Zelio OsiSwitch Phaseo Tesys EN

Zelio and OsiSwitch

Phaseo and TeSys

System User Guide

[source code]

33003495.0

Contents

Typical Applications ...4

System ...5

Architecture...5

Installation...7

Implementation ...13

Appendix...18

Detailed Component List...18

Component Protection Classes ...19

Component Features ...20

Contact...24

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

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

Abbreviations

Word/expression Explanation

PLC Programmable Logic Controller

HMI Human Machine Interface

PC Personal Computer

AC Alternating Current

DC Direct Current

PSU Power Supply Unit

I/O Input/Output

CB Isolating switch or motor protection EMERGENCY STOP EMERGENCY STOP switch

Zelio Name of a Schneider PLC (controller)

Phaseo Name of a Schneider range of SPSU power supply units TeSys U Name of a Schneider compact motor starter combination

Application Source Code

Introduction Examples of the source code and wiring diagrams used to attain the system function as described in this document can be downloaded from our „Village“ website under this link.

Typical Applications

Introduction The following chapter describes some typical applications or partial applications for this system, which are used in the following market segments:

Industry

• Small automated machines or plant components

• Remote automation systems used to supplement large and medium-sized machines Infrastructure

• Access control

• Monitoring and separation of zones

• Management of heating and air conditioning systems

Application Description Example Gas and filling stations This application facilitates the pumping

of fuel and oils (e.g., natural gas, diesel, fuel oil, etc.) for the refueling of vehicles. The volumetric flow rate or pump delivery rate is determined on the basis of a fixed pump speed and cannot be changed. Access control, building services engineering, service and maintenance workshops

This application enables roller shutters or segmented roller shutters to be opened and closed/can be used to secure access to separate zones or buildings. Multiple operation and control options are possible in conjunction with a huge range of control elements (e.g., push-button control, pull switches, motion detectors, induction loops), plus crush protection.

Stair lift This application enables a stair lift to be operated.

System

Introduction The System chapter describes the quantity, architecture, components, and dimensions of the devices and parts used.

Architecture

Overview The system consists of a “low-end” PLC with push-buttons for controlling a shutter. Within this combination, there is scope for an optional rapid shutdown function. The final upper and lower positions of the shutter are detected by roller limit switches. The shutter movement is controlled via a push-button control – the corresponding signal stati are displayed by means of illuminated buttons and a compact signal station. This configuration does not include a bus system. For the purpose of processing additional (optional) signals, the PLC has a number of unallocated inputs and outputs.

Components Hardware:

• Vario VCD master switch

• motor starter GV2ME07 and reversing contactors LC1D09BD • As an alternative to motor circuit breaker and contactors: Tesys U

• XB5-AS locking-type emergency stop switch with rotary unlocking (flush mounting) • Phaseo ABL7 power supply unit

• ZELIO compact PLC

• XB5 buttons and indicator lamps, from the Harmony Style 5 range of push-buttons

• XVBL compact signaling column • XCK OsiSwitch roller limit switches • Standard AC (brake) motor

Software:

• ZelioSoft Version 3.1

Degree of protection

Not all of the components used within this configuration have been designed to

withstand the full range of environmental conditions in the field. These components will therefore require additional protection and are only suitable for installation in a control cubicle. For information about which components are suitable for direct installation on site, please refer to the list provided in the appendix (column headed “In the field, on site”, which also gives the relevant IP protection class).

Supply voltage 3x400 V AC ± 20% (50/60 Hz) Total supply output approx. 0.9 kW

Motor output ≤ 0.75 kW

Motor brake Max. 200 W (L+N) or 1A at 24VDC Connector cross-section 5x 1.5mm² (L1, L2, L3, N, PE) Design data

Safety category Cat. 1

Safety notice In this application example, Category 1 (according to EN 954-1) has been selected for the purpose of ensuring safety. The issue of which safety or control category is to be adopted will be determined by the system’s design and the overall extent to which this system represents a hazard to people and machinery.

Size/

Dimensions

The compact dimensions of the devices used, e.g., the PLC and PSU, means that the components can be installed inside a control cubicle with the following approximate external dimensions: 300 x 300 x 250 mm (WxHxD).

Moreover, the display elements used to indicate a “group error”, “controller on” and “no protection” can be built into the door of the control cubicle along with the system master switch and emergency stop master switch.

Installation

Introduction This chapter describes the steps required to install the hardware and set up the software so that the application task concerned can be achieved.

Layout

Note The configuration used for this application is based on the example of a rolling shutter for a large industrial building.

The components and I/O points listed below represent a cross-section of the

components and signals that are absolutely essential for control and display purposes and a number of optional inputs and outputs, which can be used in conjunction with most typical applications (e.g., induction loops/pull switches).

This SMD does not claim to be comprehensive and does not absolve users of their duty to check the safety requirements of their equipment and to ensure compliance with the relevant national or international rules and regulations in this respect.

Safety Category 1, which is suggested here as one possible option, is not necessarily required/not necessarily adequate for every application, as a risk analysis must be produced and verified for each system (in accordance with national and/or international standards and regulations).

Zelio PLC inputs Description PLC wiring DC I1 DC I2 DC I3 DC I4 DC I5 DC I6 DC IB Options: DC IC DC ID DC IE DC IF DC IG Up button Down button Stop button Upper limit switch Lower limit switch Motor circuit breaker External pull switch Crush protection Protection active

Chain tightener/torque arm Motion detector/induction loop Spare

Zelio PLC outputs Class Description Q1-Q8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Class 1 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 +24 V DC power supply contactor control, up contactor control, down

Display, “up” is currently active (illuminated button) Display, “down” is currently active (illuminated button)

Group error

Warning signal (motion in progress) Spare

Display, controller on

Zelio 24 V supply Description +

-

24 V DC power supply 0 V DC reference voltage

Hardware

General • Although the motor circuit breaker together with reversing contactor circuit

components (or alternatively TeSys U), Zelio PLC, fuses and power supply can all be mounted on top-hat rails, they can also be installed individually (with exception of circuit breakers and fuses).

• For the purpose of installing the top-hat rails, use standard M5x16 countersunk head screws and washers or blind rivets.

• The master switch, emergency stop button and push-buttons for acknowledge emergency stop and control voltage on are planned for placing into the door of the cubicle.

• There are two options available for mounting the illuminated buttons:

a) 22 mm hole in the front door of the control cubicle (emergency stop, controller on)

b) XALD push-button housing for illuminated buttons located away from control cubicle for remote operation of the machine (up, down, stop buttons plus built-in displays)

• 400 V AC wiring running between the master switch, TeSys U (or alternatively, motor circuit breaker and reversing contactor circuit), and shutdown relay (via safety circuit) to the motor, with some terminals in between.

• 230 V AC wiring between terminals, safety circuit and power supply

• 24 V DC wiring between PSU, PLC, push-buttons and indicator lamps as well as emergency stop and shutdown relay control circuit.

Masterswitch VCD02

Emergency Stop button XB5-AS8445

Motor starter with reversing contactor

combination Tesys U

LU2B12BL+ LUCA05BL

Motor circuit breaker/ Switch disconnector

GV2 ME 07

Load contactor LC1 D09 BD

Phaseo power supply unit

ABL7CEM24012

Zelio PLC Zelio Logic Compact

SR201B201BD

Selector switch, push-button switch, indicator

lamp Harmony Style 5

Roller limit switch XCKP2118P16 XCKD2145P16

Compact signal light with amber continuous

light XVBL-0B5

Software

General Users do not need special software tools to set up the system.

In principle, programming and setup can be performed via the front panel of the Zelio Logic CPU.

However, from the point of view of saving data, carrying out simulations and reusability, it is more convenient to install and use the associated ZelioSoft tool, which is available for the PLC.

Your PC must have one of the following versions of the Windows operating system installed: Windows 98 Windows 2000 Windows NT. Installation

path The default installation path on the hard drive of your PC for the ZelioSoft software is:

\Programs\Schneider Electric\ZelioSoft

Communication

General The configuration presented here is based exclusively on hardware connections and not on bus-system communications.

Operation and monitoring is achieved by means of push-buttons and illuminated buttons as well as warning lamps/compact signal columns.

Implementation

Introduction This chapter describes the steps required to install the hardware and set up the software for the task associated with the following application:

Function Functional description

All the conditions required to clear the group error must be met, i.e., motor circuit breaker switched on, crush protection OK, safety circuit on (optional in some cases). Opening the roller shutter: Press the “up” button to open the roller shutter (provided that the upper limit switch has not been actuated); the roller shutter stops moving if the stop button is pressed, the external pull switch is activated or a group fault occurs. The "up" button lights up to show that this movement has been selected.

Closing the roller shutter: Press the “down” button to close the roller shutter (provided that the lower limit switch has not been actuated); the roller shutter stops moving if the stop button is pressed, the external pull switch or crush protection is activated or a group fault occurs. The "down" button lights up to show that this movement has been selected. Pull switch: Activating the pull switch will open the shutter if it is not completely open and the motor is idle; if the shutter is already open, activating the pull switch will cause it to close. Activating the switch again will stop the shutter.

Motion detectors or induction loops: If the operator stops within range of the sensors, there will be a short delay and then the shutter will open. Having opened successfully, it will wait until the set rest period has elapsed, then close again.

Crush protection: If crush protection is activated, the roller shutter will rise until the obstacle can no longer be sensed.

Warning signal: A flashing light and/or klaxon indicates that the roller shutter is in motion.

Layout

HMI

Introduction This application does not feature an HMI.

PLC

Introduction The PLC chapter describes the steps required to initialize, parameterize and program the PLC logic in order to implement the functional description described above. The application program is created using ZelioSoft.

Creating a new program

1 When you open ZelioSoft for the first time, the data entry menu for choosing a new or existing program will appear.

To create a new program, select “New Program”. A window will appear so that you can select the Zelio module (see opposite). First of all, please narrow the selection by clicking on the relevant image, then select the technical data/module type description in the lower window.

2 Once an existing module has been selected, you can choose between two programming languages.

The programming languages available are LD (Ladder Diagram) or FBD (Function Block Diagram).

3 In our example, FBD should be selected, although the use of LD would be equally appropriate.

Loading an existing program

1 To load an existing program, click on the round “folder” button or select “Open” from the “File” menu. The default folder for loading a program is the

"Z2USER" folder. However, you can use the browse function to access any other folder containing a program with the file extension *.zm2. Now open the “Example.zm2” program. 2 After opening the program, you

should check that the module configuration in the software matches the module you actually have at hand. The easiest way to check this is by comparing the inscription on the Zelio PLC (on the right-hand side as you look at it from above) with the code displayed in the bottom right-hand corner of the screen.

If the configuration does not match, it will not be possible to load the program into the controller! The module

configuration cannot be modified retrospectively.

Configuring the interface

1 Before you can transfer your program to the PLC, you need to configure your PC’s

communication interface. To do this, select “COMMUNICATION setup” from the “Transfer” menu and then select the relevant port. The pull-down menu will contain the list of recognized ports, which will depend on the PC hardware and operating system.

In this case, the first serial interface is selected -> “COM1“. If the PC is connected to the Zelio Logic controller via the programming cable, you can now test the connection by selecting “Test” from the configuration menu.

USB 1 Depending on the PC and operating system, "COM6" (or similar) will be displayed along with "COM1" or "COM2", if no serial port is available or, for example, the USB has been mapped as serial. Please note that the Zelio package does not include a USB serial adapter. For more detailed information, please refer to the Zelio help function.

2 After this, the application program can be transferred to the PLC. To do this, select “Transfer“ from the menu bar, followed by “Transfer Program” and “PC > Module”.

3

Before starting the PLC, please read the safety warnings relating to your system and make sure that everyone is clear of any potential danger zone.

4 Once the program has been successfully transferred, you are free to start the Zelio Logic PLC. To do this, select “Transfer” from the menu bar again, only this time followed by “RUN Module”.

Data Exchange

Introduction There is no exchange of data between the various devices involved in this application example.

Devices

Introduction Other than a motor circuit breaker, no settings need to be made in this application.

Appendix

Detailed Component List

Item Qty Description Part No. Rev./

Vers. Hardware

components

1.1 1 Master switch VCD02

1.2 1 Emergency stop button (flush mounting) ZB5AS8445 1.3 1 Auxiliary contact for pushbutton, NO ZBE102 1.4 Emergency stop lable, yellow ground, ZBY9330 1.5 3 Contactor, 9A, 24 V DC operated, 3-pole

AC3, 1x NO + 1x NC

LC1D09BD 1.6 1 3-button push-button housing empty XALD03

1.7 2 Illuminated button green, flat ZB5AW333 1.8 2 Auxiliary switch module with green LED + 1

auxiliary switch (1x NO)

ZB5AW0B31

1.9 1 Label holder 30x40 “up” ZBY2307

1.10 1 Label holder 30x40 “down” ZBY2308

1.11 1 Illuminated button red, flat ZB5AW343 1.12 1 Auxiliary switch module with red LED + 1

auxiliary switch (1x NO)

ZB5AW0B42

1.13 1 Label holder 30x40 “stop” ZBY2304

1.14 1 Illuminated button blue, flat ZB5AW363 1.15 1 Auxiliary switch module with blue LED + 1

auxiliary switch (1x NO)

ZB5AW0B61 1.16 1 Label holder 30x40 “emergency stop” ZBY22420001

1.17 1 Indicator lamp white, flat XB5AVB1

1.18 1 Label holder 30x40 “power on“ ZBY2326 1.19 1 Compact signal station or flashing light XVBL0B5 1.20 2 Position switch Universal (final positions) XCKP2118P16 1.21 1 Position switch Universal

(pull switch)

XCKD2145P16

1.22 1 Motor protection GV2ME07

1.23 2 Miniature circuit breaker 1P 2A GB2CB07 1.24 1 Miniature circuit breaker 1P+N 1A GB2DB06 1.25 1 Phaseo power supply

24 V DC/1.2 A

ABL7CEM24012 1.26 1 ZELIO Logic Compact (PLC + ZelioSoft +

programming cable)

SR2PACK2BD 3.1 1.27 1 (Zelio Logic Compact with 20 I/O, 24 V DC

version, included in item 1.26, if ZelioSoft cable and software already present)

SR2B201BD 3.1

Alternatively to Motor protection witth Rev. contactors: Tesys U (pos. 1.26 - 1.29 ) 1.26 1 Reversing contactor combination 12 A 24 V

DC

LU2B12BL 1.27 1 Control unit 1.25 – 5 A 24 V DC LUCA05BL

1.28 1 Function module 2 auxiliary contacts LUFN20 1.29 1 Auxiliary contacts 2x NO (fault and ready) LUA1C20

Software

components Item Qty Description Part No.

Rev./ Vers. 2.1 1 ZelioSoft (included in item 1.26) SR2SFT01 2.0

Component Protection Classes

class Emergency stop button X

Motor circuit breaker X

Contactor, 9A, 24 V DC operated,

3-pole AC 3, 1x NO + 1x NC X

3-button push-button housing, empty X

Illuminated buttons, all colors, flat X

Auxiliary switch module with LED + 1

auxiliary switch (1x NO), all colors X

Label holder 30x40, all texts X Compact signal station or flashing light X

Position switch Universal X

TeSys U complete unit X

Miniature circuit breaker, all types and

ratings X

Phaseo power supply

24 V DC/1.2 A X

Component Features

Zelio PLC: Zelio Logic PLC:

Zelio Logic Compact – SR2PACK2BD (package includes software and hardware, plus programming cable):

• 24 V DC • 12 digital inputs • 8 digital relay outputs •

• Front operator panel for Ladder and FBD programming (no PC required); also possible via PC using ZelioSoft software.

Zelio PLC, continued

Zelio PLC

Zelio software functions – LADDER:

• User-friendly “free input” mode: LADDER or FBD (electrical symbols) • 120 lines for control tasks

• 5 contacts + 1 memory per program line

28 auxilary relays

8 counter comparators

LCD screen with programable back lighting

automatic 1 hour clock change: summer/winter diversity of coil

functions: with memory (set/reset), remote switch, contactor, 16 text function blocks 16 timers 16 up/down counter 1 fast counter 16 analogue Comparators 8 clocks

Zelio software functions – Function Block Diagram/FBD:

Zelio PLC, continued

Phaseo power supply unit ABL7CEM24012 • 100..240 V AC/24 V DC • 1.2 A secondary • Short-circuit-proof Motor starter combination

TeSys U: LU2B12BL+ LUCA05BL • Motor output up to 0.75 kW

• Reversing contactor control with electr. and mech. interlock • Tripping current, adjustable within the range 1.25…5 A • Trip feedback via auxiliary contacts

• Optional activation of a brake using auxiliary contacts • Compact dimensions

• Minimum wiring requirements

Motor circuit breaker and contactor

• Motor circuit breaker and contactor • Isolating switch: GV2ME07 • 1.6...2.5A

• Thermal and 33.5 A magnetic activation

• Contactor: LC1D09BD • Rated current 9 A AC3 • 1x NO contact

• 1x NC contact

• Positive opening operation means it can be used in safety circuits • 24 V control voltage incl. suppressor circuit

Contact

Author Phone E-mail

Schneider Electric GmbH Customer & Market System & Architecture Architecture Definition Support