PacDrive 3:

The future of motion-centric

machine automation

2012
Automation
Solutions
with
PacDrive 3…
…faster
time-to-market
for your machines

2
 Contents

Table of Contents:

Comprehensive Solutions from Schneider Electric ................................... 4

Complete Solutions with PacDrive 3 .................................................................. 6
Groundbreaking Systems Engineering.............................................................. 8
PacDrive in Action ......................................................................................................... 12
Energy Savings ............................................................................................................... 16
Technology ....................................................................................................................... 18
Application Software ................................................................................................... 20
Tools ..................................................................................................................................... 24
Electronic Help Documentation ........................................................................... 38
Controls .............................................................................................................................. 40
Functional Safety............................................................................................................ 44
I/O Communication ..................................................................................................... 46
Servo Drives, Multi-axis Solutions ........................................................................ 48
Integrated Servo Drives ............................................................................................. 52
Servo Drives, Stand-alone Solutions .................................................................. 54
Servo Motors ................................................................................................................... 56
Robotics Solutions ........................................................................................................ 60
HMI ........................................................................................................................................ 66
Field Bus Devices .......................................................................................................... 68
Electrical Components .............................................................................................. 72
PacDrive 3 and the Competition .......................................................................... 74

3
Comprehensive, integrated solutions from Schneider Electric…

Your solutions partner

for your entire factory
Schneider Electric is a trusted, global provider of a full range of products and solutions
for energy distribution and management, building automation and installations, and
industrial automation. With more than 100,000 employees in over 100 countries, 207
production facilities, and more than 16,000 sales offices worldwide, Schneider Electric
can provide expert, on-site assistance in the design and development of automation
process systems, equipment manufacturing, and plant engineering.

System Software System Software System Software

System Software System Software System Software System Software

sercos Remote IO

PacDrive 3
LMC

Working in perfect harmony:

Together – PlantStruxure™, for automation of processing systems, and MachineStruxure™, for automation of
individual production machines – provide scalable, fully integrated solutions for your entire factory and production
lines. PacDrive 3 (in shaded area above) is the logic motion control solution for MachineStruxure.

4
 Comprehensive, integrated solutions from Schneider Electric…

Fully Integrated Automation Solutions

Using its proven PlantStruxure™ and management systems. As a powerful,
MachineStruxure™ architectures, PC-based control and monitoring system,
Schneider Electric can leverage its the scalable Vijeo Citect™ SCADA software
comprehensive product portfolio for is suitable for a wide range of needs, from
industrial automation to achieve a single, small companies to large corporations with
fully integrated solution. Everything works highly complex processes and demanding
together smoothly because scalable control availability requirements. Additional software
technology provides flexible automation of systems enhance the range of solutions
both individual machines and processing available for processes at different levels of
systems. Each solution can be supplemented the factory.
by a wide range of Schneider Electric
products that improve performance and Schneider Electric provides a number of
increase efficiency at multiple levels – from products and solutions for power distribution
an entire factory to a single production line, and conversion, for both primary and
or individual machine. secondary distribution. This includes wiring
and cabling technology, and switchgear
Schneider Electric also supplies solutions for technology for supplying electrical power to
the vertical integration of production machines and production systems. The
processes. SCADA and MES solutions by company also has extensive expertise in the
Schneider Electric create a seamless areas of energy management and metering
connection between production floor and technology, and has its own subsidiary for
building automation and safety technology.

HMI controllers Motion controllers

> More compact > Higher performance

n
tio lle r
Montro
Co
ic lle r ve l l e r
Logntro Drintro
Co Co
I ller
HMntro
Co

Different controllers,
one software:
SoMachine™ is your
engineering workbench
Drive controllers Logic controllers for Flexible Machine
> Added efficiency > Increased flexibility Control

Flexible Machine Control with SoMachine™

The goal of shortening development times in high-performance motion controllers, can be
machinery and plant engineering was the programmed and put into operation using a
driving force behind Schneider Electric’s single engineering workbench. This concept
creation of Flexible Machine Control. The requires no new tools or training. And, it
term Flexible Machine Control refers to a allows users to perform engineering tasks in
concept that consolidates the various the same familiar software environment,
mutually supplementing control platforms in regardless of the respective control platform.
MachineStruxure under the umbrella of a Comprehensive software libraries with
single software solution: SoMachine. Using tested Application Function Blocks provide
SoMachine, the entire range of controllers, valuable support.
from simple drive-based controllers to

5
For production, packaging, material handling, and robotics…

Complete automation
solutions with PacDrive 3
SoMachine™
Motion
Ethernet, TCP/IP, OPC, FTP,
ftp, http,
HTTP, SMS, SMTP

PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C

Logic Motion Controllers

Safe Logic Controller* IT/COM

SLC x00
Logic Motion
Magelis™ HMI
SERCOS 3 + Integrated Safety*

Other field busses:

PROFIBUS™ DP, CANopen™, EtherNet/IP,
Profinet™, Modbus™ LXM 62 Multi-axes Servo Drives
+ Power Supply + ILM 62 CM

Stand-alone
Servo Drives
LXM 52 Distribution
Box
TM5 I/O

ILx
TeSys™ ATV312

TM7 TM7 SH SH SH Torque Linear ILM 62

BRS3 Remote I/O Remote I/O Motor Motor
SD3 28
Field Bus
Components

One integrated automation platform, one versatile automation bus The foundation for fully
integrated solutions:
Based upon proven motion-logic technology, Schneider Electric SERCOS 3 technology Interoperability between
PacDrive 3 and the
the PacDrive 3 automation solution from enables the entire communication process extensive portfolio of HMI
Schneider Electric unifies PLC, motion, and for PacDrive 3 automation solutions to flow components, automation,
robotics control functionality on a single through a fully integrated, Ethernet-based and electrical equipment,
allows users to create
hardware platform. With its centralized automation bus. PacDrive 3 system single-source solutions.
system architecture, PacDrive 3 is the ideal components are part of a broad overall
solution for controlling a broad range of portfolio that includes HMI, automation, and
servo-driven production and packaging electrical equipment, that together create
machines, as well as material handling complete single-source solutions for
equipment and robotics – using fully integrated, demanding machinery applications.
IEC 61131-3-compliant program structures.

* according to IEC 61508:1998, EN/ISO 13849-1:2008

6
 For production, packaging, material handling, and robotics…

sercos
PacDrive 3
LMC
P4

D2

MAX R

Mechatronic
Components

PacDrive 3’s proven technology provides a flexible, robust hardware platform for
MachineStruxure’s logic motion automation solutions. As the new generation of the
successful PacDrive M System, PacDrive 3’s scalable controller performance allows
economical automation of applications – ranging from small systems with only a few
servo axes to high-performance solutions with up to 99 servo axes or 30 robots.

* according to IEC 61508:1998, EN/ISO 13849-1:2008

7
Groundbreaking Systems Engineering >

PacDrive 3:
Sustainable automation
solutions…with
lower engineering costs
For years, Schneider Electric has pursued a technological approach
designed to consistently reduce hardware and software complexity. Our
consistent objective has been to hold the line against rising engineering
costs for design, installation, and commissioning. PacDrive 3 technology
opens up new opportunities for achieving this goal, and also introduces
new approaches for long-term cost savings.

8
 Groundbreaking Systems Engineering >

Higher performance
with increased scalability
The PacDrive 3 Controller from Schneider
Electric provides a wide range of scalable
performance for synchronized multi-axis
motion, PLC functionality, and robotic
control – on a single hardware platform –
for both complex and simple machine
configurations. Performance in the upper
end of the range is sufficient for up to 99
servo axes or 30 robots. At the lower end of
the range, new controllers for a maximum of
4 or 8 servo axes are designed for more
economical automation of simple machines.
This approach delivers fully integrated
control technology for both simple and highly
complex applications!

Fully integrated
Ethernet-based communication
With the addition of SERCOS 3, Schneider
Electric has created the first fully Ethernet-
based communication solution for PacDrive
applications, enabling communication with
both drives and field devices. SERCOS 3
can also streamline the integration of safety
automation*, and is a true standard. It does
not rely upon a specific manufacturer, and
it’s one of the most powerful Ethernet-based
communication solutions currently on
the market.

* according to IEC 61508:1998, EN/ISO 13849-1:2008

9
Groundbreaking Systems Engineering >

Flexible Drive Design

by Schneider Electric
Innovative drive design allows flexible drive
architectures. A multi-axis system, in which
single and dual-axis servo drives are
connected to a shared power supply,
reduces costs and space requirements in
systems with more than four servo axes.
Pluggable interconnects and a quick-
connect front-side bus also reduce
installation costs.

For compact applications with a small

number of servo axes, the newly developed
stand-alone servo drives offer a more
cost-efficient approach to automation.

10
 Groundbreaking Systems Engineering >

SoMachine™ for your machine…

SoMachine Motion is the new software from
Schneider Electric for your entire engineering
process, including: commissioning of
PacDrive 3 and diagnostics. SoMachine
Motion includes tools for motion design and
drivetrain design (ECAM), program
development (EPAS with ETEST, Vijeo
Designer™), diagnostics, and data handling
(assistants) – all in a single package.
A Safety Editor has also been added for
safety automation* software development.
EDESIGN is a new type of graphic
structuring of machine functions –
to further simplify software engineering.

The latest programming standards

EPAS, SoMachine Motion’s central software
development tool, is based upon CoDeSys
V3, and offers groundbreaking potential in
object-oriented programming.

* according to IEC 61508:1998, EN/ISO 13849-1:2008

11
PacDrive 3: Proven, trusted technology

12
 PacDrive 3: Proven, trusted technology

International
Acceptance
In the consumer goods, durable goods, and capital goods industries,
machine buyers are the primary decision-makers when it comes to
choosing the best automation systems for their production and packaging
machinery. PacDrive systems from Schneider Electric have built an
excellent reputation among many European and international machine
manufacturers with their…

Proven technology
PacDrive is a tested technology based upon
internationally accepted open IT standards that
conform with IEC… and has demonstrated its
capabilities extensively since its introduction in
1998. Already more than 55,000 machines
worldwide have been automated with PacDrive
systems. Schneider Electric is also well-
regarded around the world, with a reputation
for long-term reliability.

Compliance with OMAC and Weihenstephan Standard

For international manufacturers of consumer The Weihenstephan standard of making
Y
goods products, the OMAC User Group’s production data available to management READ
PackML state machine plays an important role systems has become increasingly important
in integrating production and packaging in the beverage industry. PacDrive provides
machinery for production lines. The creators of software Function Blocks for implementing
PacDrive 3 were active participants in OMAC this standard.
from the very beginning, and integrated the
OMAC guidelines into PacDrive.

13
PacDrive 3: Proven, trusted technology

At a glance:
LEDs and system
messages displayed in
plaintext often provide
crucial information
about error locations.

High availability thanks to effective diagnostic tools…

Maintaining equipment availability depends operation can be traced, regardless of the
on how quickly operators can localize individual machine‘s diagnostic capabilities.
malfunctions and eliminate errors. PacDrive The diagnostic tool contains almost the
controllers provide basic diagnostic same functionalities as the programming
information in plaintext on an integrated and commissioning tool for engineering,
display. A free diagnostic tool is also without the risk of unintended changes
available for PacDrive users…both machine to the machine program.
builders and operators. Any improper

Plug-and-play technology for fast

component replacement
Simple servo drive
configuration: The ability to easily replace the electronic
Less mechanical effort, components responsible for improper
no parameterization –
the centralized operation is just as important as a rapid
controller automatically diagnosis of the improper operation itself.
configures servo drive PacDrive users can quickly change-out
and motors by using
servo drives or servo motors using the
their electronic
name plates system’s plug-and-play technology.
Parameterization of replacement
components via laptop or software
installation is unnecessary. The centralized
PacDrive controller detects the replacement
components or motors by their electronic
name plates, and configures them
automatically. There is also no need to
activate switches for the SERCOS or IP
address. The controller performs a firmware
check and updates when the equipment
is replaced.

14
 PacDrive 3: Proven, trusted technology

Standards instead
of proprietary
control technology:
IEC 61131-3-compliant
programming languages
are familiar to technical
personnel, thus reducing
the need for time-
consuming training
sessions in proprietary
programming solutions

Faster training thanks to standardized programming

Consumer goods manufacturers are very machine designs, on the other hand,
enthusiastic about the fully integrated IEC demand intensive training. A training
61131-3-compliant program structure in program for PacDrive 3 is available, as well
machines automated with PacDrive. These as a migration seminar for the changeover
companies generally have personnel who from PacDrive M to PacDrive 3. The new
are familiar with IEC programming, and can PacDrive 3 training program will include
handle retooling of lines or machine training modules on programming,
adjustments internally. The proprietary, commissioning, and service, as well as
manufacturer-specific programming mechatronic design and robotics.
concepts so common in robot-assisted

Remote maintenance options

Remote maintenance reduces travel costs and mobile telephony. Schneider Electric
and increases availability by accelerating provides advice and support to machine
response times. PacDrive provides the users and machine builders for integration of
interfaces and/or protocols needed for the most practical options – worldwide.
remote maintenance via the Internet, modem,

15
PacDrive 3: Saving energy…

Energy efficiency –
a selling point
with a future!
The consumer goods industry places a
premium on energy-efficient manufacturing
systems, with lower energy use proven to
reduce machine lifecycle costs. Another
important factor in the competition for
market share, is to be seen as a “green“
company. Environmental consciousness
is increasingly important to consumers.
Develop an energy-efficient production and
packaging system, and you too can benefit
from a greener image. Schneider Electric
makes it easy for you with PacDrive 3.

16
 PacDrive 3: Saving energy

Efficient motor technology

from Schneider Electric…
Servo technology is one of the most efficient
ways of transforming electrical energy into
kinetic energy. Among industrial electrical
motors, the high efficiency of servo motors
makes statutory minimum efficiency levels a
non-issue. This is particularly true for
PacDrive servo motors. Whether you are
using standard servos or servos with an Energy-optimized
integrated servo drive, all Schneider Electric motion design
PacDrive 3 motors deliver high efficiency
and low inertial loads. Technically optimized motion sequences
require less power, put less stress on parts, and
can be executed with less energy. PacDrive
Tools create the basis for energy-optimized
DC bus sharing and motion design, which reduces the need for
energy recovery braking energy. These tools offer various motion
DC bus sharing among servo drives is a rules for simulating different approaches, or
standard feature for PacDrive 3 LXM 62. they can use blending functions to create ideal
Thanks to the front-side quick-connect, no pick-and-place paths for robots.
additional installation is required to connect
to the bus. DC bus sharing is particularly
well suited for packaging machines with Save energy with the PacDrive 3
servo drives that don’t all need power at the “intelligent line shaft“
same time. The generous storage capacity
in these servo drives and their power When machine speeds increase, some
supplies, optimizes the energy produced individual axis movements exceed their set
during a process. energy consumption limits. This circumstance
can’t be changed if the system uses an
electronic line shaft that rigidly synchronizes all
of the axes with the master. The alternative – the
Automation with less heat… PacDrive 3 “intelligent line shaft” – offers a new
without control cabinets approach. Here the virtual master can activate a
speed profile over the course of a machine
Like other electronic components, servo
cycle, increasing speed only for portions of the
drives in the control cabinet generate heat.
motion profile that do not involve critical
If the resulting heat exceeds permissible
changes in energy consumption. The speed of
levels, then the control cabinet needs to be
the critical individual axis movements, however,
cooled, consuming precious energy.
is increased only up to a predefined limit.
Schneider Electric ILM servo motors – with
integrated drive electronics – require only a
shared power supply in the control cabinet.
This lowers heat in the control cabinet and
reduces the need for climate control.

17
Winning Technology: PacDrive 3

Logic motion control –

the key to standardized,
cost-effective solutions
For more than a decade, a central element in Schneider Electric’s PacDrive
technology has been the integration of motion, PLC, and IT functionalities
on one automation platform. This allows the creation of fully integrated
software structures that enable modular machine designs and help reduce
engineering time.

Centralized controllers for all Basis for simulation and

machine functions plug-and-play
PacDrive’s digital system architecture is The centralized PacDrive 3 controller
based upon the concept of a centralized generates the motion data for all servo axes
controller. Using an IEC 61131-3-compliant in the system. It also stores all relevant
machine program, a single processor system data and equipment-specific
performs all control functions, from parameters. This centralized approach offers
Cartesian and robotic motion to temperature significant benefits:
regulation and machine logic. All of the • Moves can be tested and simulated in
system functions run through the centralized the controller without having to connect
controller, from the Human/Machine real drives.
Interface to motion and device bus
• The controller supports reliable
communication, line synchronization,
communication with every servo
and vertical integration.
axis,including process data and motor
status, which can be analyzed for
different purposes.
• Servo motors and drives can also be
automatically configured based upon
electronic ‘name plates.’ The controller
recognizes the motors and drives, and
can send the centrally stored parameters
to each device for easy commissioning
or replacement.
• Configuration of individual drives is a
thing of the past.

18
 Winning Technology: PacDrive 3

Ethernet

PacDrive 3:
Scalable – from basic to
high performance
ERP Data Regardless of whether a system involves
one machine or an entire production line, a
single PacDrive 3 controller can control up to
99 servo axes or up to 30 robots. Even less
complex architectures can be automated
economically. The scalable controller
hardware also offers a solution for
Centralized applications with 4 or 8 axes. It can even be
machine used as a pure-play PLC or a data
controller IT
concentrator to acquire production data from
a packaging line. Users can synchronize up
to 40 controllers in real time – a fully
integrated solution for entire production lines.
PLC Motion

Real-time line
synchronization
A foundation for fully integrated
software designs
Setpoint position Current position
Control info Status info One of the major advantages of PacDrive’s
Service data Service Data centralized controller designs, is a unified
software development environment, with
one programming tool to implement the
functionalities.There’s no need for additional
tools, some of which might be proprietary.
One tool, one programming standard, one
software structure: This is the key to the
SERCOS automation bus
ground-breaking approach of modular
engineering, in which mechatronic functions
are mapped on reusable software modules.
To counter the trend toward rising
1 2 99 engineering hours, pre-tested software
libraries minimize programming time and
Motor Motor Motor ease the way for FDA validation based upon
control control control cGMP/GAMP and CFR 21 Part 11.
loops loops loops

Distributed
servo drives

19
PacDrive 3: Application Software

Solutions designed to
reduce engineering costs…

While the hardware design has to be correct, it‘s the software that really
makes a solution work…and companies often spend more on software than
on hardware. Schneider Electric‘s PacDrive 3 software concept provides
a clear response to this development: Machine functions that have been
mapped in standardized software modules and collected in software
libraries serve as tested, off-the-shelf software to shorten development
times and increase engineering quality. A universal program structure also
paves the way for modular, reusable machine programs.

20
 PacDrive 3: Application Software

Two approaches designed to reduce engineering costs…

The Schneider Electric PacDrive 3 software concept offers two ways to reduce rising
engineering costs: Programs can be programmed either in the conventional way, using
Application Function Blocks (AFBs), or by using PacDrive’s pre-defined program structure and
Equipment Modules (EMs). The latter option further reduces programming work for the user.
The program structure also creates standardized modular software that improves the
reusability of machine modules.

Conventional Programming Advanced Programming

conventional advanced

PacDrive
Program Structure
User program

User program

EM
(Equipment module)
= AFB + Op-Mode + Diagn.
+ Error handling

AFB AFB

(Application Function Block) (Application Function Block)

PacDrive portion of the

pre-programmed application
System Functions System Functions
User portion of the
pre-programmed application

Conventional programming with Function Blocks

PacDrive software libraries consist of Function Blocks (AFBs -

Application Function Blocks), which map a variety of motion, PLC, Significant reduction
visualization, and IT functionalities in pre-programmed software objects. in programming times
These range from universal AFBs, for generating axis movements in Higher software quality
with documented and
positioning and movement functions – to temperature regulation well-tested programs
operations. These libraries also contain Function Blocks that can be Easier program
parameterized for complete mechatronic functional units, such as validation
robots, rolling and unrolling functions, flying shear, or film sealing units. IEC 61131-3
compliant AFBs

21
PacDrive 3: Application Software

Advanced programming with Equipment Modules and programming template…

PacDrive 3‘s predefined programming template is a universal, basic

machine program into which users can integrate their own software
components. The program’s basic functionalities are already in place, Reduced
including OMAC-compliant operating modes, diagnostic mechanisms, engineering times
and error handling and response. These can be adapted to the Transparent, modular,
individual application by configuring them as needed. easy-to-use programs
Basis for creating
modular, customized
A machine‘s functionality can be mapped to the program by connecting
software libraries
the Equipment Modules. Equipment Modules are the functional
Complete machine
equivalent of Application Function Blocks. AFBs become Equipment functions can be stored
Modules when they are supplemented with a standardized interface, as reusable, standardized
operating modes, and diagnostic functions, and sometimes with other functions
Equipment Modules as well. They can then be used within a Compliance with OMAC
and Weihenstephan
programming template to create a cohesive, well structured program. guidelines for machine
and line standardization
In addition to simple AFB functionalities, an Equipment Module also
includes interfaces that allow error handling, diagnostics, and
operating mode functions to be utilized. By subdividing the program
into Equipment Modules and providing flexible linking mechanisms,
the programming template permits users to separate and reuse entire
machine functions.

Equipment Modules can also

be individually adapted by
Robot 1
users, e.g. to incorporate Robot 2
special know-how or to Robot 3
distinguish their machine
programs from the
competition.
Transparent
representation
of the machine:
The modular program
consists of Equipment
Modules, whose Infeed
functions can be either
based on AFBs or
assembled using other
Equipment Modules. Dual Belt
Conveyor Belt

Machine Level Secondary Packaging

Equipment Module Level 1 Grouping Cartoner

Equipment Module Level 2 Infeed Dual Belt Robot 1 Robot 2 Robot 3 Conv. Belt

22
 PacDrive 3: Application Software

Identical functions available as AFBs or Equipment Modules…

Software functions available for PacDrive 3 have been created as AFBs, or as corresponding Extensive Function
Equipment Modules. Block libraries, including
PLCopen
Enhanced software
The libraries contain most of the functionalities needed for forming, filling, and sealing quality thanks to off-
machines, dosers, cartoners, labelers, pick-and-place applications, and end-of-line the-shelf software
packaging machines. They also offer a variety of mechatronic functions typically used in (FDA, cGMP, 21CFR
Part 11)
production machinery and in handling, assembly, and sorting systems.

The AFBs and EMs are documented and have been well-tested in practical use, a basic
requirement for high software quality, reduced engineering time, and rapid commissioning.
This also makes certification of machines and software much easier.

Application Library Included Application Function Blocks (examples)

Individual machine PD_Template.Lib Function Blocks for operating mode management, control of state changes,
exception handling, error reaction, or predefined commissioning screens
PLC Function Blocks PacDrive.Lib Standard PLC functions such as bit or conversion functions, shift register for
LREAL values with access functions, etc.
FieldbusDevices.Lib Field bus diagnostic function blocks, Function Blocks for motor protection
switches or frequency converter, etc.
System.Lib Event-driven adjustments of any number of cam switch groups
Motion Function Blocks PacDriveLibModules.Lib Universal axis AFB for homing, positioning, curve functionality, jogging, etc.
PacDrive.Lib Safety*/Hardware, e.g.
Power on and power off of axes with monitoring functions, etc.
PacDrive.Lib Axis and encoder positions, homing, positioning (automatic and manual), virtual
master axis control, minimization of mechanical wear and tear, increase of
machine speed, and reduction of energy usage with the ´Intelligent Line Shaft,´ etc.
Cam disk handling PacDrive.Lib Processing from table or modification of cam disk profiles on the fly, cold or warm
start functions, etc.
Mathematical functions PacDrive.Lib Matrix operations, vector and polynomial functions or functions for toggle
transformations, etc.
Technology functions PacDrive.Lib and others PID controller, registration mark control, winding and unwinding with and without
dancer, sealing, etc.
Torque handling System.Lib Speed-dependent torque limit (e.g. for bottle sealing equipment), etc.
Robotics Robotic.Lib Automatic path planning, path generation and optimization, transformation to
different kinematics, belt tracking, synchronization of robots, etc.
Infeed MultiBelt.lib/-Module.lib Control of dual-belt and multi-belt mechanisms for product grouping and infeed
Infeed SmartInfeed.lib/-Module.lib Control of serial conveyor belts as infeed lines, product detection, management,
and transfer, synchronization of conveyor belts, etc.
Standardization ISA.Lib, Weihenstephan.Lib Weihenstephan Standard, OMAC PackML FDA
HMI application Vijeo Designer ™
Vector graphics for design, open source software, functions for machine
operation, including recipe handling, sample screens, simulation/teleservice,
also via Web servers, etc.
Machine Pilot SoMachine™ Motion Universally adaptable sample programming template
programming

Description of the most

important PacDrive
libraries, with examples
showing the scope of
function. The software
functions are available
as either AFBs or
Equipment Modules

* according to IEC 61508:1998, EN/ISO 13849-1:2008

23
Tools: SoMachine™ Motion Software

PacDrive 3 Tools:
Actively shaping
the modern
engineering process
To keep pace with increasingly complex machine functions and designs,
and the software and data that support them, engineers will have to rethink
their project processes and adopt new approaches. Schneider Electric’s
SoMachine Motion software is the engineering workbench for PacDrive 3
applications that can help actively shape the current transformation
in engineering.

24

24
 Tools: SoMachine™ Motion Software

SoMachine™ Motion:
A workbench with all the
tools needed for the
engineering process,
and for service during
live operation

Intuitive user interface:

The tools are structured
based upon area of use
(upper left), and dedicated
icons allow users to orient
themselves easily within
the program
SoMachine Motion software Engineering Workbench
The SoMachine™ Motion workbench from permits rapid analysis of detected problems
Schneider Electric consolidates – in a single during production.
package – the tools needed for the entire
lifecycle of a PacDrive 3 solution. This “toolkit” No need for folders full of CDs or optional
includes: tools for program development, HMI tools: The necessary tools are available once
applications, motion design, drivetrain design, SoMachine Motion is installed on the user‘s
and data handling…and provides all the Windows PC. Selected individual tools can
functionalities needed for engineering and be installed for servicing or other purposes
commissioning. Users can use the integrated that require only part of the program‘s total
help system when creating programs, and the functionality. For example, installation can
workbench’s integrated documentation can be limited to diagnostic functions for
answer questions about PacDrive 3 hardware servicing purposes.
components. A powerful diagnostic tool

25
Tools: SoMachine™ Motion Software

Multi-user design with a central database…

Schneider Electric SoMachine™ Motion allowing an entire team to work concurrently
software stores all project data in a central on the same software project, with
database (project file). This data is universally simultaneous access to AFBs (Application
accessible for all of the tools on the Function Blocks) and motion profiles. This
workbench. This central storage of project reduces unwieldy version management
data forms the basis for SoMachine Motion’s processes and coordination tasks, that can
soon-to-be-released multi-user design – slow down teamwork.

Team A Project data

Team B

One project,
multiple participants:
A central database and a
powerful multi-user design
will enable future users to
have simultaneous access Project file – central data pool
to software projects down
to the Function Block level
Team D Team C

Trusted open standards

SoMachine Motion can be used to create
IEC 61131-3-compliant programs.
SoMachine Motion’s central software
development tool – EPAS – is based upon
CoDeSys V3, which offers the option of
either traditional or object-oriented
programming. Object-oriented programming
has been the de facto standard in embedded
Object-oriented programming: and PC software development for years, and
EPAS, the programming tool for SoMachine Motion, is based upon CoDeSys V3 has also been a central focus of technical
instruction at universities.

Continuity to preserve value

In addition to these new tools, Schneider Electric’s
SoMachine Motion also includes the proven
PacDrive M tools. Projects created for PacDrive M in
EPAS-4 can be converted for editing in SoMachine
Motion, and can be ported to PacDrive 3. This idea
of reducing engineering costs by producing modular,
reusable software continues in the next generation
of PacDrive. Project conversion:
Software projects
created with EPAS-4
can be converted to
SoMachine Motion

26
 Tools: SoMachine™ Motion Software

Building bridges between mechanics and software

In modern engineering, the areas of many similarities with mechanical drive
mechanics and software are increasingly design. Moreover, the same curves can also
involved in interdisciplinary collaboration. be processed in EPAS, the programming tool
As the need for this collaboration grows, it in SoMachine Motion. Both tools contain all of
requires tools to bridge these two disciplines. the necessary data, parameters, and editing
Schneider Electric’s SoMachine™ Motion has functions, so that edits performed in EPAS
succeeded in building just such a bridge. are then available in ECAM, and vice versa.
For example, electronic cam disks created
with graphic CAM can be edited with the This establishes a functional interface
ECAM tool. With its emphasis on curve between both tools, which serves as a bridge
design, drivetrain layout, and power for interdisciplinary collaboration between
requirement calculation, this tool shares mechanical and software engineering.

Motion design in ECAM:

ECAM is the classic tool for
drivetrain design and power
requirement calculation

Motion design in EPAS:

The CoDeSys 3-based
programming environment
has been enhanced
with a plug-in that adds
functionalities for editing
electronic curves

27
Tools: EPAS Automation Toolkit

EPAS:
Uniform programming and parameterization

Configuration editor:
Hardware components and
field buses (PROFIBUS™ DP,
CANopen™, SERCOS 3)
can be configured and
parameterized in the editor

Trace Function:
The integrated oscilloscope
in EPAS permits simultaneous
plotting and display of
multiple PLC and motion
signals, as well as mixed
PLC and motion signals with
millisecond resolution

With its combination of advanced functionality process. With the integrated configuration
and proven software, the EPAS Automation editor, a few entries are sufficient to
Toolkit from Schneider Electric is a powerful configure, parameterize, modify, or expand
programming tool for PacDrive applications. the solution’s hardware components and
EPAS can be run from SoMachine Motion, field buses – and EPAS’s customizable HMI
and its interface has the look and feel of offers assistance when developing, testing,
typical Windows applications. EPAS’s easy and simulating the controller application.
navigation between editors and within Preprogrammed screens are already
libraries provides for ease of use and available for the commissioning process,
transparency when creating and simulating while machine programs can be simulated
programs and commissioning. And, EPAS onscreen – in EPAS – without real drives.
functionality streamlines the engineering

28
 Tools: EPAS Automation Toolkit

System check
of device configuration:
The nodes in the SERCOS
interface can be scanned,
resulting in a display with
status information on
each node

An eight-channel software oscilloscope system and user diagnostic messages.

integrated into EPAS permits simultaneous EPAS Automation Toolkit can be used with
plotting of up to eight PLC and motion all models of the PacDrive 3 Controller.
variables (including mixed variables). During No conversion is needed to download
commissioning, the tool’s message logger programs to different controllers.
makes it easy to track down the source of

Ladder Diagram

Function Block

Uniform programming
Instruction List
and parameterization
Program simulation
Structured Text without real axes
Hardware configuration
and parameterization
Sequential Function Chart without the need for
additional editors
Visualization tool with
pre-programmed
commissioning and
service screens
Simultaneous trace
plotting of PLC and
Continuous Function Chart
motion signals
(software oscilloscope)
Diagnostic functions,
Programming in compliance including message
with IEC 61131-3: logger
EPAS includes editors and
debuggers for all six standard IEC 61131-3 editors
IEC languages CoDeSys V3-based

29
Tools: EDESIGN Graphic Programming

EDESIGN:
A revolutionary new form of graphic
programming from Schneider Electric
Graphic programming:
A significant reduction of
programming complexity
shortens engineering times

At Schneider Electric, efforts to further reduce handling and operating mode management
programming complexity and an emphasis on is radically simplified.
modular software are producing completely
new approaches for the creation of machine The results are clearly structured
programs. The result is EDESIGN. configurations in which predefined modules,
e.g. a servo axis, can be configured with
Using a structure editor that allows easy easy dialogs. Movements can be integrated
assembly of a complete machine, using a directly from ECAM. And, hardware is
drag-and-drop function to select predefined assigned to the modules by means of
modules…together with other editors using selection fields with dialogs to assist
command lists to define operating modes the user.
and state diagrams…EDESIGN tools
provide virtual graphic programming. With EDESIGN: Innovative simplicity for your
commissioning and debugging being complex machine design.
performed directly in these editors, exception

30
 Tools: ETEST

ETEST:
For developing and executing system tests of modular
machine programs…

Early detection of
software problems:
ETEST is the tool
for creating and
performing automated
software tests

PacDrive 3 libraries have AFBs (Application Motion ETEST tool is used to develop and
Function Blocks) that can be parameterized execute system tests of modular machine
for a variety of mechatronic, mathematical, programs. By using test routines that
and technical process functions. The ability automatically test isolated software modules
to create programs based upon years of within a program, software problems can be
proven and documented off-the-shelf identified, even at an early phase of the
software not only saves time, but also project. These module tests are a valuable
significantly improves software quality. In component of the software validation process.
addition, Schneider Electric’s SoMachine™ ETEST fully performs this valuable function.

31
Tools: SoSafe

SoSafe
Safety Editor* and Configurator
for safety automation…

IEC 61131-3-Editor:
The programming
languages Function
Block Diagram (FBD) and
Ladder Diagram (LD) can
be used to develop the
program code

The integration of safety automation into the parameterization of system component

standard automation is a critically important safety functions. In addition to the program
user requirement. Schneider Electric’s editor, the SoSafe tool also has a
PacDrive 3 SoMachine™ Motion software configuration editor that can be used to
SoSafe includes an editor for safety parameterize components such as I/O
automation. And, the creation of IEC 61131- components or servo drives that are
3-compliant programs for PacDrive safety integrated into the safety solution.
controllers is as integral to the workbench as

* according to IEC 61508:1998, EN/ISO 13849-1:2008

32
 Tools: ECAM

ECAM
Motion and drivetrain design tool…from
Schneider Electric’s PacDrive 3 SoMachine Motion software
ECAM is a single tool that can be used to
design a complete system, from mechanics
and motion design to calculation of system
power requirements. To streamline the
engineering process, ECAM includes a library
of predefined standard mechanical drive
configurations, simplified motion design –
with a graphical motion profile editor – and
standard motion profiles.

This makes ECAM a functional tool for

mechanical engineers in designing and
selecting motors, gears, and power
components. Tools for calculating power
requirements and determining the energy
available from the DC bus also help in
developing energy-efficient machine designs.

A seamless, bidirectional interface allows

curve data and mechanical parameters to Graphical motion design:
be automatically provided to EPAS – the By cascading editor windows, users can place movement
SoMachine Motion programming tool. Data patterns in chronological relationship to one another
can be adapted in EPAS and are then
immediately available again in ECAM – a
bridge between mechanics and software.

Drivetrain design:
Predefined applications Motion design with
offer adaptability for virtual or real master
typical power transmission axes
configurations Use of multi-segment
profiles, such as VDI
2143 profiles or fifth
order polynomials
Import of cam tables via
Excel tables
Database for servo
motor/drive and gear
reduction sizing and
selection
Predefined applications
such as general loading
condition, belt drive,
spindle drive,
rack-and-pinion drive,
and crank drive

33
Tools: Vijeo Designer™

Vijeo Designer™
Customized design of Human/Machine Interfaces

Vijeo Designer:
A large number of
predefined elements,
graphics libraries, recipe
and alarm management One tool for all panels
functions, and an easy- Predefined functions
to-modify suggested and graphic elements
schematic make HMI provide design support
development fast and easy. Fast solutions with
open-source sample
program
ARTI driver for browsing
control variables without
an OPC server

Open-source
software included:
A suggested schematic
diagram is easy to modify,
simplifies the learning
process for Vijeo Designer,
and produces fast results

Schneider Electric’s Vijeo Designer software recipe maintenance program manages 256
can be used to configure all Magelis™ recipes with 1,024 ingredients in up to 32
touchscreen panels, from the smallest 3.8" recipe groups, and users can perform
panel up to complex HMI applications for the periodic or event-driven processing of
19" panels. This tool set also includes the Java-based procedures to automate
ARTI protocol driver that allows users to operations, including: switching screens,
access runtime system variables via the performing mathematical and logical
browser. The tool’s graphical editor provides calculations, and making automatic changes
a number of ready-made elements for in variables. Also, Vijeo Designer’s alarm
customizing HMI interfaces. And, the management system is designed for up to
graphics library has more than 4,000 9,999 alarms.
predefined vector graphics. An integrated

34
 Tools: Controller Assistant and Drives Assistant

Controller Assistant and Drives Assistant

PacDrive 3 tools for data management

Schneider Electric’s PacDrive 3 support The Controller Assistant supports firmware

tools make it easy for PacDrive users to exchanged between PacDrive controllers via
handle program and firmware data and to Ethernet. If a user wants to check a network
perform program version management. for existing PacDrive controllers, the
Controller Assistant can identify connected
The Controller Assistant stores data and controllers and display their identifying data.
files on the flash drive and creates a copy on
the user’s PC. If necessary, this copy can be The Drives Assistant allows the
used to restore the program to original maintenance and exchange of firmware on
status. The tool’s functions also include the SERCOS nodes. Servo drives, bus
creation of CompactFlash cards for interfaces, and even TM5 I/O modules can
PacDrive controllers (including bootable be easily supplied with new firmware from a
cards). These cards include the VxWorks central location. The integrated management
operating system and firmware. of firmware versions optimizes their storage
and retrieval.

Data management:
Tools make it easier to
transfer and handle
program and firmware data.
This screenshot shows the
Controller Assistant

35
Tools: Diagnostics

Diagnostics
PacDrive 3 maintenance without EPAS

Diagnosis of
machine malfunctions:
Diagnostics can be used
to perform comprehensive
system diagnostics even
without programming
knowledge. The screenshot
shows a check of the PLC
configuration.

Simple tool for

collecting service-related
system data
No EPAS required
Firmware-independent
System map of servo
drive data (drives,
message loggers,
cam switch group)
System check: Intuitive user interface
Diagnostics can be used
to check the hardware
and software versions
of the servo drive
components on the PC

EPAS – SoMachine Motion’s programming knowledge, since the intuitive program

language – integrates comprehensive interface allows users to quickly collect the
diagnostic functionalities, but is not always necessary servicing data. Diagnostic
available if a machine breaks down during information is displayed upon demand,
production. This is why PacDrive Diagnostics stored, or forwarded directly to technical
was developed specifically for use by support, and the tool can be used regardless
machine operators for servicing purposes. of the firmware version.
This tool offers a full range of diagnostic
functions, runs independently of EPAS, and
is available at no cost to PacDrive users. It
also can be used without any programming

36
37
Electronic Help Documentation >

PacDrive 3:
Complete online
documentation
Schneider Electric knows that even with intuitive tool interfaces, sometimes
you need help. From your first steps with SoMachine™ Motion to routine
project work…experience has shown that support is most useful when it is
available right on screen. In SoMachine Motion, “Guided Tours” familiarize
users with tools, while electronic documentation on tool and library
functions make printed manuals unnecessary.

Guided Tours through SoMachine Motion

Guided Tours are an easy way to learn how project, with the demo project and the
Guided Tours – Help for to use SoMachine Motion. Each tour step-by-step instructions in the Help files
beginners, including an
interactive demo project addresses different topics and/or learning displayed side-by-side. With the demo
Keyword search in the objectives. The Guided Tours are listed in an project, users can practice the steps
documentation via the overview, and can be started from there. explained in the Tour. The demo project
Index function Each tour completely covers a given topic already contains all of the Function Blocks
Search for topics using and consists of a number of easy-to-follow required for performing the demonstrated
content directories
(and illustrated) steps. Users can move back instructions from the Guided Tour, and users
Extensive
documentation
and forth between the steps, and can have access to appropriate editors, which
of library functions proceed through them at their own speed. are already opened for this purpose.
Each Guided Tour also includes a demo
“Guided Tours” are closely linked with other
Help components. Individual steps are linked
not only with each other, but also with
relevant information in the normal Help files.
This makes it easier for users to explore the
topics addressed in even greater depth
if desired.

“Guided Tours” through

the tools help users get
started with
SoMachine Motion

38
 Electronic Help Documentation >

PacDrive 3:
Electronic Documentation –
the paperless manual

The tools, particularly EPAS and ECAM,

offer comprehensive documentation for
users. This wide array of systematically
recorded information can be accessed by
keyword search, and provides
comprehensive technical background
information and instructions on using the
tool. Unlimited availability of the
“E-Documentation” makes it unnecessary to
keep a hardcopy manual next to the keyboard.

Schneider Electric’s SoMachine Motion tools

are largely intuitive in their operation. The
Help function for each tool provides answers
Search via the Index:
to more detailed questions on operation, or on The terms related to a
the technical and mathematical background particular topic are listed in
of the available functions. As with typical alphabetical order;
the input field for keywords is
Windows applications, the Help function can shown above the list
be started with the click of a mouse.

EPAS E-Documentation offers two ways to Search in

access information: via a table of contents content directories:
listing topics contained in the Calling up help
information in EPAS
E-Documentation…or, users can also use
the Index to search alphabetically for
available topics. A search algorithm limits
the content that is displayed.

On-screen documentation is also available

for library Function Blocks, with technical
background, scope of functions,
parameterization, and integration of each
function described in detail. Integrated
hyperlinks in the explanations let users jump
to other sections of the documentation for
more detailed explanations of specific terms.

Documentation of library Function Blocks:

The image shows the table of contents and one page from the library Function
Block for implementing wrapping mechanisms with and without a dancer

39
PacDrive 3: Controllers

Scalable controller
performance
The PacDrive 3 LMC 101C, 201C, 300C, 400C, and 600C automation
controllers cover a wide range of applications. Variables including: the number
of axes to be synchronized, data transmission volumes, and the range of
robotic elements to be integrated – all determine which controller offers the
optimum balance of price and performance.

LMC x01C and x00C

Series controllers:
Scalable controller
performance for
cost-effective
automation solutions.

40
 PacDrive 3: Controllers

A single platform for all

controller functionalities
Functional:
PacDrive 3 LMC x01C and x00C controllers The compact Flash
memory card behind
provide scalable performance for the display contains
synchronizing up to 99 servo axes (at 1 all of the software that
msec network update rate for 99 axes), and needs to be transferred
when replacing the
for up to 255 virtual axes. In addition to
controller
motion functionality, all controllers combine
an integrated PLC, HMI, and IT
functionalities on a single hardware platform.
They are software-compatible, since each of
these controllers has identical Schneider
Electric Logic Motion Runtime software, and
users can program up to 4096 dynamic
electronic cam disks operating in parallel. Depending upon the controller type, memory A scalable controller
can be up to 512 MB DDR2 RAM, or 128 or platform
The program can switch between electronic
One runtime software
cam disks during operation, and control can 256 KB NV RAM, with additional compact
All controllers are
be distributed across a number of continuous, Flash memory of 128 MB or more. The
software-compatible
periodic, or event-driven user tasks. memory card can be changed out without Ethernet-based, fully
removing the enclosure, as can the battery. integrated automation
Each controller has two integrated cam An alphanumeric display shows diagnostic bus
switch groups, each with 32 cam disks. The data, and the controllers include an Can control up to 99
integrated eight-channel software real axes and another
system can allocate up to 254 cams, with up 255 virtual axes
to 32 different positioning or encoder signals oscilloscope and a message logger for
Up to 254 SERCOS 3
assigned to each of the two groups. Cam diagnostics. All controller types are CE and nodes
signals can be routed to a memory cell or to cULus certified. 1 msec network update
a digital output. rate for 99 axes
Up to 4096 electronic
cam disks can be
switched during
operation
5 µsec for 1000 bit
instructions
Integrated plaintext
display for system
messages
Integrated software
oscilloscope and
message logger

Integrated I/Os – externally expandable

PacDrive 3 LMC x00C controllers can use both standard and high-speed I/Os (touch
integrated, digital and analog I/Os to probes) that allow significantly faster
communicate with a variety of sensors and responses to events (such as motion-
actuators directly, without being redirected relevant signals) recorded by sensors.
through field busses. Controllers include External I/Os can also be added.

41
PacDrive 3: Controllers

Interfaces and communication

SERCOS 3 is the PacDrive 3 automation bus All Schneider Electric PacDrive controllers
for servo drive and field communication, as also have a CANopen™ interface, and the
well as for safety communication*. Real-time LMC x00C controllers have a PROFIBUS™
and standard Ethernet interfaces are also interface (master and slave) as well. In
standard. The standard Ethernet connection addition to communication via SERCOS 3
serves as an interface to the engineering and Ethernet, LMC x00C controllers can also
system and the HMI via OPC, ARTI, or simultaneously communicate via two field
Modbus™ TCP, and as an open interface for bus protocols and real-time Ethernet, e.g.
customized communications solutions. CAN and Profinet™. Optional expansion
cards are also available for all controllers to
implement additional field bus interfaces,
such as EtherNet/IP.

USB and serial interfaces are also standard

in all controllers. The serial interface can be
configured as an RS 232 or RS 485 interface.

Performance overview:
All LMC x01C and x00C Controller types
Controller type PacDrive LMC 101C 201C 300C 400C 600C

Availability Immediately
Motion Performance Maximum number of synchronizable 4 8 8 16 99
axes/network update rate (1 msec)
Number of dynamic electronic cam 4096
disks operating in parallel
PLC Performance Time required per 1000 bit instructions 5
[µsec]
Programmable dynamic cams 254
Cam cycle time [µsec] 250
Number of user tasks, continuous, Any number, within the system limits
periodic, or event-driven
Fast task network update rate [µsec] 250
Communication Integrated motion bus SERCOS 3 interface
Integrated Ethernet connection 10/199 Base-T 10/100 Base-T
Number of integrated 1, CAN 2 (3), PROFIBUS DP, CAN oder EtherNet/IP
field bus interfaces
Number of optionally integrable 1 2, PROFIBUS DP, CAN oder EtherNet/IP
field bus interfaces
Housing dimensions Width x Height x Depth [mm] 45 x 230 x 220 104 x 270 x 240

Subject to change without notice

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

42
 SERCOS 3

SERCOS 3
Automation Bus
SERCOS 3 is the universal automation bus for PacDrive 3.
Drive-based communication, I/O communication, and safety
communication* can be implemented using the same medium.

Cat5e Baudrate: 100 Mbit/s

Cycle time: 1 ms to 4 ms

Vendor-neutral Powerful
With IEC 61491, SERCOS established itself Greater bandwidth makes SERCOS 3 even Bidirectional full-duplex
Ethernet communication
as the worldwide communication standard faster than SERCOS 2. This allows a
Media redundancy to
for automation. SERCOS 3 uses industrial network update rate of 1 msec for up to 99 reduce failure probability
Ethernet for its transmission physics. More drives. An innovative synchronization Simpler, more
than 50 controller manufacturers and 30 procedure makes SERCOS 3 even more cost-effective design
drive manufacturers worldwide support precise than before. No hubs or switches
the standard. CAT5e cable is
generally sufficient
Universal Complete setup via
software, including
The use of standardized profiles for drive and field bus communications, including assignment of
bus addresses
technology, I/O, and communication between communications in safety automation*.
controllers (C2C) increases the range of SERCOS 3 also permits parallel transmission
possible applications for SERCOS 3. For the of standardized or proprietary IP protocols
first time, SERCOS can be used as a fully over a non-real-time channel.
integrated Ethernet-based solution for drive

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

43
PacDrive 3: Functional Safety

Safety functions* for the

entire machine
With Schneider Electric’s PacDrive 3 system, standard communication and
safety communication* are completely integrated, and SERCOS 3 is the
shared basis for communication. Components for safety* signal acquisition
and safety* dialog (page 72) can also be integrated into the safety solution*
using safety I/O components (page 46).

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

44
 PacDrive 3: Functional Safety

Ethernet, TCP/IP, OPC, FTP,

ftp, http,
HTTP, SMS, SMTP

PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C

Logic Motion Controllers

Magelis™ IT/COM
HMI
Logic Motion
Safe Logic Controller*
SLC x00
SERCOS 3 + Integrated Safety*

Stand-alone LXM 62 Multi-axes Servo Drives

Other field busses: Servo Drives + Power Supply + ILM 62 CM
PROFIBUS™ DP, CANopen™, LXM 52
TM5 I/O
EtherNet/IP, Profinet™ ,
Modbus™
Distribution
Box

TM7 TM7 SH SH Torque Linear ILM 62

Remote I/O Remote I/O Motor Motor

Complete integration…
A safety protocol via SERCOS 3 enables the Schneider Electric’s SoMachine™ Motion Fully integrated safety
complete integration of safety communication Workbench is a programming tool for the solution
into standard communication, without the engineering functions. In addition to the Reduced installation
costs, no more
need for additional dedicated cabling or a program editor, it also contains tools to set dedicated cabling
safety bus. Safety signals from data the safety device parameters for functional Integrated Workbench
acquisition or dialog devices are connected safety components (drives, I/O components). tool for safety software
through safety terminals or remote I/Os, while Also, the Safe Logic Controller can be in IEC 61131-3
a safety controller on the SERCOS 3 ring programmed directly via the PacDrive
permits programming of the safety functions. controller, which functions as a gateway.
Both standard safety functions and safety
functions enhanced in accordance with PLC Other classic designs based on hardwired
Open Safety definitions can be implemented safety components can be implemented
with the integrated solution. as well. Please consult with your
Schneider Electric or Distributor representative
to determine which Preventa Machine Safety
products are best suited for your applications.

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

45
PacDrive 3: I/O communication

Rapid I/O communication

via SERCOS 3
The new SERCOS 3 bus interface for the Schneider Electric universal TM5
I/O system lets you create I/O solutions for rapid communication. The TM5
product line offers a variety of products for designing your specific I/O solution
on the SERCOS 3 automation bus.

PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C

Logic Motion Controllers Flexible I/O design:
The TM5 I/O bus can connect
IT/COM up to 25 additional remote units
to each I/O island, and can bridge
Logic Motion a distance of up to 100 m between
Safe Logic Controller*
SLC x00
two remote units.
SERCOS 3 + Integrated Safety*

TM5 Bus ... ≥ 100 m ... ≥ 100 m ... ≥ 100 m ... ≥ 100 m ... ... up to 2500 m

TM5/SERCOS TM5/... TM7 IP67 TM7 IP67 TM5/... TM5/...

distributed I/O island remote I/O island Remote I/O Remote I/O remote I/O island remote I/O island ... up to 25 remote I/O islands

Flexible and modular

The modular TM5 I/O system is specifically the benefits of this design including rapid
designed for creating distributed I/O assembly and a reduced need for spare
solutions on the SERCOS 3 automation bus. parts. Functional units that incorporate
I/O networks can be built with both line and digital/analog I/Os, mixed-function units,
ring topologies. and power supplies are also available.

One terminal block can include up to The TM5 system provides additional
250 individual modules, with the basic unit flexibility with the option to connect
of each I/O island being the SERCOS 3 additional remote terminal blocks to a
interface, which is plugged into a bus base terminal block via the TM5 I/O bus at
module together with the first terminal. distances of up to 100 m, using transmitter
Additional I/O modules can be snapped to and receiver units. Up to 25 of these remote
this unit. I/O units can be connected serially to a
terminal block via the TM5 bus, and in
Each of these modules consists of three extreme cases, the range can be extended
basic components: bus base, function unit, up to 2.5 km for a distributed I/O solution!
and one of the various terminal blocks, with

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

46
 PacDrive 3: I/O communication

Plug together
and snap in:
Components can be
combined to create
both the basis unit with
the SERCOS 3 interface,
as well as all additional
functional modules,
including safety modules*

Expandable with IP67

Standardized and fast technology or safety terminals*
Communication on the TM5 system The TM5 technology in IP 20 is essential for Up to 30 % time savings
for assembly, cabling,
corresponds to that of SERCOS 3 I/O-Profil connecting the soon-to-be-released, highly
and commissioning
V1.1.2. In addition to consolidation of drive compact TM7 modules to a SERCOS
Compact technology,
and I/O communication on a shared, automation bus…and expanding the ability small footprint
Ethernet-based medium, the primary of I/O systems to operate under harsh Decentralized I/O islands
advantage of I/O communication via environmental conditions. Safety via TM5 bus
SERCOS is its high transmission speed. communication* versions of both TM5 and TM7 modules for IP67
With network update rates of up to 1 ms, TM7 modules are available, with special TM5 and TM7 modules
the system can satisfy the most demanding coloring to clearly differentiate them from both available for safety
communication*
response time requirements. standard technology. Standard and safety
I/O modules can be mixed.

I/O islands in IP67:

The TM5 bus can be used
to connect TM7 modules
in both standard and
safety* designs

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

47
PacDrive 3: Servo Drives, Multi-axis Solutions

Schneider Electric
Lexium™ Servo Drives:
Flexible configuration
and lower costs
The modular servo drives of the LXM 62 Series and the integrated ILM 62
drives reduce space requirements in the control cabinet and lower
costs, particularly for multi-axis applications. Stand-alone drives with an
integrated power supply will soon be available for servo drive solutions with
self-contained single axes. These drives will also be supplemented with
integrated stand-alone versions, as in the multi-axis design.

SERCOS 3 + Integrated Safety*

Flexible
servo drive design:
Control-cabinet-based
stand-alone or multi-
axis servo drives are
supplemented with
integrated variants

Cabinet Cabinet Integrated

Stand-alone Axes Multi Axes Multi Axes
Pos & Speed Pos & Speed Pos & Speed

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

48
 PacDrive 3: Servo Drives, Multi-axis Solutions

Lexium™ LXM 62
Universal servo drives for multi-axis solutions
Schneider Electric’s fully digital servo drives All LXM 62 components offer easy handling
in the Lexium™ LXM 62 series are modular, and installation, startup, and replacement.
consisting of single drives (1 axis) and The rapid, front side-connection to the power
double drives (2 axes) of equal size, as well supply automatically includes integration
as power supplies with different output. All into the DC bus as well. The motor and
single and double drives in a group use a encoder cables exit at the bottom of the unit,
shared power supply. Multiple groups are leaving room for easy access at the front of
possible, with the number of axes being the device.
limited by the type of Controller used.

The Lexium LXM 62 series lets users

implement cost-effective compact multi-axis
solutions, with the double drives providing
particular advantages.

Integrated design:
Power supply and two
drive modules – each
half the width of the
power supply

49
 PacDrive 3: Servo Drives, Multi-axis Solutions

Motor/encoder cables
exit at the bottom of
the unit: Connection to DC bus,
Leaves room at the front 24 V power supply,
of the device for rapid and ground wire:
assembly/disassembly of Move the slide to the
LXM-62 components left, tighten the screws,
and it’s done

Fast connection
to SERCOS:
Single and double
drives are integrated
into the SERCOS
ring with short cable
bridges.

Technical Data / Servo Drives

Type: LXM 62 DU60A DD15A DD27A DD45A DxxxA DU60B DD15B DD27B

Availability Immediately Pending Immediately

Number of synchronizable 1 2
axes
Continuous current Aeff (4kHz) 2 5 9 22 50 2x2 2x5 2x9
Peak current Aeff 6 15 27 45 100 2x6 2 x 15 2 x 27
Supply voltage [V] Min. 250 V DC, max. 700 V DC
Supply frequency [Hz] 48 to 62
Control voltage [V] DC 24 V (-20% / +25%)
Motion bus SERCOS 3
Encoder Hiperface (more available soon)
Inverter Enable 1 input 2 inputs
Inter-
faces Digit. inputs 2 2x2
Digit. inputs or TP 2 2x2
Digit. inputs or 2 2x2
outputs
Housing dimensions 270 x 44 x 310 270 x 89 x 310 270 x 44 x 310
D x W x H [mm]
Protection rating IP 20
Excess voltage category K3, T2 (DIN VDE 0110)
Excess voltage resistance –
Degree of radio interference –
Certifications CE, ULus

Subject to change without notice

50
 PacDrive 3: Servo Drives, Multi-axis Solutions

More innovation from Schneider Electric…

Another innovation is that all servo drives are LXM 62 Series servo drives can be used with Less space required in
the control cabinet
coupled to the DC bus and to the power all PacDrive System motors, both rotary and
Minimal assembly/
supply: No backplane connections are linear, and all servo drives have an electronic installation time
required, and the modules can be coupled to name plate. Upon first use or exchange of Tool-free motor
the adjacent module with a front-side the device, it is identified by the centralized connection
quick-connect with stop screws in less than controller and configured based upon the Optimized feedback
two minutes. specified parameters. The servo drives loops minimize
contouring errors
themselves in turn detect connected motors
Safety input Inverter
When the connection is made, LEDs signal by their name plates. Enable (pursuant to
proper power supply with the 24 V control IEC 61508:1998, EN/ISO
voltage. The design functions without any LXM 62 servo drives can be integrated into 13849-1:2008)
additional effort, even when drives are taken safety automation designs (in accordance for each axis
out and reinstalled from a continuously with IEC 61508:1998 SIL2, EN/ISO 13849- Automatic motor
detection
connected series of devices. 1:2008 PL d) by using the Inverter Enable
Software-compatible
input (or two in the case of double drives). with integrated servo
drives ILM and with
stand-alone servo drives

Technical Data / Power Supplies

Type: LXM 62 PD84A Pxxxx

Availability Immediately Pending

Continuous current (A) 42 120
Peak current (A) 84 179
Continuous output [kW] 25 67
Peak output [kW] 50 100
Supply voltage [V] 3AC208V (- 10%) to 3AC480V (+8%)
Control voltage [V] DC24V (-15% to +25%)
DC bus voltage [V] DC250V to DC700V
SERCOS 3 interface integrated
Bleeder Integrated Recovery planned
EMC-Filter Integrated External
Housing dimensions 270 x 89 x 310 270 x tbd x 310
D x W x H [mm]
Protection rating IP 20 IP 20
Excess voltage category K3, T2 –
(DIN VDE 0110)
Excess voltage – –
resistance
Degree of radio – –
interference
Certifications CE, ULus

Subject to change without notice

51
PacDrive 3: Integrated Servo Drives

Lexium™ ILM 62
Multi-axis design for true plug-and-play
modular machine building

Plug-and-play solution…
Multi-axis design requires With quick interconnects and hybrid cables Servo modules move servo drives out of the
up to 90 % less control for signal and power level, automatic network control cabinet and into the field. iSH
cabinet space
configuration, and diagnostic functions… technology reduces wiring and cabling
Different dimensions,
with peak torques of Schneider Electric’s Lexium™ ILM 62 servo requirements in the control cabinet by up to
up to 55 N•m modules with integrated drive electronics 90%, with the only components remaining in
Can be combined with are the technological successors to iSH the control cabinet being the PacDrive
single and double servo modules. With more functionality than controller, the shared power supply for 40 or
drives to a shared
power supply compact drives alone, this drive and network more servo modules, and the CM
70% shorter cable combination together form a true plug-and- (connection module).
lengths play solution combining mechanics,
90% less wiring required electronics, and software. The CM feeds power to the ILM 62 servo
in the control cabinet modules from the same power supplies as
50% less cable the LXM 62. The components, which have
installation required on
the machine frame compatible dimensions, allow the
assignment of ILM servo modules to groups
with different safety functions*, for example.

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

52
 PacDrive 3: Integrated Servo Drives

Smaller control cabinets:

With intelligent servo
modules, the servo drives
are mounted in
the machine frame,
leaving only the
controller and the shared
power supply in the
control cabinet

Reduced costs…
shorter installation time
ILM servo modules use a flexible cabling
approach, consisting of pre-terminated
hybrid cables and distribution boxes…and
the network itself is configured as a plug-
and-play solution. Compared to conventional Peak torques of
servo solutions, this reduces the required 3.5 to 55 N•m
cabling by up to 70%, and the labor required
ILM servo modules are planned in flange
for installing the servo solution is reduced by
sizes of 70, 100, and 140 mm. A 55 mm
approximately 50%.
flange will be available at a later date. This
will completely cover a holding torque range
Schneider Electric ILM servo modules are
of 1.1 to 12.5 N•m and/or a peak torque of
the key element in modular machine design.
3.5 to 55 N•m.
They permit modular design of mechanics,
software, and even electronics. This makes
The models are software-compatible with
ILM servo modules an ideal solution for
one another and with LXM 62 and LXM 52
machines with a variety of optional
Series servo drives… and, additional options
mechatronic modules. Aside from any
include a holding brake, a feathered key
additional power supply units required, any
groove, and a multi-turn encoder with
later addition of modules to a machine
electronic name plate. The addition of a shaft
requires no changes in the control cabinet.
seal can increase the protection rating from
IP40 to IP65.

53
PacDrive 3: Servo Drives for stand-alone Solutions…

Lexium™ LXM 52
Servo drives for compact applications
Compact design In a conventional stand-alone design, The servo drives have electronic name
High power density Schneider Electric’s Lexium™ LXM 52 Series plates and can be automatically configured
Software compatible servo drives are particularly well suited for by the controller upon initial commissioning
with LXM 62 and ILM 62 economical configuration of servo drive or following an exchange. They identify
solutions with self-contained single axes. connected servomotors based upon their
They communicate via SERCOS 3 and are name plates and perform parameterization
interchangeable with the LXM 62 and ILM 62 based upon the program specifications.
Series without any programming changes.

Technical Data
Type Lexium™ LXM 52
Availability Pending
Lexium™ LXM 52
servo drives Number of synchronizable 1
are ideal for applications axes
with a small number Continuous current (Aeff ) 1,5 3 6 10 24
of axes
Peak current Aeff 6 9 18 30 72
Continuous output [kVA] 0,3 0,9 1,8 3 7
Supply voltage [V] 380 V (-15%) to 480 V (+10%) AC
Supply frequency [Hz] 48 to 62
Control voltage [V] DC 24 V (-20% / +25%)
Motion bus SERCOS 3
Housing dimensions 220 x 48 x 230 220 x 68 x 230 220 x 108 x 230
D x W x H [mm]
Protection rating IP 20
Excess voltage category KIII, T2 (DIN VDE 0110)
Excess voltage resistance –
Degree of –
radio interference
Certifications CE, cULus (Pending)

Subject to change without notice

Lexium integrated stand-alone servo drive:

The integrated drive for compact applications
Stand-alone drives installed in control innovative integrated servo drives, the
cabinets are not the only option for required components for controlling and
applications with a small number of axes. powering a servo motor are combined into a
Integrated drives are also available, just single assembly.
as with multi-axis designs. With these

54
55
PacDrive 3: Servo Motors

Rotary and linear

servo motors
Modern, high-speed production machines require highly dynamic,
precise AC servo motors with a wide range of rated torques. Brushless,
overload-protected servo motors – with high resolution encoders as well as
torque and linear motors – provide solutions for a variety of applications.
All of the Schneider Electric servo motors shown below can be operated by
Lexium™ LXM 52 and LXM 62 servo drives, and integrated into synchronized
multi-axis systems on the SERCOS 3 interface.

Low inertia rotor:

Lexium SH Series
AC motors meet the
highest performance
requirements

56
 PacDrive 3: Servo Motors

SH
Servo motors in five flange sizes

Schneider Electric SH motors are available in

five flange sizes – from 55 mm to 205 mm,
and a wide range of rated torques – and are
ideal for many applications. SH motors
deliver impressive dynamics because of their There are different options available for
low inertia compared to other servomotors. including SH servo motors with customized
They are exceptionally compact thanks to drive solutions, as all of the motors are
salient pole winding technology, and the equipped with high-resolution, single-turn or
sleek housing is equipped with plug multi-turn absolute value encoders. Additional
connectors that can be rotated 270°. The shaft seals can be integrated for increased
electronic name plate makes these motors protection of bearings, and these motors can
an integral component of the PacDrive 3 be adapted to harsh environmental conditions
automation system. with an optional IP67 kit.

Technical Data
Flange Size/ Holding Holding Holding Holding Peak Rotor Rated Compact design and
Length torque torque torque torque torque inertial speed high power density
Ambient current Fan current load thanks to salient pole
cooling Ambient cooled* Fan windings
cooling cooled*
Low inertia rotor
M0 [N•m] I0 [A] M0 [N•m] I0 [A] Mmax [N•m] JM [kgcm²] nN [min-1] Electronic name plate
SH055/1 0,5 0,73 – – 1,5 0,059 8000 Optional shaft seals,
SH055/2 0,8 1,2 – – 2,5 0,096 8000 integrated brakes
Triple overload capacity
SH055/3 1,2 1,7 – – 3,5 0,134 8000
Exterior fan cooling or
water cooling for better
SH070/1 1,4 1,8 – – 3,5 0,25 6000 capacity utilization
SH070/2 2,2 2,9 – – 7,6 0,41 6000 Optional IP 67 rating
SH070/3 3,1 4,1 – – 11,3 0,58 6000
for harsh environmental
conditions
Single-turn or
SH100/1 3,3 3,5 4,3 4,7 9,6 1,0 5000 multi-turn absolute
SH100/2 5,8 4,8 7,5 6,3 18,3 2,31 4000 value encoder
SH100/3 8,0 6,6 11,0 9,0 28,3 3,22 4000
SH100/4 10,0 6,2 14,2 8,9 40,5 4,22 3000

SH140/1 11,1 7,8 15,6 11,0 27,0 7,41 3000

SH140/2 19,5 13,2 30,8 21,6 60,1 12,68 3000
SH140/3 27,8 17,6 42,4 27,7 90,2 17,94 3000
SH140/4 33,4 21,3 54,8 33,6 131,9 23,0 3000

SH205/1 36,9 2,01 46,9 28,9 110,0 71,4 3000

SH205/2 64,9 25,7 87,2 37,3 220,0 129,0 2000
SH205/3 94,4 33,2 124,5 47,2 330,0 190,0 2000

Subject to change without notice

57
PacDrive 3: Servo Motors

Direct drives
High precision with minimal wear
In contrast to conventional drive solutions, In contrast to standard servos, both direct
rotary and linear direct drives generate drive models generally require more precise
torque precisely where it is needed in the tuning and/or adaptation to a specific
machine. The absence of detours through application. Schneider Electric recommends
gears or belts allows the generation of that you consult with our expert teams of
significant torque. It also reduces the space application engineers and motor specialists to
requirements for drive components, and select suitable motor types for your machines.
eliminates parts that may be subject to
mechanical wear and tear. Benefits include If necessary, we can even provide assistance
less maintenance and greater reliability. on integrating the motors into your
Because of its superior dynamics when application. This helps reduce risks when
compared with other drive solutions, direct getting started with direct drive technology.
drive technology offers improved machine Highly dynamic drives
performance in many cases. Linear drives reduce
wear and tear
Schneider Electric’s PacDrive 3 technology Direct drives generally
can be used to integrate rotary and linear deliver high precision
direct drives into synchronized multi-axis Engineering support
available upon request
systems. Both motor types can be operated for drive selection and
with standard Lexium™ LXM 52 and Lexium application
LXM 62 Series servo drives, even with
high-speed machines having demanding
synchronization requirements.

Direct drive technology

for PacDrive:
Lexium servo drives can
operate a wide range of
linear and torque motors

58
59
PacDrive 3: Robotics Solutions

Integrated Robotics
The integration of robotics into the machine control solution is one of
the outstanding benefits of Schneider Electric’s PacDrive 3 automation
system. On the software side, the integration of robots is made
simpler by an IEC-compliant library with Equipment Modules (EMs)
and Application Function Blocks (AFBs) for motion programming
and transformation to all commonly used kinematics. Thanks to
the availability of complete robot arm mechanics, development of
customer-specific kinematics or integration of third-party products
is no longer necessary. This permits even faster creation of robot-
enabled machine designs.

Picture: Cavanna robotic division

60
 PacDrive 3: Robotics Solutions

Integral automation architecture

The Schneider Electric PacDrive 3 system supports an almost unlimited variety of kinematic configurations, allowing
robotics to become an integral part of a machine‘s automation architecture. High-performance PacDrive 3 Controllers
are capable of synchronizing up to 99 axes in a real-time multi-axis system. From the controller perspective, a robot is
reduced to a motion control system with a corresponding number of servo axes, which can operate under demanding
real-time conditions. In this way, the controller can manage one or more robots in addition to other machine functions
within an IEC 61131-3-compliant program.

SoMachine™
Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP Motion

PacDrive 3 LMC x00C

Logic Motion Controller

IT/COM

Logic Motion Integration of robots in

Safe Logic Controller*
SLC x00
SERCOS 3 + Integrated Safety
the automation architecture:
Depending upon the number of axes, kinematics,
speed, and other requirements, one PacDrive LMC
600 C controller, for example, can control between
six and 30 robots, each with three axes

In/Out

Infeed Dual Belt Robot Robot Robot Conveyor Belt

Grouping Cartoner

Easy software integration Transformation modules for

thanks to AFB and EM libraries PacDrive 3 and standard kinematics
One controller can The integration of robots into the PacDrive 3 In the PacDrive robotics solution, motion
control machines and automation solution software drastically programming and its transformation to robot
multiple robots
reduces the number of complex software kinematics are separate processes. This
Software integration
using Function Block algorithms needed for the solution. Robots means that the robot kinematics can be
library are mapped onto a software module, which selected independently of the generated
Integrated IEC is then inserted into modular, IEC-61131-3- motion program. Regardless of whether the
61131-3-compliant compliant program structures, just like other project uses standard kinematics developed
software, no additional
programming tools
mechatronic machine modules. This by the customer, third-party suppliers, or
Easy access to process structure is based upon library Function PacDrive mechanics – Delta-2, Delta-3,
parameters Blocks that are parameterized by the user or gantry, and portal kinematics are currently
One HMI concept for “fed“ with motion data in the form of a available – the appropriate transformation
machines and robots program or a table. Once motion paths have module adapts the selected solution to the
Transformation modules been defined, parameters can be specified motion program.
for popular robotic
in order to limit the acceleration forces that
kinematics such as
Gantry, Scara, Portal, act on the transported product. The option to In principle, the available transformation
Articulated, Delta specify blending parameters provides further modules can be used to adapt all typical
potential for optimizing the motion paths. 2 to 6-axis systems.
The controller performs all of the other
functions, including actuation of the robot
axes, based upon library Function Blocks.

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

61
PacDrive 3: Robotics Solutions

Motion transformation:
Appropriate
transformation modules
incorporate all typical
kinematics into the
controller software,
whether it involves
PacDrive robotics or
customized kinematics

Delta 2 Delta 3

Gantry Portal

In addition to
transformation
modules mapped to
these kinematics, a
universal
transformation
module is also
available for
custom-designed
or third-party
kinematics, allowing
various robots
to be controlled
with PacDrive 3
Controllers

Scara Articulated

62
 PacDrive:
Robotics Solutions

PacDrive P4
Complete robotics
packages for
Delta 3 kinematics
Everything fits together: Robot mechanics,
servo systems, and the robotics library
provide a ready-to-use solution. In addition, P4 delta-3 robot
kinematics:
complete packages, including engineering, With standard motors,
can accelerate the integration of robotics into available in washdown
an application. configuration up to IP 65

The P4 delta-3 robot from Schneider Electric, Type P4s-F / P4s-R P4i-F / P4i-R
featuring full stainless steel construction, is Load capacity 1,5 [kg]*
designed for pick-and-place applications, as Max. speed 10 [m/sec]
the software includes a pre-programmed Max. acceleration at 1kg 100 [m/sec2]
interface for integration of the most commonly Max. acceleration at 1.5kg 75 [m/sec2]
encountered vision solution. The P4 can be Number of axes 3 (4**)
equipped with an optional rotational axis Repeatable position accuracy +/- 0,1 [mm]
Work envelope height 225 / 350 [mm]
(P4s-R), with the P4 robot arm being driven by
Work envelope diameter 1200 / 750 [mm]
conventional motors with cabinet-mounted Work envelope rotation* Unlimited
servo drives (P4s-F or P4s-R) or by intelligent Protection rating IP 65 –
servo modules with integrated control * up to a maximum of 3.5 kg with reduced acceleration
electronics (P4i-F or P4i-R). Thanks to their IP ** including rotational axis in the R version
65 rated washdown configuration, the P4s-F Subject to change without notice
and the P4s-R are also suitable for hygienic
environments. The P4 is also available in
an ISO 14644-1-certified Class 6
cleanroom design.

63
PacDrive 3: Robotics Solutions

Linear Motion
Single and multi-axis systems for linear motion
The Schneider Electric modular linear
motion system consists of basic elements
and complete solutions for a variety of 1, 2,
and 3 dimensional motion tasks. Thanks to
Portal axes: its modular structure, the elements can be
Left: PAS S (spindle
drive), center: PAS B configured as needed, with the length and
(timing belt drive), and stroke of each axis system being
right: TAS linear table individually determined.

Portal axes in various sizes – with timing

belt drive or spindle drive as desired – can
move loads of up to 100 kg. The structural
elements of these linear tables are extremely
rigid, and the overall assembly has very
compact dimensions, with Cantilever axes
with round rods or a profile design being
Cantilever axes: particularly well suited for limited spaces.
Left: CAS (round rod axis),
right: CAS 4x (profile axis) Thanks to the fixed motor and moving body
of the axis, cantilever axes can move flexibly
into the work envelope.

MAX H Double-axis systems move loads

with great flexibility and speed across
distances of up to 5 1/2 meters. They also
serve as a basis for complete solutions
MAX H two-axis system: involving multi-dimensional motion tasks.
Designed for positioning
over long distances
The MAX P linear positioner, a
combination of double-axis system and
cantilever axis, moves up to 50 kg with a
high level of precision.

MAX P linear positioner:

The combination of
double axis system and
cantilever axes can be
mounted both above and
below the workspace

64
 PacDrive 3: Robotics Solutions

Mechanics packages
available for linear axes
up to three-axis portal
Compatible
The MAX R portal robot with two servo
components
axes, and the MAX R 3 with three servo
Support and service
axes, are the top-of-the-line designs for the from a single source
modular linear motion system. A rotational for the entire
axis can also be integrated as an option. automation solution
Complete package of
mechanics and
For models with up to five axes, PacDrive 3 engineering support
offers pre-programmed or adaptable available upon request
transformation modules to integrate robotic
solutions into a machine’s program structure.

Portal robot
MAX R2 or R3:
This robot is used for
applications mounted
over the work envelope
as either an x-y or an
x-y-z unit, depending
upon requirements.

Technical Data

Single-axis systems
PAS B PAS S TAS CAS
Portal axis Portal axis Linear table Cantilever Telescoping axis
Design Profile Round rod Profile
max. load [kg] 100 100 150 50 18 35
max. stroke [mm] 5500 3000 1500 1200 500 2400
Positioning speed [m/s] 8 1,25 1 5 2 5
Guides Roller bearings/ Ball bearings Recirculating Roller bearings/ Recirculating ball Roller bearings/
ball bearings ball bearings Recirculating ball bearings Recirculating ball
bearings bearings
Version – – – Profile Round rod Profile
Drive element Timing belt Spindle Spindle Timing belt Timing belt

Double-axis and Multi-axis systems

MAX H MAX S MAX P MAX D MAX R2 MAX R3
Double-axis system Linear positioner Portal robot
Axes 1 1 2 2/2 2 3
max. load [kg] 250 300 50 2/5 137 50
max. stroke in x [mm] 5500 5500 5500 300/700 5500 5500
max. stroke in y [mm] – – – – 1500 1500
max. stroke in z [mm] – – 1200 150/300 – 1200

Subject to change without notice

65
PacDrive 3: Human/Machine Interfaces

Operator interfaces
with display panels
from 3.8" to 19"
The variety of product sizes provided by Schneider Electric’s Magelis™ HMI
program – with its Small and Advanced Panels – opens up a wide range of
HMI design possibilities. An ARTI driver simplifies the engineering phase for
integrating PacDrive 3 solutions, by providing direct access to the runtime
system variables.

The right size

for the right display:
Magelis HMI panels
allow users to create
customized solutions with
less engineering time

66
 PacDrive 3: Human/Machine Interfaces

Hardware variety
Depending upon the model,
Schneider Electric’s Magelis™ HMI systems
are available in display sizes ranging from Easy connection:
3.8" to 19", with different hardware features Magelis HMI display
opening up possibilities for individual panels include most
popular interfaces
applications. Touchscreen panels with
VxWorks, Windows® XP, or XP embedded
are available for standard operating
systems, and solutions with separate display
monitors and their associated hardware, or
handheld devices offer still more alternatives.
Flexible configurations with application
memory and/or memory cards for flexible
memory expansion – as well as a variety of
interfaces – make it easy to integrate display
panels into your applications.

Efficient Engineering
Schneider Electric’s Vijeo Designer™ the controller application, providing direct Touchpanels,
keyboard entry devices
configuration software can be used to access to runtime system variables, which
Detachable solutions
uniformly implement PacDrive 3 Magelis- can then be easily browsed using the
and handheld devices
based HMI solutions. An ARTI protocol driver configuration tool. The “otherwise typical, Different operating
reduces engineering time by building a additional definition” of variables for the HMI systems
bridge directly from the configuration tools to application is no longer required. Optimal integration into
PacDrive 3 solutions
with ARTI drivers

Magelis HMI

Vijeo Designer
Ethernet, TCP/IP

PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C Direct access:

Logic Motion Controllers An ARTI protocol driver
is the basis for high-
IT/COM speed communications
between the HMI panel
and the controller, with
Logic Motion
access to the runtime
system variables

67
PacDrive 3: Field Bus Devices

Automation components
on the field bus
As an alternative to integrated Ethernet-based communication,
Schneider Electric’s PacDrive 3 system also offers dual-track designs
for conventional field buses. In this case, SERCOS 3 is the bus for
communication with the servo drives, and field devices can be integrated
into the automation solution via CAN, PROFIBUS™ DP, or other field bus
standards. Positioning solutions, variable frequency drives – and motor
protection components communicating via field bus – supplement the
automation solution to meet specific application needs. With PROFIBUS,
CANopen™ and DeviceNet™ connections, the range of products covers all
standard IP 20 and IP 67 rated I/O configurations.

68
 PacDrive: Field Bus Devices

Lexium™ ILx
Integrated Positioning Drives
Schneider Electric’s Lexium™ line of integrated drives combines the motor, positioning 40% less wiring required
control, power electronics, field bus, and the “Safe Torque Off” safety* function in a single 25% less cabling
assembly. Three product options are available: required
Flexibility thanks to
three possible motor
The Lexium ILA, with a servo motor, delivers The Lexium ILS, with a step motor, is the technologies
a high degree of dynamics. It generates high most precise of the three. The 3-phase step Can be used with
torque even during acceleration. Different motor generates high torque at low speeds popular field buses
winding types are available for application- – often eliminating the need for a gear Simple installation and
commissioning
specific requirements. reduction – permitting space saving direct
Integrated safety*
drive solutions. The Lexium ILS is the thanks to
The Lexium ILE, with an electronically solution for high resolution positioning with safety* function
commutated motor, offers a high degree of good synchronization. Commissioning Safe Torque off (STO)
flexibility. The 3-phase synchronous involves little effort – the user merely needs pursuant to IEC/EN
61800-5-2
electronically commutated brushless DC to adjust the power supply.
motor has a high holding torque of up to 8
N•m (with spur gear drive), often eliminating All integrated Lexium drives can
the need for a holding brake. The integrated communicate via CAN, EtherNet/IP, or
electronics communicate absolute position PROFIBUS™ DP.
to the automation controller.

Lexium
integrated drives:
Three product options
with three different
motors

Technical Data
Motor Speed range Continuous Peak torque Encoder Holding Optional gearing
[rpm] (direct torque (direct (direct drive) brake
drive) drive)

[1/min] [N•m] [N•m]

ILA servo motor < 7500 < 0,26 < 1,62 High-resolution Yes Planetary gear unit
drive encoder (16384 (Gear ratios from
increments) 3:1 to 40:1)
ILE EC motor drive < 5000 < 0,24 < 0,80 Hall sensors No Cylindrical and
planetary gear unit
(Gear ratios from
18:1 to 115:1)
ILS step motor drive < 2000 <6 <6 With or without Yes Planetary gear unit
index pulse encoder (Gear ratios from
(optional) 3:1 to 8:1)

Subject to change without notice

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

69
PacDrive 3: Field Bus Devices

Altivar™ 312/32/71
Variable frequency drives
Schneider Electric’s Altivar™ family of variable frequency drives offers the right drive speed
controller for different applications. Like the Altivar 32, the Altivar 312 is appropriate for simple
machines with a power range of up to 15 kW. For more complex machines with higher
performance, the Altivar 71 with its power range of 0.37 to 1300 kW is the right solution.

Altivar:
Variable frequency
drives for both simple
and complex machines;
pictured are the ATV
312, 32, and 71 models

Altivar 312
Altivar 71
Altivar 32

The Altivar 312, 32, and 71 series are well All models can communicate via Modbus™ Wide performance
suited for areas such as packaging, or CANopen™, and all can be connected to range
transportation, conveyors, positioning PROFIBUS™, Ethernet IP, and DeviceNet™ Integrates easily into
PacDrive 3 solutions
systems, or textile machines. This makes through integrated communication cards.
CANopen integrated,
them ideal for PacDrive 3 automation Versions with connection via SERCOS 3 additional field bus
solutions. Time-saving Function Blocks – are pending. options available
for integrating these frequency drives – are for ATV 71 and 32
provided in the PacDrive software library.

Technical Data
Altivar type ATV 312 ATV 32 ATV 71
Single-phase 0,18 to 2,2 0,18 to 2,2 0,37 to 5,5
200 to 240 V
3-phase 200 to 240 V 0,18 to 15 0,18 to 15 0,37 to 75
Power range in kW 3-phase 380 to 480 V – – 0,75 to 1300
(50 to 60 Hz power supply)
3-phase 380 to 500 V 0,37 to 15 0,37 to 15 –
3-phase 525 to 600 V 0,75 to 15 – –
3-phase 500 to 690 V – – 2,2 to 2000
1 to 1600 Hz to 37 kW,
Output frequency in Hz – 0,5 to 500 0,1 to 599 1 to 500 Hz from
45 to 500 kW
Short-term overload for 2 s 200 200 220
moment in % of the rated
motor moment for 60 s 170 170 170

Subject to change without notice

70
 PacDrive 3: Field Bus Devices

Lexium™ SD3 28
Step motors on the field bus
The Schneider Electric Lexium™ SD3 28 step motor drive is a powerful positioning solution Lexium SD3 28
for communication via PROFIBUS™, CAN, and CANopen™. The different product options step motor drives:
Compact plug-and-play
are designed for holding torques of 1.7 to 19.7 N•m, with the safety function “Safe Torque solutions with minimal
Off” (STO pursuant to IEC 61800-5-2) already integrated with the device. These drives are space requirements in
available for up to 6.8 A, with the SD3 28 being suitable for a power supply with 1~115 VAC the control cabinet
and 230 VAC (50/60 Hz). A power filter is integrated, and the current is reduced automatically
at zero speed. The SD3 28 can also be equipped with motion monitoring on request.

Technical Data
Plug-and-play without
3-phase step motor Step motor drive Holding torque at Maximum torque Maximum
115 V/230 V zero speed speed (RPM) encoder systems and
commissioning software.
Type Type [N•m] [N•m] [1/min] Excellent
BRS368Wx 1,7 1,5 2000 synchronization
BRS397Wx 2,3 2,0 2000
High torque even at
SD3 28 x U25 (2,5 A) low rotational speeds
BRS39AWx 4,5 4,0 2000
Integrated safety
BRS39BWx 6,8 6,0 2000 functionality (STO)*
BRS3ACWx 13,5 12,0 2000
SD3 28 x U68 (6,8 A)
BRS3ADWx 19,7 16,5 2000

Subject to change without notice

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

71
PacDrive 3: Electrical Components

Recording, notification,
power distribution
and switching
Schneider Electric manufactures an extensive product line of electrical
equipment for machine construction, production lines, and entire production
facilities, including: Power supplies, mounting and cabling systems for
low voltage and medium voltage applications, and control and signaling
equipment. The following excerpt from our product portfolio demonstrates
the wide variety of solutions we offer. Together, they can provide you with the
tools necessary for your particular needs and your specific solutions.

TeSys™ U
Motor starter:
Space-saving combination
of short-circuit protection
disconnect switch,
overload relay, and
contactor, with modular
design for greater flexibility

Safety signal recording*

with Preventa™:
Light curtains, switches,
switch mats, and many
other components trigger
safety responses in a wide
variety of situations

Safety dialog*
with Preventa:
With pullcord emergency
switches, emergency
stop buttons, enabling
switches, foot switches,
and two-hand control
units, this program
includes all of the
popular solutions for
safety-related command
and signaling devices

* according to IEC 61508:1998, EN/ISO 13849-1: 2008

72
 PacDrive 3: Electrical Components

Harmony™ control and

signaling devices:
Signaling technology
as well as a series of
lighted and unlighted
pushbuttons, switches,
and much more

GV3 motor
Altistart™ 01 and 48: starter and protector:
Soft starters for AC Triggers at motor currents of 9
induction motors to 65 A, with thermomagnetic
and three-phase AC or magnetic triggers if needed
induction motors for
0.18 to 630 kW. Ideal
for use in combination
with Altivar™ ATV 312
and ATV 71 frequency
converters

Control cabinets
and enclosures:
Wide range of sizes,
OsiSense™ XG: materials, and installation
Open and extremely accessories
compact RFID system
for all popular ISO data
media based on the
13.56 MHz standard

OsiSense - Recording
systems and sensors:
A complete range of
sensors – optoelectronic,
inductive, or ultrasound
recording as well as
positioning switches
– for most industrial
automation applications

73
PacDrive 3 vs. the Competition

Compare
for yourself
The complexity of power automation systems and the number of individual
factors involved often make it difficult to directly compare one system
with another. Use our checklist on page 75 to identify the benefits of the
Schneider Electric PacDrive 3 system…then compare these with what our
competitors offer.

74
 PacDrive 3 vs. the Competition

User benefit PacDrive 3

International International assistance is standard at Schneider Electric, one of the world’s largest
assistance available suppliers of automation technology and electrical equipment.
Complete solutions from a Complete automation solutions, electrical equipment, installation, mechatronics, SCADA and
single source MES systems
Support 24/7 Help Line
Open standards Programming design is IEC 61131-3 compliant. IEC standards for field bus communication,
international IT standards for vertical integration or remote maintenance
Sustainability PC Intel platform, long-term availability of controllers, drives, and motors
Universal controller functionality PLC, motion, and IT functionality, no additional and/or proprietary controller hardware
of the hardware platform required for the complete machine (incl. robotics)
Scalability Up to 99 servo drives, software can be ported between platforms
Ethernet-based automation bus SERCOS 3, manufacturer-neutral and IEC standard
Diagnostic functionalities Up to motor shaft thanks to electronic name plates in motors and drives, and message loggers.
Software oscilloscope for simultaneous display of PLC and motion variables
Simulation Programs can be tested without real axes by using centralized controller architecture
Flexible design of servo drive Stand-alone servo drives, multi-axis system with single/double drives and shared power
architectures supply. Servo drives with integrated controllers to be released soon
Broad range of servo motors High-performance standard motors, torque motors, and linear drives for a wide range
of torque
Safety design* Standard solution available, integrated solution with safety PLC*.
Safety communication and safety I/Os* via SERCOS 3 to be released soon
Rapid installation and Plug-and-play technology thanks to electronic name plates in servo system components.
commissioning Hot-plugging of components on motion bus, extensive use of plug connectors
Remote maintenance Remote maintenance via IP connection and diagnostic tools
Integrated tool design Complete workbench with tools for the entire engineering process…for functional safety*,
commissioning and diagnosis, central database, and multiuser design for simultaneous
work on projects
Tool for motion design Graphic motion design, drivetrain design, and power supply analysis in a single tool.
VDI motion rules available
Machine diagnostics Software tool diagnostics integrated into SoMachine Motion Workbench. Can also be used
separately from Workbench (available free of charge).
Support of modular machine Programming tools completely designed for modular program structures. Standardized
designs software structures with optional use of the PacDrive programming template (Machine Pilot)
Function Blocks for creating the PacDrive Libraries with AFBs for basic motion, PLC, cam disk, and technology functions,
machine program mathematical functions, torque handling, dual-belt and multi-belt mechanisms, infeed,
HMI applications, simulation and testing (ETest), etc.
Function Blocks for program PacDrive Libraries with AFBs for ANSI/ISA S88 Technical Report (OMAC/PackML),
standardization Weihenstephan standard, and FDA…as well as operating mode, error and error response
management, process control, and pre-defined commissioning screens.
Function Blocks at the Operating modes, error and error reaction management, process control, predefined
machine/machine module level commissioning resources in the HMI
Hardware and software Robots are controlled by the machine‘s centralized PacDrive 3 Controller, requiring no
integration of robotics additional controller hardware. Software integration with IEC 61131-3-compliant library
in machines Function Blocks for path generation, path optimization, transformation to all popular
kinematics…as well as synchronization with conveyor belts, products, and other robots.
Robots Complete robotics kinematics packages are available, including drives, electronics,
and software

75
 http://www.schneider-electric.us/
Schneider Electric USA, Inc. The information and dimensions in this catalog are provided for the convenience of our
8001 Knightdale Blvd. customers. While this information is believed to be accurate, Schneider Electric
Knightdale, NC 27545 reserves the right to make updates and changes without prior notification and assumes
no liability for any errors or omissions.
USA Customer Care Center
Tel: 888-778-2733
Altistart, Altivar, CANopen, Citect, Designer, DeviceNet, Harmony, Historian, Lexium,
MachineStruxure, Magelis, Modbus, Modicon, OsiSense, PlantStruxure, Preventa,
Schneider Electric Canada
PROFIBUS, Profinet, SoMachine, TeSys, Vijeo, Schneider Electric and logo, and
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“Make the most of your energy” are trademarks or registered trademarks of
Missassauga, Ontario, Canada L5R 1B8
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Canada Customer Care Center trademarks used herein are the property of their respective owners.
Tel: 800-565-6699
Design: Schneider Electric
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VM08141-001EN-US
© 2012 Schneider Electric. All rights reserved. 05/2012