be ascertained with a proper risk analysis.

This document is not comprehensive for any systems using the given architecture
and does not absolve users of their duty to uphold the safety requirements with
respect to the equipment used in their systems or of compliance with either national
or international safety laws and regulations

Dimensions The control cabinet components can be housed in an enclosure with external
dimensions of approx. 600 x 1000 x 300 mm (WxHxD). The safety module with
circuit breaker can also be included in the cabinet.

The components of the remote cabinet can be installed in very close proximity to
one another. The TeSysU motor starters can be installed side-by-side and supplied
with power via busbars. The IP20 I/O modules can also be installed side-by-side.
The external dimensions of the remote cabinet, as with the main cabinet above,
need to be approx. 600 x 1000 x 300 mm (WxHxD). Again, this allows a 20%
reserve for optional devices.

An enclosure is not required for the field devices and taps. Thanks to IP 67 degree
of protection, the installation location can be adapted to meet requirements and,
therefore, be situated near to the sensors and actuators in the field.

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 Installation

Introduction This chapter describes the steps necessary to set up the hardware and configure the
software required to fulfil the described function of the application.

Assembly

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Notes  The components intended for installation in a control cabinet, i.e. Phaseo power
supply unit, safety monitor, automatic circuit breakers, load contactors, and motor
starters, can be connected to a 35 mm DIN rail. The Premium-PLC, with its rack, can
be mounted directly on the rear wall of the cabinet.

 The emergency-off switches and the installation box for the main switch have been
designed for installation in a cabinet door.

 Two mounting options are available for XB5 pushbuttons and indicator lamps:

1. A hole measuring 22 mm drilled into the front door of the control cabinet in the
appropriate location.

2. An XALD housing able to accommodate up to 5 momentary-contact switches or

indicator lamps. This XALD housing is designed for backplane mounting or
direct wall mounting.

 400 V AC wiring between the main circuit breaker, primary side of the 24 V power
supply plus motor circuit breakers, motor starters and motors.

 230V AC-wiring between the master switch and Premium (the premium also has a
power supply of 24 VDC).

 24 V DC wiring between power supply unit and safety module.

 AS-Interface power supply and auxiliary power supply (30/24 VDC) via yellow and
black AS-Interface cable.

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 Hardware

Components
Installation box
Control GV2MP
Cabinet
+ Combination
for the installation of a
Emergency-off GV2ME motor circuit breaker
switch in a cabinet door
GV2K04 as a
circuit breaker with fault clearing capability
+ (lockable)

Control lamp
GV2SN37

Motor circuit
breaker

GV2ME16

Circuit breaker
2-pole

multi9

Circuit breaker
1-pole

multi9

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 Phaseo power
supply unit

ASIABLM3024

Components
Power section,
Control motor starter
(reversing
Cabinet
contactor)
LU2B12B

Control module
motor starter
LUCA05BL

AS-Interface
module
ASILUF C5
+
Coil connection
LU9MRC
+
AS-Interface tap
XZCG0142

Busbar system
GV2G345
with Can only be used if the motor starters are
terminal block installed side-by-side.
GV1G09

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 Premium-PLC
TSXP572634M

+ Power Supply
TSXPSY2600

+ Rack
TSXRKY6EX

+ Terminal
Resistor
TSXTLYEX (1) display
(1) TER-socket
(1) AUX-socket
5 PCMCIA-slot for memory card
6 PCMCIA-slot for communcations card
8 Ethernet Port
10 RESET button

Components
Premium
Control AS-Interface
Master Module
Cabinet
TSXSAY1000

Magelis
terminal

XBTGT1100

(1) XBTGT1100 without Ethernet

Option in
main cabinet: AS-Interface
safety monitor
Emergency-
ASISAFEMON1
off and safety
guard

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 Emergency-off

ASI SSL B4 +
ZB4BS844

Safe input slave

1 x 2 inputs

ASISSLC2

Harmony 5
momentary-
contact switch
with LED
XB5AW-36M5
and
switch housing
XALD01

TeSys load
contactor

LC1D09BL

Components
Power section,
Remote motor starter
(reversing
Cabinet
contactor)
LU2B12B

Control module,
motor starter
LUCA05BL

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 AS-Interface
module
ASILUFC5
+
Coil connection
LU9MRC
+
AS-Interface tap
XZCG0142

Busbar system
GV2G345 Can only be used if the motor starters
with are installed side-by-side.
terminal block
GV1G09

AS-Interface
Input/output
module (IP20)

ASI20MT4I3OSE
with
ASI20MACC1

ASI 20MACC1

Option in
Remote Emergency-off
cabinet:
ASISSLB4
Emergency-off +
and safety ZB4BS844
guard

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 AS-Interface
safety monitor

ASISAFEMON1

TeSys load
contactor

LC1D09BD

Components
AS-Interface
Field input/output block
Installation IP67

ASI67FMP43E
with
ASIDCPM12D03

ASI DCPM 12D03

AS-Interface

sensor/actuator
connection
XZCP1564x

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Option:
Safe input slave
Safety in the 1x 2 inputs
field
ASISSLC2

Safety limit switch

XCSM3915L1

Acknowledgement
button housing

Harmony 5

Push button with

LED
XB5AW36M5
and
switch housing
XALD01

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 Software

General The programming software tool Unity is used for programming the Premium PLC.
This software is also used for configuring the communication of the AS-Interface
and assigning the I/O.

The Magelis display is configured using the software tool Vijeo-Designer.

The ASISWIN software is used for first use and parameterization of the two optional
safety monitors.

To run the software, you must have one of the following Windows operating systems
installed on your PC:

Windows 2000 or
Windows XP

The default installation path on the hard drive of your PC for each of these software
programs is:

Unity: C:\Program Files\Schneider Electric\Unity

Vijeo-Designer: C:\Program Files\Schneider Electric\Vijeo-Designer
ASISWIN: C:\Program Files\Schneider Electric\ASISWIN

Unity Pro XL V2.2 Vijeo-Designer V4.3 ASISWIN V2.0.3

Note: To use the example program for Vijeo Designer you will need to
download and install the patch V4.3.0C update

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 Communication

General This architecture uses 2 different communication systems:

 UniTelway
 AS-Interface

A Unitelway connection is used to exchange data between the Magelis terminal and the
Premium PLC. The XBTZ9680 communication cable shown below is needed to connect
these two devices. The software driver required for Unitelway communication is
contained in both the software package for the Magelis panel and the Premium PLC.

The AS-Interface communication consists of Premium Mastermodules TSXSAY1000.

Each master can be expanded up to 62 Moduls. When using standard modules and
safety Slaves together, 31 Modules can be used.

Premium <> PC Serial

Programming Cable

TSX PCX 1031

Optional:

USB Programming
Cable

TSX PCX 3030

Driver must be installed

seperately.

Standard Cross-Over
CAT5 cable can be
used for programming
via the Ethernet
interface.

Magelis <>
Premium Communication Cable

XBTZ9780

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Magelis <> PC
USB Programming
Cable

XBTZG925

AS-Interface
Module for use in a
IP20-Modules cabinet
In-/Outputs
ASI 20MT4I3OSE

AS-Interface Connection for using

TeSysU-devices,
IP20 Motor-starter consisting of 3
module components :

ASILUFC5 ASILUFC5

XZCG0142

LU9MRC *)

*) resistor module integrated in

TeSysU, no image ASIDCPM12D03

AS-Interface
Modules for use
IP67-Modules in the Field
In/Outputs
ASI67FMP43E

ASIDCPM12D03

ASI67FMP43E ASIDCPM12D03

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 AS-Interface Expansion module
connects to the Twido
Safety Monitor
ASISAFEMON1
(optional)

AS-Interface Safety Input slaves for

AS-Interface for
safety Slaves implementing safety
(optional) functions :

ASISSLB2
ASISSLB2 ASISSLC2
ASISSLC2

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 Implementation

Introduction This chapter describes how to install and set up the software for the task associated
with the following application.

Function 1. The entire application is controlled via the Magelis terminal in the main
cabinet.

The installed hardware must be operational:

- The components must have been installed correctly.

- The main switch, circuit breakers and motor starters must have been
switched on.
- The emergency-off switch must be off (neither pressed nor latched).
- The roller limit switches for the safety guard function must both be in
their proper positions (safety guard established).
- Both safety monitors must have been acknowledged (the blue
indicator lamp has gone out).

2. The HMI has several screens for monitoring and controlling the motor
starters. Each screen indicates the states of the motor starters
(ready/running) and enables them to be controlled (forward/reverse).

3. Two additional HMI screens are used for supervising the AS-interface
and the Safety modules

4. The right-hand navigation buttons (R1-R6) are used to control the

corresponding TeSysU

5. The Alarm screen can be called up to display the current system condition.

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 PLC

Introduction The PLC chapter describes how to initialize, parameterize and download the program to
the PLC in order for the functional scope outlined above to be provided. The PLC
program is created using the Unity Pro XL software..

Preconditions The procedure described below is subject to the following preconditions:

 Version 2.2 of Unity Pro XL is installed on your PC.

 The Unity example project is at hand.
 The Premium-PLC is connected to the power supply and switched on.
 The PLC and PC are connected to each other with the programming cable
TSXPCX1031, via the TER port on the PLC.

Create a New 1 To create a new Unity project

Project select:

File->New

or use the New Project icon

2 In the following dialog select

the CPU type.

Our example uses a Premium.

A double click on the CPU type

Premium opens up a selection
list.

Change PLC 1 In the list of premiums

Type displayed select:

TSXP572634M

If your CPU does not have the

suffix M, assume it has.
(models without M are older
models but work just the same)

Continue with OK

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 2 Once the CPU type has been
defined you are shown the
Unity desktop.

3 In the Project Browser select :

Station->
Configuration->
0:X-Bus

4 Start the hardware config-

uration by double clicking the
marked element (right mouse
click works too) to open up a
pop-up menu for the bus.

Here, select: Open.

5 The graphical configuration

display opens.

Unity automatically offers a

default power supply module

If the power supply module is

not of type TSXPSY2600 (as
used in the example) then it
must be changed
Double click on the modul and
select the new one.

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Inserting a Memory 1 add the memory extension
Module card to slot A on the CPU.
Right mouse click on the
slot opens up a menu.
Select:

New/Replace Submodule..

In our case we are using the

memory expansion card
type:

TSXMAPC002M

with 2 MB memory.

2 In the New/Replace
Submodule dialog select
the card type :

TSXMAPC002M

under SRAM.

continue with OK.

Adding Extension 1 To add the AS-Interface-

Modules Master module click on an
empty slot with the right
mouse button.

Click on

New Device..

in the pop-up menu.

2 In the New Device dialog

expand the
Communication section
and select the AS-Interface
Master TSXSAY1000.

Continue with OK.

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 3 the module has now been
added to the graphics image
in the slot that you selected.

4 The Project Browser also

shows the added devices in
its projct directory.

AS-Interface 1 In the project browser you

Configuration will now see that an
AS-Interface V2 (AS-i V2)
bus has been added.

To configure all the

modules, double click on it.

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 2 An empty configuration
dialog appears.

3 A double click on an
AS-Interface-Slave entry
(left A- and right B-channel),
opens up the Associate
Profile dialog. Here you can
select the AS-I family
name.

Note: Slave 0 cannot be

configured.

4 To configure the TeSysU

Modules select the family
group with Code 4 Motor-
starters and then select the
TeSysU Modul ASILUFC5
in the catlog below it.

Confirm the selection with

OK.

5 Repeat the above selection

to integrate the other 5
TeSysU modules.

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 6 In this image all the
standard slaves and 2
extended slaves on the B
channel have been
configured.

Slave 1A-6A ASILUFC5

Slave 7A-9A ASI67FMP43E
Slave 7B-8B ASI67FMP43E
Slave 10A-13A
ASI20MT4I3OSE

7 Safety Modules always

require both A and B
Kanal.

Slave 21 + 22 ASISSLB4
Slave 25 ASISSLC2

8 The same applies to the

safety monitors on the last 2
addresses.

Slave 31 + 30
ASISAFEMON1

Safety Monitors for the AS-

Interface bus should always
occupy the last addresses.

9 Setting the check-box

Automatic Addressing

allows the PLC to

automatically configure
replacement slaves that
have been changed for
maintenance/repair.

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 10 The addresses are listed in
the Input / Output
Symbols table. They have
the format:
%I\Slot.Slave\0.0.0-3

e.g.:

%I\1.12\0.0.0 => Input (%I\)

on AS-Interface-Master in
Slot 1 (\1.) at Slave 12A
(.12\) Wort 0 (\0.0.0)

%Q\2.112\0.0.3 => Ouput

(%Q\) on AS-Interface-
Master in Slot 2 (\2.) at
Slave 12B (.112\) Word 3
(\0.0.3)

2 AS-Interface Masters on
one CPU is not possible –
the image is for examples
only.
11 The family and code are
shown in the

Specifications

12 Unity only allows you to

configure the AS-Interface-
Safety-Slaves. They cannot
be addressed. The modules
must be configured in Unity
howecer, so that the safety
monitor can recognise them.

13 To take on the changes, the

configuration is only
accepted when the check
box (upper left corner) is
set.

If you exit the dialog before

setting the check box all
changes are lost.

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 14 After changing the
configuration, the changes
can be seen in the
project browser.

Configuring 1 Select Communication In

the Ethernet the project browser and
Interface open the directory tree.

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 2 Under Communication,
right mouse click on
Network to open up a pop-
up menu.

In the menu select:

New Network..

3 In the Add Network dialog

that now appears, select the
type of network.

Here, Ethernet.

4 Give the network a name

and exit with OK .

Here, the name

Ethernet_Premium1 is
used.

5 after successfully
configuring the Ethernet
network, it is displayed in
the project browser under
Networks with the name
you have given it.

Note the icon has a red

cross on it to signify that it
has not been consigned to
an interface.

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Setting the 1 The IP addresse can be
Ethernet Address assigned by double clicking
on the element
Ethernet_Premium1 in the
project browser.

In the dialog you can enter

the Model Family. Here
there are several different
types of model but only
those fitting the configured
interface are listed.

2 Choose an IP address from

your private IP range
Hier einfach eine IP.

Here, we have chosen:

IP: 192.168.100.10
Subnet: 255.255.255.0

A Gateway is not
necessary.

3 Again, to take-on the

configuration you must set
the check box.

Optional:

Once the program has been

downloaded to the PLC, if
your PC is in the same
network (i.e. IP-range:
192.168.100.0-255), you
can use the Ethernet
connection to communicate
with the PLC

4 To link the Network to the

CPU Ethernet interface,
select the graphic display
via the X-bus entry in the
project browser.

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 5 In the graphic display left
clcik on the ETY PORT
module to enter the pop–up
and select:

Open module

6 In the dialog that opens up,

select Channel 0.

7 In the list box Function

select ETH TCP IP.

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 8 Once the function has been
selected, the dialog
expands to allow the choice
of a Net Link.

cahng ethe default value No

Link to the name of the
ethernet network in the
project browser -

Ethernet_Premium1.

9 To take on the changes set

the check box on the left in
the tool bar.

10 Check the entry in the

Project Browser under
Communication to see if
the red cross has dis-
appeared.

If the configuration was

successful you should now
see a PLC icon.

If this is so, the network can

now be used.

Configuring 1 Expand the entry

Variables
Variablen & FB Instances

in the Project Browser.

click on the entry

Elementary Variables

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 2 In the desktop you should
now see the variables table.

Note the tabs at the top for

the different types of
variables and that the list is
empty.
3 A double click on an empty
field in the Name column
allows you to enter the
name of a variable.

4 To select the variable type

double click on the column
Type and select one of the
offered data types.

5 Similarly add the memory

address of the variable in
the column Address.

6 A comment can be added in

the Comment column.

7 To create more variables

you can ‚pull‘ a vriable name
from one line to the next.
the editor will automatically
shuffle the list, if needed, to
make room for the new
variable. the new varaibles
have the same name as the
original with a suffix added.

_0, _1, _2, _3 etc.

Create a Program 1 In the Project Browser

under:
New Section
Programm->
Tasks->
MAST->
Sections.

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 2 Right mouse click on
Sections opens up a pop-
up menu.

select: New Section

3 In the New dialog that

appears select the
programming language
and give the section a
Name.

This example uses FBD and

Safety.

Exit the dialog with OK.

The section name should

now appear in the project
browser.

Function Block for 1 To select a function block

AS-Interface Safety right mouse click in the FBD
Monitor editor.

in the pop-up menu select

FFB Input Assistant

2 The assistent lists all the

function blocks that have
already been instanced in
the program. Here, in a new
program, it is empty.

Click on the icon at the end

of the list box FFB Typ

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 3 The dialog now displayed
lists the names of all the
Libraries and the function
blocks existing in those
libraries that were delivered
with Unity.

4 The function block for the

safety monitor is a DFB.

To find the DFB for the

safety monitor set the check
box DFB. Only libraries with
DFBs are now listed.

Select a library and browse

the list of DFBs it contains.

Select the DFB

SAFETY_MONITOR
and click on OK
5 The Function Input
Assistant now lists the
input and output parameter
names and their data types
for this function block.

Exit this dialog with OK to

position the DFB in the FBD
editor.

6 Here is the DFB displayed

in a section. You can use
drag & drop to position the
function block.

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 7 Double-click on a pin of the
DFB to enter a variable
name for that parameter.

Note: the datatype of the

variable and parameter
must match.

there are several ways to

enter a variable:

 Type in a Name in the

box.
 Select an existing
variable from the list
(downward arrow)
 Select a Variable from
the complete variable
list (dotted icon)
 Abort the input (cross
icon)
 Confirm the selection
(tick icon)

8 The F1 function key calls up

the helptext.

Inputting the function block

name (Safety_Monitor) in
the index gives the help text
on the function.

9 The function block still has

the instance name given to
it by the system (FBI_0).

To rename the instance, a

right mouse click on the
function block invokes a
pop-up menu. Here, select:

Data Properties

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 10 In the Data Properties
dialog double-click on the
name to change it to a
better mnemonic, e.g.
Safety_Mon1.

11 The new name now appears

in the Data Properties and
will also be displayed above
the DFB in the FBD section.

12 the Variable List also

displays the new instance
name of the DFB.

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Open an existing 1 To work on an existing
Program program use

File->Open.

2 In the open dialog select the

path to look in.

Enter the file type you wish

to open (*.STU).

The files of the selected

type in the given path are
listed.

Select a file and click on

Open to load it.

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Build the Program 1 Before downloading a
program it must be built, i.e.
compiled.

Select:

Build->Rebuild All Project

to generate the program.

2 Confirm the safety warning

with Yes.

3 The progress bar is now

displayed.

4 The process of the Build is

displayed in the window
beneath the main window.

Once the build is finished

errors/warnings are listed.

If errors are indicated these

must be remedied before
you can download the
program.

Warnings do not block the

download but may still need
to be remedied.

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Connect the PLC 1 Before making a connection
between the PC and the
PLC they must be
connected with the
programming cable
TSXPCX1031 (serial).

Ensure that the cable is set

to

TER Direct (2).

Use the TER port on the

PLC.

2 Before connecting to the

PLC the connection must be
setup.

Select:

PLC->Set Address

3 in the Set Address dialog

set

Address : SYS
Media : UNTLW01

for the serial Unitelway

connection.

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Download the 1 To download a program to
program to the PLC the PLC the connection
must first be established.

select:

PLC->Connect

2 The connection status is

indicated in the status bar at
the bottom of the window.

The image shows the PLC

in RUN mode but running
with a DIFFERENT program
to that which is being
viewed.
3 To download the current
select:

PLC->Transfer Project to
PLC

To upload a program from

the PLC use:

PLC->Transfer Project
from PLC

4 Before downloading the

program you will be asked
to confirm your action.

Here you can set the check

box PLC run after transfer
to automatically start the
PLC when the download is
finished
5 If the PLC is in RUN mode
you will be asked to confirm
the STOP before the
download starts.

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 6 During the download you
will see the progress bar.

7 When the download is

finished you will be asked to
confirm setting the PLC to
run mode.

8 Once the download is

finished and the PLC is
started, the status bar
should indicate EQUAL and
RUN

9 Once the PLC is running

you can animate the
program sections.

Here an example of an FBD

section.

Green coloured variables

indicate a boolean 1
(high/on), red a boolean 0
(low/off).

10 The toolbar has iconsfor

downloading, uploading,
starting and stopping the
PLC.

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 AS-Interface Configuration

Introduction This chapter defines the steps required to initialise and configure the AS-interface. It
includes the method of configuring the addresses of the AS-interface components.

Equipment 1 Use the ASITERV2 handheld to

for Node address the individual slaves.
Addressing

ASITERV2
Handheld

ASISSL* 2 Use the ASITERIR1 infrared

Safety Input adapter to address safe input
Slaves slaves.

Please note the coding key on

the slave and connect the
adapter to the node.

3 In order for slave addressing to

be successful, the nodes must
be connected to the power
supply via the yellow AS-
Interface cable. Before you start
addressing, switch the master
‘offline’ by pressing and holding
down the PB2 button on the
AS-interface master module for
3 – 4 seconds. The master will
switch to offline mode and will
indicate this on the module via
an LED lighting up red next to
the word OFF.

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ASILUFC5 4 Use the XZMG12 adapter to
ASI20M* address ASI20M* and
ASILUFC5 IP20 devices
(TeSysU motor starters).
Connect the adapter to the
node via the yellow plug.

On slaves requiring a 24 V
auxiliary supply (black AS-
interface cable) at output level
(e.g., as is the case with
TeSysU), the power supply M12 male with
must be connected when the yellow and green plug-in connectors
nodes are programmed.
ASI67FMP* 5 Use the ASITERACC1F
adapter to address IP67 field
devices.

Connect the adapter to the M12

female ASI AUX on the right
underside of the device.

Addressing 1 To perform addressing, turn the

Slaves rotary switch to the ADDR
position and press the OK
button on the top right.

The device will now look for

connected nodes and display
the address of any slaves it
locates within a few seconds.

2 If no ASi appears on the

display, the device has not
been able to locate any AS-I
nodes and you should check
the connection between the
addressing device and the
slave.

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 3 The address of the connected
slave will appear on the display
as read by the device.

The factory setting for new

slaves is 0.

4 You can press the two arrows in

the centre of the device
(up/down) to set the address in
the range from 0 to 31 (0 is not
a valid slave address).
While an address is being set,
the current address will
continue to appear on the
display.

On slaves with advanced

addressing, an A or B will
appear on the display after the
address, indicating the channel
assignment. In this example,
both the IP20 (ASI20M*) and
IP67 (ASI67FMP*) modules
support advanced addressing.

The photo shows an

ASI20MT4I3OSE module with
address 12A.

5 Once you have set the required

address, press OK to apply the
setting. During transmission,
the display will switch to ProG.

6 Once you have made the

address setting, the new
address will appear
permanently on the device
display.

To address another device,

press the ESC button on the
left-hand side and resume the
process at Step 4.

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 HMI

Introduction This application features a touchscreen Magelis XBT-GT1100 HMI which can be
connected to the PLC via Modbus or UniTelway protocol. Due to the Premium PLC
UniTelway is used here.

The terminal is programmed and configured using the Vijeo Designer software.

Programming and configuring the HMI is described on the following pages.

Preconditions The procedure described below is subject to the following preconditions being met.

 The configuration software tool, Vijeo Designer V4.30 is installed on your PC.

 The “Example.dop” project is available in the default directory that has been set up
(C:\Program Files\Schneider Electric\XBT-L1000\Apps).

 The Magelis terminal is connected to the power supply.

 The Magelis terminal and the PC have been connected via the PC <> Magelis USB
data cable (XBTZG925).

note: For the example program you must also have at least the patch B for Vijeo
Designer v4.30 installed. The example program was created using Vijeo Designer
V4.3.0c and cannot be used with V4.3.0. Version 4.3.0b will accept the program.

Create a new 1 After starting Vijeo Designer

Configuration a dialog asks you if you to
create a new, or open an
existing, project.

Select Create New Project

and click on Next.

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 2 Input a Project Name

e.g. “ASI Premium”

and select:

Project with Single Target

To proceed, click on Next>.

3 Select the target device

Target Name: Target1

Target Type: XBTGT
1000 Series
XBTG Model: XBTGT1100

Proceed with Next>.

4 Other Magelis devices have

an ethernet interface. The
selected model has no
ethernet interface and the
input mask is de-activated.

Proceed with Next>.

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 5 The Magelis needs the
correct driver to exchange
data with the PLC.

Use Add to go to the driver

selection dialog and select a
new driver.

6 In the New Driver dialog

Select:

Manufacturer:
Schneider Electric
Industries SAS

Driver: Uni-Telway

Equipment:
Unitelway Equipment

confirm with OK.

7 After setting up the driver
you can exit the dialog with
Finish.

8 Vijeo Designer now returns

you to its work top, with an
empty display and the
project navigator.

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Configuring the 1 Once the UnitelWay
Programming connection has been
Interface configured, the
programming interface must
be set up for the USB
programming cable
XBTZG925.

In the Navigator, click on

Target1 and view the
information in the Property
Inspector (lower window).

If the Property Inspector is

not visible a right mouse
click on Target1 gives you a
pop-up menu in which you
can select the properties.

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 2 The default values offer a
serial COM1 interface.

As we are using a USB

programmning cable this
must be changed.

3 First check in the Windows

device manager which
COM port has been
configured for the USB
cable and that the cable is
connected.

In our example it is COM4

4 Now you can configure the

port in the Property
Inspector.

Set the COM Port to (in our

case) COM4.

The type of connection

remains as serial.

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Configuring the 1 For better legability the
UniTelway Driver name of the UniTelway
Equipment01 should be
changed.

To do this right click on

UniTelwayEquipment01 in
the Navigator to go to the
pop-up menu to do the
Rename.

2 In the example it was

renamed to Premium as
the Premium uses this
interface.

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 3 Right mouse click on
UniTelway01 to setup the
interface.

In the pop-up menu select:

Configuration..

4 In the driver configuration

dialog the setup must match
the setup as for the Unity
TER interface.

The Transmission Speed

must changed from 9600 to
19200.

5 As a comparison, the Unity

set up for the TER.

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Linking Variables 1 All the variables are already
programmed in Unity.
(Variable Import from
Program file) Vijeo Designer offers a
function to Link Variables..
and read them in from the
Unity program.

To do this select the tab

Variables in the Navigator

In the Navigator, right

mouse click on Target1 and
in the pop-up menu select
Link Variables..

2 In the Link Variables dialog

that opens up, enter the
path and file type to display
and the equipment
(premium)

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 3 In the example the path is
Unity, the file type is
UnityPro (*.stu) and the
equipment Premium.

4 After linking to the file, the

dialog shows all the
variables that can be
imported

By setting the check box

next to the variable a
selection of variables can be
made (click select all for all
variables).

Clicking Add adds the

selected variables to the
Vijeo Designer variable list.

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 5 Added variables are now
disabled in the list.

When finished with the

import clcik on Close.

6 The variables can be

viewed in the Variables tab
in the Navigator under:

Traget->PLC_Premium

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Creating a Variable 1 To create a new variable,
right mouse click on
Target1 or PLC_Premium.

In the pop-up menu select:

New Variable followed by

the type of variable, here
Discrete.

2 In the variable properties

dialog you can enter the
name and a description for
the variable

Important here is what

device delivers the value if it
comes from an external
system.

If this is the case you must

enter a ScanGroup and a
Device Address.

The device address is not

the hardware address. It is
the memory address in the
device that delivers the
value.

To select a device address

click on the button at the
right end of the list box.

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 3 In the dialog that opens,
input the memory address
of the variable as given in
the device.

The example here shows

the discrete as bit 3 of
memory word 55 and can
be addressed as

%MW55:X3

Exit with OK.

4 The device address is now

listed in the list box.

Confirm with OK.

Import a Project 1 Select the Tab Vijeo-

Manager in the Navigator

A right mouse click on

Vijeo-Manager in the
Navigator opens a pop-up
menu. here, select:

Import Project…

If the Import Project function

is de-activated, first shut all
open projects with:

File->Close Projekt

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 2 The import file is of type
Vijeo-Frame Archive
(*.vdz).

Check that the path is

correct and select a file to
import.

Click on Open to import the

file

3 When the import is finished,

acknowledge with OK.

4 In the Navigator you can

now see the project listed.
Double click on it to open it.

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Example Program 1 The example program here
has several screens that are
activated through the touch
screen or the buttons R1-
R6.

2 There are 2 alarm groups,

grouped in a single alarm
category.

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Build the 1 Before you can downlaod a
Program program to the HMI it must
be compiled.

Use the Build All function to

do this

Build->Build All

2 A progress bar will be

displayed.

3 when the build is finished

the feedback zone lists the
results

Only when the green

coloured message Build
Complete is shown can the
program be downloaded to
the HMI

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Download the 1 The configurated connection
Program of an imported program may
be incorrect.

First, check that the

imported program has the
correct programming cable,
XBTZG925 (USB),
configured.

For this you can use the

Property Inspector.

Right mouse click on the

program name (here
plattform1) and select
Properties in the pop-up
menu

2 The Image shows a

program using a serial
connection on COM5.

The example, however,

uses a USB programming
cable.

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 3 First check in the Windows
device manager which
COM port has been
configured for the USB
cable and that the cable is
connected.

In our example it is COM4

4 Now change the COM port

to COM4.

The interface type remains

at serial.

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 5 Use:

Build->Download All

to start an automatic build

before downloading the
program to the HMI.

6 A progress bar is displayed.

7 Once the build is finished

the Feedback Zone
displays the results and
indicates if the download is
complete.

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 Safety Monitor

Introduction This section describes how to parameterize, load, start, and stop the safety monitor.
Please note that only an appropriate overall layout and appropriate
interconnection of the individual function blocks in the software, along with their
hardware structure, can ensure that the machine will operate correctly and in a manner
that poses no risk to personnel or equipment.

In order to transfer and also enable, start and stop an application on the safety monitor,
a unique password must be entered, thereby ensuring protection against unauthorized
access.

As an additional measure, the RJ 45 programming port on the safety monitor can also
be capped using the transparent plastic stoppers supplied with the product and sealed
to prevent access. The breaking of a seal or removal of a stopper would indicate
tampering.

The Asiswin 2 software, which is described below, is used to create the application on
the safety monitor.

Preconditions The procedure described below is subject to the following preconditions being met:

 The ASISWIN V2.0.3 is installed on your PC.

 The safety monitor is connected to the power supply and to the AS-Interface master
on the Twido (via the AS-i cable).

 The safety slaves and the standard slaves used for safety (e.g., for
acknowledgement, error reset) are correctly addressed and ready for operation on
the AS-Interface network.

 The PC is connected to the safety monitor (ASISAFEMON1) via the special interface
cable (ASISCPC).

 The password for configuring the safety monitor is known (the default setting on
delivery is “SIMON”).

 If you wish to adapt the preconfigured example to your application, example

“Example.as2” must be available in the software’s default directory (“C:\Program
Files\Schneider Electric\ASISWIN\Example.as2”).

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Starting 1 When the ASISWIN software
ASISWIN starts up, the screen opposite
will appear, offering you the
following options (some of
which will be grayed out):

 Diagnostics
 New configuration
 Open configuration
 Load configuration from AS-
Interface safety monitor

If this dialog box does not

appear, use New or Open in
the File menu.

Create a New 1 To create a new configuration,

Configuration first assign a unique title to your
configuration on the
Setting up the Information about monitor
Monitor tab.

In this example, an
ASISAFEMON1, which has just
one OSSD and basic
functionality, is being used.

Note: An ASISAFEMON2B safety

monitor, however, would have two
OSSDs, which could be switched
independently or dependently and
support an extended range of
functions.

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 2 On the Information about bus
tab, enter the safe and standard
slaves you are using.

If you are using standard slaves

for acknowledgement and error
reset, you will need to enter
them here.

The safe slaves' address range

starts at address 21, the
standard slaves' range is from
20 downwards.

The safety monitors for which

addresses 30 and 31 have
been reserved are not entered
here.

3 Enter the address of the safety

monitor on the last tab,
Diagnosis / Service.

The highest addresses

available on the bus should be
assigned to the safety monitors;
it is for this reason that, in this
example, addresses 30 and 31
are being used for the safety
monitors.

In the example, the slave with

address 8B is used with the
first input (IN-0) to reset the
safety monitor in the event of an
error (e.g., if the delay time is
exceeded for an NC/NO
combination

Confirm with OK.

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Create a New 1 The screen on the right will
Configuration appear for the base controller.
A variety of functions can be
implemented, these include:

 Emergency-off
 Safety guard
 Module
 Feedback loop
 Monitored start

To use the individual blocks,

drag the elements from the
yellow area on the left-hand
side to the white area on the
right-hand side (1. OSSD).

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Adding an 1 The following dialog box will
Emergency- appear if you place a forced
Off emergency-off in the area.

In the Name field, enter a

unique name, which will help
you to find the device reliably
and without confusion (all
device names should be
selected on this basis).

Next, assign an Address to the

device; only the addresses you
entered as safe slaves when
configuring the motor and have
not yet used will appear.

Local acknowledgement and

the Start-up test are not used
here.

Note: If you activate the Start-up

test, when the power supply is
restored, the device specified must
be forced (triggered) in order to be
able to acknowledge the monitor.

Confirm with OK.

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Adding a 1 The example safety guard is
Safety Guard implemented using two roller
switches assigned to the same
guard.

As the switches are positioned

to the left and right of the guard,
the contacts are not forced
directly; rather, there is a
dependency between the two
switches.

On the left of the window, select

the Safety guard module under
Double channel dependent.

A period of 0.5 s is entered for

the Synchronization time.

This time defines the

permissible delay of the lagging
roller switch.

Confirm with OK.

Adding a 1 Once the switches and safety

Monitoring guard monitoring have been
Circuit added to the configuration, the
monitoring circuit for the load
contactors is added.

The default Switching time of

100 ms can be used for smaller
compact load contactors (e.g.,
LC1D09). This value will need
to be increased accordingly for
larger load contactors.

Confirm with OK.

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Selecting the 1 A standard non-safe slave now
Start has to be configured for the
Condition monitored start of the monitor.

In this example, slave 8B,

which has already been used
for the error reset, is used again
with input IN-0.

Note: Please note that for the slave

type used (ASI67FMP), the
designations are I1 to I4, although
in the software, the designations
start with IN-0 and end with IN-3.

Confirm with OK.

Defining a 1 Switch-off features are based

Stop on stop category 0 (undelayed
Category switch-off).

Note: If frequency inverters have

been integrated, a delayed switch-
off (stop category 1) can be
selected, enabling the controlled
ramping-down of load
disconnection. However, this option
must be checked in respect of its
relevance to safety.

Confirm with OK.

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 2 The complete configuration of
the monitor now looks like this.

All conditions [32..34] must be

true in order for the monitor to
be enabled.

3 Click on the check-mark icon

to check the configuration. The
result will appear in a separate
window which will hide itself
automatically.

Transferring 1 The following preconditions now

the need to be met:
Configuration
to the Monitor  Connect the safety monitor
to the power supply.
 Connect the configured AS-
interface slaves via the
yellow cable.
 Wire the monitoring circuit
for the load contactors on
the monitor.
 Connect the PC and
monitor via the ASISCPC ASISCPC ASISAFEMON
cable [COM1 (PC) & config
port (monitor)].

2 Before you connect to the

monitor, select Interface from
the Monitor menu to check
which communication port has
been set. In this case, COM1 is
the only port.

There is no need to modify the

baud rate or transfer protocol
settings.

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 3 To transfer a configuration to
the monitor, select

PC->Monitor

from the Monitor menu and

continue with Step 4.

If the four items at the top of the

menu list cannot be selected
(because they are grayed out),
a safety monitor may already
have been started (if this is the
case, you can stop it by
selecting Stop from the
Monitor menu).

Note: As when starting, the monitor

will prompt you to enter a
password if you have not
connected to the device in the last
five minutes or have been offline.

4 You will need to enter your

password in order for the
actions you have requested to
be executed. If you are using
the safety monitor for the first
time, the password will be
SIMON.

Confirm with OK.

5 The PC will now start to transfer

the configuration to the monitor.

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 6 Once the transfer is complete,
you will be asked if you would
like to teach the code
sequences.

Confirm the prompt with YES.

The subsequent procedure

demonstrates the teaching-in of
code tables in order to monitor
the state of the safety AS-
Interface slaves cyclically.

7 Next, the PC will receive a

handshake from the monitor in
the form of a log representing
the “understood” configuration.

This will appear on the screen

as a section of plain text and
you will be prompted to check
the configuration, along with the
function of the monitor.

Confirm the message with OK.

Once you have carried out this
check, you can click on the
close icon (cross) in the top
right-hand corner to exit the
screen.

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Changing the 1 The factory-set default
Password password for new monitors is
SIMON.

To change the password,

select:

Change password…

in the Monitor menu.

2 In the top line of the next dialog

box that appears, enter the old
password SIMON (remember
that passwords are case-
sensitive). In the middle line,
enter your new password and
then repeat your entry in the
bottom line.

Confirm your entries with OK.

An error message will appear if

the password you have entered
is not valid.

Validating 1 To validate the monitor, select:

the Monitor
Validate…

In the Monitor menu.

Validation is the last stage

before starting the monitor and,
functioning virtually as the
signature of the responsible
programmer, represents the last
check prior to first use.

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 2 In the next screen, enter your
name, confirm your identity by
entering the correct password
and confirm your entries with
OK.

3 Make a note of the information

that appears in the next
message and keep this in a
safe place.

Note: Monitors can only be used

with valid passwords. However, a
generic password can be
generated using the field entries.

Starting the 1 Select Start from the Monitor

Monitor menu to activate the validated
safety monitor. It is only when
this last setting is made that the
signals from the safe slaves are
processed and the OSSD can
be switched (load connection).

Note: Depending on the last direct

access via PC to the monitor, you
may need to re-enter your
password.

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 Data Exchange

Introduction The Magelis terminal is connected via UniTelway to the Premium PLC. The AUX
interface on the Premium PLC is used for this connection

This chapter explains how the data is exchanged between the Magelis terminal and
the Premium PLC via the Unitelway connection as well as the assignment of
communication data to the AS-Interface modules.

Data Transfer Data Direction PLC from/to HMI

Primary Premium PLC <-> Magelis XBT-GT1100
Variable Symbol Designation
%M101 HMI_Mode HMI-Mode selected

AS-Interface Data Direction PLC to HMI

Premium PLC -> Magelis XBT-GT1100
Variable Symbol Designation
%M102 ASI_BUS_Fail BUS Error on ASI Master (%I0.2.0.ERR)
%M103 ASI_Modul_Fail Module failure on am ASI Master (%I0.2.MOD.ERR)
%M104 ASIMON_01_Fail ASI Safety monitor 01 activated
(%I\1.30\.0.0.0.ERR)
%M105 ASIMON_02_Fail ASI Safety monitor 02 activated
(%I\1.31\.0.0.0.ERR)
%M106 ASIMON_01_ok ASI Safety monitor 01 okay
%M107 ASIMON_02_ok ASI Safety monitor 02 okay
%M210 ASIMON_01_Fail_0 ASI Safety monitor 01 triggered by DFB
%M211 ASIMON_02_Fail_0 ASI Safety monitor 02 triggered by DFB
%M212 ASIMON_01_Running ASI Safety monitor 01 on DFB is running
%M213 ASIMON_02_Running ASI Safety monitor 02 on DFB is running
%M214 ASIMON_01_Estop1 ASI Safety Mon. 01 triggered by DFB contact 01
%M215 ASIMON_01_Estop2 ASI Safety Mon. 01 triggered by DFB contact 02
%M216 ASIMON_02_Door1 ASI Safety Mon. 02 triggered by DFB contact 01
%M217 ASIMON_02_Door2 ASI Safety Mon. 02 triggered by DFB contact 02

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 TeSysU Data Direction PLC to HMI
(Status data) Premium PLC -> Magelis XBT-GT1100
Variable Symbol Designation
TeSysU 1(A) %M110 TeSysU_01_Fail Motor starter TeSysU, Slave address 1A, is faulty
(from AS-Interface-Address %I\1.1\0.0.0.ERR)
%M111 TeSysU_01_Ready Motor starter TeSysU, Slave address 1A, is ready
(from AS-Interface-Address %I\1.1\0.0.0.0)
%M112 TeSysU_01_Run Motor starter TeSysU, Slave address 1A, running
(from AS-Interface-Address %I\1.1\0.0.1.0)
TeSysU 2(A) %M120 TeSysU_02_Fail Motor starter TeSysU, Slave address 2A, is faulty
(from AS-Interface-Address %I\1.2\0.0.0.ERR)
%M121 TeSysU_02_Ready Motor starter TeSysU, Slave address 2A, is ready
(from AS-Interface-Address %I\1.2\0.0.0.0)
%M122 TeSysU_02_Run Motor starter TeSysU, Slave address 2A, running
(from AS-Interface-Address %I\1.2\0.0.1.0)
TeSysU 3(A) %M130 TeSysU_03_Fail Motor starter TeSysU, Slave address 3A, is faulty
(from AS-Interface-Address %I\1.3\0.0.0.ERR)
%M131 TeSysU_03_Ready Motor starter TeSysU, Slave address 3A, is ready
(from AS-Interface-Address %I\1.3\0.0.0.0)
%M132 TeSysU_03_Run Motor starter TeSysU, Slave address 3A, running
(from AS-Interface-Address %I\1.3\0.0.1.0)
TeSysU 4(A) %M140 TeSysU_04_Fail Motor starter TeSysU, Slave address 4A, is faulty
(from AS-Interface-Address %I\1.4\0.0.0.ERR)
%M141 TeSysU_04_Ready Motor starter TeSysU, Slave address 4A, is ready
(from AS-Interface-Address %I\1.4\0.0.0.0)
%M142 TeSysU_04_Run Motor starter TeSysU, Slave address 4A, running
(from AS-Interface-Address %I\1.4\0.0.1.0)
TeSysU 5(A) %M150 TeSysU_05_Fail Motor starter TeSysU, Slave address 5A, is faulty
(from AS-Interface-Address %I\1.5\0.0.0.ERR)
%M151 TeSysU_05_Ready Motor starter TeSysU, Slave address 5A, ist ready
(from AS-Interface-Address %I\1.5\0.0.0.0)
%M152 TeSysU_05_Run Motor starter TeSysU, Slave address 5A, running
(von AS-Interface-Address %I\1.5\0.0.1.0)
TeSysU 6(A) %M160 TeSysU_06_Fail Motorstarter TeSysU, Slave address 6A, is faulty
(from AS-Interface-Address %I\1.6\0.0.0.ERR)
%M161 TeSysU_06_Ready Motor starter TeSysU, Slave address 6A, is ready
(from AS-Interface-Address %I\1.6\0.0.0.0)
%M162 TeSysU_06_Run Motor starter TeSysU, Slave address 6A, läuft
(from AS-Interface-Address %I\1.6\0.0.1.0)

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 TeSysU Data Direction HMI to PLC
(control data) Magelis XBT-GT1100 -> Premium PLC
Variable Symbol Designation
TeSysU 1(A) %M113 TeSysU_01_Forward Motor starter TeSysU, Slave address 1A, forwards
(to AS-Interface-Address %Q\1.1\0.0.0.0)
%M114 TeSysU_01_Reverse Motor starter TeSysU, Slave address 1A, reverse
(to AS-Interface-Address %Q\1.1\0.0.1.0)
TeSysU 2(A) %M123 TeSysU_02_Forward Motor starter TeSysU, Slave address 2A, forwards
(to AS-Interface-Address %Q\1.2\0.0.0.0)
%M124 TeSysU_02_Reverse Motor starter TeSysU, Slave address 2A, reverse
(to AS-Interface-Address %Q\1.2\0.0.1.0)
TeSysU 2(A) %M133 TeSysU_03_Forward Motor starter TeSysU, Slave address 3A, forwards
(to AS-Interface-Address %Q\1.3\0.0.0.0)
%M134 TeSysU_03_Reverse Motor starter TeSysU, Slave address 3A, reverse
(to AS-Interface-Address %Q\1.3\0.0.1.0)
TeSysU 2(A) %M143 TeSysU_04_Forward Motor starter TeSysU, Slave address 4A, forwards
(to AS-Interface-Address %Q\1.4\0.0.0.0)
%M144 TeSysU_04_Reverse Motor starter TeSysU, Slave address 4A, reverse
(to AS-Interface-Address %Q\1.4\0.0.1.0)
TeSysU 2(A) %M153 TeSysU_05_Forward Motor starter TeSysU, Slave address 5A, forwards
(to AS-Interface-Address %Q\1.5\0.0.0.0)
%M154 TeSysU_05_Reverse Motor starter TeSysU, Slave address 5A, reverse
(to AS-Interface-Address %Q\1.5\0.0.1.0)
TeSysU 6(A) %M163 TeSysU_06_Forward Motor starter TeSysU, Slave address 6A, forwards
(to AS-Interface-Address %Q\1.6\0.0.0.0)
%M164 TeSysU_06_Reverse Motor starter TeSysU, Slave address 6A, reverse
(to AS-Interface-Address %Q\1.6\0.0.1.0)

I/O-Module Data direction PLC to HMI

(Control Data) Premium PLC -> Magelis XBT-GT1100
Variable Symbol Designation
Modul FMP 01 %M170 FMP_01_Fail IP67-Modul ASI67FMP, Slave address 7A,
(7A) (to AS-Interface-Address %I\1.7\0.0.0.ERR)
Modul FMP 02 %M171 FMP_02_Fail IP67-Modul ASI67FMP, Slave address 8A,
(8A) (to AS-Interface-Address %I\1.8\0.0.0.ERR)
Modul FMP 03 %M172 FMP_03_Fail IP67-Modul ASI67FMP, Slave address 9A,
(9A) (to AS-Interface-Address %I\1.9\0.0.0.ERR)
Modul MT 01 %M180 MT_01_Fail IP20-Modul ASI20MT, Slave address 10A,
(10A) (to AS-Interface-Address %I\1.10\0.0.0.ERR)
Modul MT 02 %M181 MT_02_Fail IP20-Modul ASI20MT, Slave address 11A,
(11A) (to AS-Interface-Address %I\1.11\0.0.0.ERR)
Modul MT 03 %M182 MT_03_Fail IP20-Modul ASI20MT, Slave address 12A,
(12A) (to AS-Interface-Address %I\1.12\0.0.0.ERR)
Modul MT 04 %M183 MT_04_Fail IP20-Modul ASI20MT, Slave address 13A,
(13A) (an AS-Interface-Address %I\1.13\0.0.0.ERR)
Modul Safety %M200 FMP_Safe01_Fail IP67-Modul ASI67FMP, Slave address 7B,
FMP 01 (7B) (to AS-Interface-Address %I\1.107\0.0.0.ERR)
Modul Safety %M201 FMP_Safe02_Fail IP67-Modul ASI67FMP, Slave address 8B,
FMP 02 (8B) (to AS-Interface-Address %I\1.108\0.0.0.ERR)

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 Appendix

Detailed Component List

Hardware Hardware components (main cabinet) – Group 1: Main switch, power supply and distribution, load
current components
Main cabinet Rev./
Item Amt. Description Part Number
Vers.
1.1 1 Motor circuit breaker as main switch, GV2ME16
configurable from 9 to 14 A
1.2 1 Installation box for motor circuit breaker, IP55 GV2MP02
1.3 1 “Power ON” indicator glow lamp, clear, GV2SN37
380/440 V AC
1.4 1 Emergency-off button for installation box, GV2K04
latching, with turn-to-reset
1.5 1 multi9 circuit breaker D 1.5 A, 2-pole 17453
(Phaseo primary side)
1.6 1 multi9 circuit breaker B 3 A, 1-pole 24502
(Phaseo secondary side)
1.7 1 Phaseo, combined power supply for ASIABLM3024
AS-Interface and 24 V, 3 A sec. rated current
1.8 2 multi9 circuit breaker, C 6A, 3-pole (back-up 24112
fuse for TeSysU motor starter groups)
1.9 3 TeSysU – power section for motor starters, LU2B12B
2 directions of rotation, 12 A
1.10 3 TeSysU – control module for motor starters, LUCA05BL
standard; 1.25 .. 5 A
1.11 3 TeSysU - motor starter for AS-Interface ASILUFC5
module
1.12 3 TeSysU - coil connection for motor starters LU9M RC
1.13 3 AS-Interface tap for TeSysU motor starters XZ CG0142
1.14 1 Busbar system, 3-pole, 3 outgoing feeders GV2G345
1.15 1 Busbar terminal block, 3-pole GV1G09

Hardware components (main cabinet) – Group 2: Emergency-off (optional)

Rev./
Item Amt. Description Part Number
Vers.
2.1 1 AS-interface safety monitor, 1 switch-off ASISAFEMON1
circuit, basic functionality
2.2 1 Emergency-off switch, set up as safe AS-i ASISSLB4
slave, metal
2.3 1 Mushroom pushbutton, red/yellow, d=40 mm, ZB4BS844
turn-to-reset
2.4 1 Yellow “emergency-off” plate, d=90 mm ZBY8330
2.5 2 TeSys D, redundant load contactors, 9A/AC3, LC1D09BD
1xNO, 1xNC, 24 V, incl. protective circuit
2.6 1 multi9 circuit breaker B 1 A, 1-pole 24045
(protection for safety monitor and contactors)

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 HardwareComponents (control cabinet) – Group 3: Control components and HMI
Rev./
Pos. Amt. Description Part Number Vers.
3.1 1 Premium CPU for CANopen and AS-interface TSXP572634M
with Ethernet interface
3.2 1 Memory expansion module SRAM 2MB TSXMRPC002M
3.3 1 Premium AS-interface Module TSXSAY1000
3.4 1 Rack for 6 modules TSXRKY6EX
3.5 1 Terminal resistor for Rack TSXTLYEX
3.6 1 Power module 26 W Standard 230V/24V TSXPSY2600M
3.7 1 Power switch, C60 N B 6A, 1-polig 23612A
(Premium safety)
3.8 1 Magelis-Display, graphic monochrom XBTGT1100
3.9 2 Communication cable Magelis <> Premium XBTZ9780
3.10 1 Circuit breaker B 1 A, 1-pole 24045
(protection for Magelis)

Hardware Hardware components (remote cabinet) – Group 4: Load components

Remote Rev./
Item Amt. Description Part Number
cabinet Vers.
4.1 1 TeSysU – power section for motor starters, LU2B12B
2 directions of rotation, 12 A
4.2 1 TeSysU – control module for motor starters, LUCA05BL
standard; 1.25 .. 5 A
4.3 2 TeSysU – motor starter for AS-Interface ASILUFC5
module
4.4 1 TeSysU – coil connection for motor starters LU9MRC
4.5 1 AS-Interface tap for TeSysU motor starters XZCG0142
4.6 1 Busbar system, 3-pole, 3 outgoing feeders GV2G345
4.7 1 Busbar terminal block, 3-pole GV1G09

Hardware components (remote cabinet) – Group 5: Safety guard combined with emergency-off
Rev./
Item Amt. Description Part Number Vers.
5.1 1 AS-interface safety monitor, 1 switch-off ASISAFEMON1
circuit, basic functionality
5.2 1 Emergency-off switch, set up as safe AS- ASISSLB4
interface slave, metallic
5.3 1 Mushroom pushbutton, red/yellow, d=40 mm, ZB4BS844
turn-to-reset
5.4 1 Yellow “emergency-off” plate, d=90 mm ZBY8330
5.5 2 TeSys D, redundant load contactors, 9A/AC3, LC1D09BD
1xNO, 1xNC, 24 V, incl. protective circuit
5.6 1 Circuit breaker B 1 A, 1-pole 24045

Hardware components (remote cabinet) – Group 6: ASi control components

Rev./
Item Amt. Description Part Number
Vers.
6.1 4 AS-Interface - IP20 digital input/output block, 4 ASI20MT4I3OSE
inputs, 3 transistor outputs
6.2 1 AS-Interface - insulation displacement ASI20MACC1
connectors (IDC), 4 x yellow, 4 x black, 5/5
items
6.3 3 AS-Interface tap for TeSysU motor starters XZCG0142

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Hardware Hardware components – Group 7: Field installation
Field devices Rev./
Item Amt. Description Part Number
Vers.
7.1 1 AS-Interface profile cable, yellow (ASi), 100 m XZCB11001
7.2 1 AS-Interface profile cable, black (AUX), 100 m XZCB11002
7.3 3 AS-Interface tap for AS-Interface module ASIDCPM12D03
7.4 3 IP67 I/O block with 4 inputs/3 outputs ASI67FMP43E
7.5 1 Cover caps for unused M12 connectors, set of 10 FTXCM12B optional
7.6 2 Retroflective sensor, M12 connector XUK0AKSAM12
7.7 2 Terminal block for 18 mm sensors XSZB118
7.8 2 M12 connecting cable, 1 m length XCR1511041C1
7.9 4 Inductive sensor, d=18 mm, M12 connector XS618B1PAM12
7.10 4 Terminal block for 18 mm sensors XSZB118
7.11 4 M12 connecting cable, 1 m length XCR1511041C1
7.12 2 Ultrasonic sensor, d=18 mm, M12 connector XX518A1KAM12
7.13 2 Terminal block for 18 mm sensors XSZB118
7.14 2 M12 connecting cable, 1 m length XCR1511041C1

Hardware Hardware components – Group 8: Safety components for installation in the field
Field devices Rev./
Item Amt. Description Part Number
Vers.
8.1 1 AS-Interface, safe slave, 2X IN M12 ASISSLC2
8.2 2 Safety roller limit switches XCSM3915L1
8.3 2 M12 connecting cable (male + female), length 1 m XZCR1511041C1
8.4 2 M12 male for customer assembly XZCC12MDP40B
8.4 2 Pushbutton housing, standard, for XALD01
acknowledgements
(1x emergency-off, 1x safety guard)
8.5 2 Illuminated pushbutton, blue, 24 V LED, 1 NO ZB5AW0B61
contact
8.6 4 M12 connecting cable, with M12 male connectors XZCP1541L2
fitted at one end, length 2 m

Software Software Components – Group 9

Components Rev./
Item Amt. Description Part Number
Vers.
9.1 1 UnityPro XL Programming software UNYSPUEFUCD22 2.2
9.2 1 Premium Programming cable TSXPCX1031
9.3 1 Magelis-Configurationssoftware Vijeo-Designer VJDSUDTGAV43M 4.30
incl. USB Programming cable XBTZG925 patch C
needed
9.3b 1 Magelis-Programming cable for XBT-GT1100 XBTZG925
9.4 1 Configurations software for AS-Interface safety ASISWIN2 2.0.3
monitors
9.5 1 Download cable for AS-Interface ASISCPC
safety monitors
9.6 1 Hand terminal for Programming ASI Slaves ASITERV2
9.7 1 Infrared adapter for Hand terminal (ASITERV2) ASITERIR1

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Cabinet Cabinet Componensn – Group 10 (SAREL)
Components Rev./
Item Amt. Description Part Number Vers.
10.1 1 Cabinet, 800x600x300mm (HxBxT, with Monting ENN83357
plate, Sarel)
10.2 2 Filter Fan, 230V, 56 m³/h (Sarel) ENN17901
10.3 2 Filter mounting for fan (Sarel) ENN17911
10.4 1 Thermostat for Filter fan, 0..60°C (Sarel) ENN17562

Component Protection Classes

Cabinet
Positioning Component In Field, On Site
Front Inside
Protection
IP54 IP65 IP67 IP55 IP65 IP20
Class
Emergency-off installation box for GV2ME X X
Load contactors LC1D X
Circuit breakers, all power ranges and X
types
Phaseo power supply unit X
TeSysU motor starters, all ratings X
Premium PLC incl. expansion modules X
Magelis display terminal X X
“Harmony” range of pushbuttons in X
housing
AS-Interface – input/output modules X
ASI20MT***/ASI20MA***
AS-Interface – input/output modules X
ASI67FF***/ASI67FM***
AS-Interface safety monitor X
AS-Interface emergency-off slave X
ASISSLB4
Mushroom attachment/switch for IP66
ASISSLB4
AS-Interface emergency-off slave X
ASISSC1/C2
Preventa safety limit switch XCSM*** X

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 Component Features

Premium-PLC
with
AS-Interface
Master
Module

TSXP572634M

TSXSAY1000
The remote I/O is implemented with AS-Interface function blocks .

 240 VAC power supply with integrated 24V/5A power supply

 Ethernet interface, 2x UniTelway (TER & AUX)
 Up to 9 expansion modules in local rack (digital/analog/remote E/A and
communications modules such as ASI and CANopen)
 AS-Interface-Master-Module for 31 Slaves with standard addressing /
62 Slaves with extended addressing

5 Programming languages:

 ST
 IL
 FBD
 SFC
 LD

Pre-definierte functions:

 Diverse communications modules for Fipway, Modbus Plus, Fipio Agent,

UniTelway, Modbus/Jbus, CANopen, Modem, serial interface, Ethernet
TCP/IP
 Memory Expansion using PCMCIA card (RAM or Flash-EPROM)
 Real-time clock
 Online program changes during RUN Mode
 Digital and analog In-/Output modules
 closed loop control, counter, positioning und communications modules
 Temperature range: 0..+ 60°C (+5..+55 acc. IEC 1131-2)
 Licences : UL, CSA, BV, DNV, GL, LR, RINA

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 Magelis
Operator
Terminal

XBT-GT1100

The functions implemented with the Magelis display unit are:

 Displaying data of the control system and reporting alarms

 Modifying control system parameters and controlling a process using
discrete commands

The HMI terminal is powered from the 24 VDC sensor supply output from the PLC.
This has the advantage that PLC and HMI work independently of other system
components.

Display:

 Graphic, monochrom
 LCD with background lighting, 3,8“, green/orange
 6 Function keys

Communication:

 Modbus
 UniTelway

Phaseo power
supply unit  100 bis 240 VAC

ASI ABLM3024  30 VDC/2,4 A

 Short-circuit-proof, earth fault detection

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 AS-Interface
Safety
Monitor for
E-off and
safety doors

ASISAFEMON1

Safety module for monitoring safety cicuits (E-Off and safety doors)

 1 or 2 release circuits (1 release circuit with ASISAFEMON1)

 basic or extended functions
 Up to Category 4 safety according to EN 954-1
 2 poles per release circuit
 Usable in an AS-Interface bus segment with standard slave (e.g. TeSysU
ASILUFC5 and safety slaves (e.g. ASISSLB2)
 Diagnosis LEDs on the front

TeSysU Motor starter base for two directions with

Motor Starter indication

LU2B12B  screw clamp connectors 12 A

(12 ..32A available)

 control unit LUCA 05BL, 1.25..

5A /1.5 kW max. (0.09 .. 15 kW
available)

 communication module ASI

LUFC5, AS-Interface Version
2.0, standard addressing

 connection to AS-Interface and

auxiliary cable via Tap
XZCG0142

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AS-Interface Discrete modular interface IP20
Digital I/O
Module IP20  4 inputs, 3 transistor outputs, 0.5 A
 output supply via external power 24
ASI20MT4I3OSE VDC (black cable)
 AS-Interface Version 2.1, extended
addressing
 connection to AS-Interface and
auxiliary cables via screw clamp
connectors or insulation
displacement connectors

AS-Interface
Digital I/O Discrete interface, remote connection
Module IP67
 4 inputs, 3 transistor outputs, 2A
ASI 67FMP43E  output supply via external power
24 VDC (block cable)
 AS-Interface Version 2.1,
extended addressing
 connection to AS-Interface and
auxiliary cables via Tap ASI
DCPM 12D03 (module types
with insulation displacement
connectors available)

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 Contact

Author Telephone E-Mail

Schneider Electric GmbH +49 6182 81 2555 [email protected]
Machines and Process
Architectures

Schneider Electric GmbH As standards, specifications and

Steinheimer Strasse 117 designs change from time to time,
D - 63500 Seligenstadt please ask for confirmation of the
Germany information given in this
publication.
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