Harmony eXLhoist EIO0000001505 04/2014 Harmony eXLhoist Wireless Remote Control System User Guide EIO0000001505.00 04/2014 www.schneider-electric.
The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications.
Table of Contents Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 1 Wireless Remote Control System . . . . . . . . . . . . . . . . . Wireless Remote Control System Overview . . . . . . . . . . . . . . . . . . . . Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification and Main Features . . . . . . . . . . . . . . . . . . . . . . . .
Safe State of the Wireless Remote Control System . . . . . . . . . . . . . . Response Time and Process Safety Time (PST) . . . . . . . . . . . . . . . . Legal RFU (Recommendation for Use) . . . . . . . . . . . . . . . . . . . . . . . . Summary of the Reliability Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Functional Safety Function Commissioning . . . . . . . . . . . . . . . . . . . . . Safety Parameters and Steps to Configure the Safety Functions . . . . Machine Signature . . . . .
.2 Functionalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Project Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Exiting eXLhoist Configuration Software . . . . . . . . . . . . . Creating a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit a Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Project Passwords Management . .
Safety Information Important Information NOTICE Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.
PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation, and has received safety training to recognize and avoid the hazards involved.
About the Book At a Glance Document Scope This manuel describes how to use the Wireless Remote Control System. Validity Note The technical characteristics of the devices described in this document also appear online. To access this information online: Step Action 1 Go to the Schneider Electric home page www.schneider-electric.com. 2 In the Search box type the reference of a product or the name of a product range. Do not include blank spaces in the model number/product range.
Title of Documentation Reference Number Instruction Sheet Accessory Remote Holder HRB57277 Instruction Sheet Accessory Rubber Protection EAV52994 Instruction Sheet Accessory Pad & Trigger EAV52985 Instruction Sheet Accessory External Antenna EAV59906 You can download these technical publications and other technical information from our website at www.schneider-electric.com.
WARNING UNINTENDED EQUIPMENT OPERATION Only use software approved by Schneider Electric for use with this equipment. Update your application program every time you change the hardware configuration. Failure to follow these instructions can result in death, serious injury, or equipment damage. NOTE: To increase the system security, it is recommended to use Configuration File transfer password.
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Harmony eXLhoist Wireless Remote Control System EIO0000001505 04/2014 Chapter 1 Wireless Remote Control System Wireless Remote Control System What Is in This Chapter? This chapter contains the following topics: Topic Page Wireless Remote Control System Overview 14 Package Contents 19 Parts Identification and Main Features 20 Certifications and Standards 29 Accessories 33 EIO0000001505 04/2014 13
Wireless Remote Control System Wireless Remote Control System Overview Overview The Harmony™ eXLhoist range of wireless remote control systems is an operator control station used in hoisting and material handling applications. The Wireless Remote Control System is based on 2 types of devices: Remote Device (or transmitter), which is the operator command device to interface with the machine. Base Station (or receiver), which is hardwired to the machine.
Wireless Remote Control System Main Applications Example of overhead traveling crane: Type Description SINGLE With 1 trolley The Remote Device controls one trolley.
Wireless Remote Control System Type Description SINGLE With 2 trolleys By using the selector button, the Remote Device separately controls the trolley 1, trolley 1+2 or the trolley 2.
Wireless Remote Control System Type Description SINGLE With 2 hooks By using the selector button, the Remote Device separately controls the hook 1 or the hook 2.
Wireless Remote Control System Type Description TANDEM* By using the selector button, the Remote Device separately controls the bridge 1, bridge 1+2 or the bridge 2.
Wireless Remote Control System Package Contents Overview Applicable items included in the package: 1 2 3 4 5 6 Base Station Remote Device Set of labels to customize the Remote Device buttons Instruction Sheet Charger of the Remote Device battery (only in starting kits) Shoulder belt for the Remote Device (only in starting kits) EIO0000001505 04/2014 19
Wireless Remote Control System Parts Identification and Main Features Wireless Remote Control System Overview The Wireless Remote Control System is a combination of 2 kinds of devices: Base Station: References Connectors ZARB12W ZARB12H ZARB18W ZARB18H Cable gland for wires Industrial plug type Cable gland for wires Industrial plug type No. of inputs 0 18 No.
Wireless Remote Control System Reference Starting Kit System Accessories XARS8KD18H XARS8D18H ZARC01 + ZARC02 XARSK12D18W XARS12D18W ZARC01 + ZARC02 XARSK12D18H XARS12D18H ZARC01 + ZARC02 Base Station Parts Identification Side Description Front ZARB•W Front ZARB•H EIO0000001505 04/2014 21
Wireless Remote Control System Side Description Rear without the cover 22 Part Description A M12 for external antenna (covered by cap) B Status LEDs C M20 for the safeguarding function input wires (covered by cap) D 62 pins connector (covered by cap) E M25 for output wires (covered by cable gland) F M25 for detected applicative alarms input wires (covered by cap) G 4 holes for standard mounting on support (covered by cap) EIO0000001505 04/2014
Wireless Remote Control System Base Station Main Features References ZARB12W ZARB12H ZARB18W ZARB18H Cable gland for wires Industrial plug type Radio communication Yes External antenna connector Yes Connectors Cable gland for wires Industrial plug type Q0 safety relays outputs 2 (Q0_A, Q0_B) 1 IN0 / S2_S3 feedback loop terminals for mirror contacts from safety actuator Configurable inputs for detected applicative alarms 0 6 (IN1…IN6) Inputs dedicated for safeguarding function 0 12 (IN
Wireless Remote Control System Remote Device Front View Parts Identification ZART8L ZART8D 24 ZART12D EIO0000001505 04/2014
Wireless Remote Control System Part Description 1, 1H, 2, 2H, 3, 3H, 4, 4H, 5, 6 Motion buttons 7 Trigger button 8 OFF/STOP button 9 ON/START/Horn button 10,11,12,13,14,15 Auxiliary buttons Remote Device Rear View Parts Identification 1 2 3 Cover RJ45 connector Reset button EIO0000001505 04/2014 25
Wireless Remote Control System Remote Device Bottom Display Parts Identification 1 2 3 Remote Device battery charge connector Protective plug E-STOP button DANGER OBSTRUCTED PUSH-BUTTON MOTION Ensure push-button will fully operate. Failure to follow these instructions will result in death or serious injury.
Wireless Remote Control System ZART•D Display Parts Identification 1 2 3 4 5 6 7 Battery level Radio communication level Operating status Bridge label Detected applicative alarms Selector status E-STOP LED EIO0000001505 04/2014 27
Wireless Remote Control System ZART8L Display Parts Identification 1 2 3 4 Battery level LED START LED Selector LEDs E-STOP LED Remote Device Functionalities Description Number of configurable buttons ZART8L 8 OFF/STOP button ZART12D 8 12 Yes ON/START/Horn button Yes Motion & Stop function Yes Selector 2 or 3 positions (1, 1+2, 2) Yes E-STOP function Yes Optional E-STOP reset code sequence Yes Optional START code sequence Yes Optional automatic STOP function after a time-out Yes Op
Wireless Remote Control System Certifications and Standards Environment The Wireless Remote Control System devices are compliant with: WEEE, directive 2002/96/EC REACH, regulation 1907/2006 RoHS, directive 2011/65/EU Overall Standards Criteria Level Principles of design for safety EN IEC 60204-1 EN ISO 13849-1 EN ISO 13849-2 EN IEC 62061 EN IEC 61508 EN ISO 13850 Specific standards for hoisting applications EN IEC 60204-32 EN 13557 Low voltage equipment EN IEC 61010-1 EN IEC 60947-5-1 EN IEC
Wireless Remote Control System Criteria Description Countries certifications (electrical devices) CCC UL508 for base + UL functional safety CSA C22-2 n° 14 Gost C-tick KC US-specific standards for safety UL 1998 (Covered by IEC 61508) UL 991 Canadian specific standards for safety CSA 22.2 N° 0.
Wireless Remote Control System Certification organism Certification organism country Certification marks SRRC China SRRC See on the device SDPPI Indonesia Technical Conformity Mark Japan SIRIM Malaysia See on the device COFETEL Mexico See on the device ictQATAR Qatar EAC Russia IDA Singapore See on the device See on the device ICASA South Africa See on the device KCC South Korea See on the device NCC Taiwan See on the device NTC SDoC Thailand See on www.
Wireless Remote Control System 32 Certification organism Certification organism country TRA United Arab Emirates FCC USA Certification marks See on the device EIO0000001505 04/2014
Wireless Remote Control System Accessories Base Station Accessories Reference Description ZARC03 External antenna for Base Station: The use of this accessory allows an increase of the radio range in severe environment conditions. ZARC05 Connector plug female with cable 1.5 m (4.92 ft) for ZARB•H ZARC06 Cable gland kit with wire grommets ZARC09 Kit silent bloc: Use this accessory in case of applications with severe vibration constraints.
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Harmony eXLhoist EIO0000001505 04/2014 Chapter 2 Specifications Specifications What Is in This Chapter? This chapter contains the following sections: Section Topic Page 2.1 Base Station Specifications 36 2.2 Remote Device Specifications 46 2.
Section 2.
Base Station Specifications Environment The Base Station specifications are described in the table: Specifications Details Product certifications - Value ZARB•H ZARB•W CE, UL/CSA, CCC, Gost Environment - RoHS compliant Life time - 10 years Degree of protection - IP65 Degree of pollution - 3 Operating temperature For 24…48 V ac/dc power supply -25…70 ° C (-13…158 ° F) For 48…130 V ac/dc power supply - -25…70 ° C (-13…158 ° F) For 130…240 V ac/dc power supply - -25…50 ° C (-13…122 °
Specifications Details Value Resistance to radiated fields IEC 61000-4-3 10 V/m Immunity to fast transient IEC 61000-4-4 Power line: 4 kV (direct) Outputs: 4 kV (direct) Inputs: 2 kV (coupling) Surge immunity 2 kV IEC 61000-4-5 between the ground and power supply wires (Common mode) ZARB•H ZARB•W IEC 61000-4-5 between the power supply wires (Differential mode) 1 kV Immunity to conducted magnetic fields Conforming to IEC-61000-4-6 10 V from 150 kHz to 80 MHz Emission disturbances Conducted
Safety Relays The safety relays specifications are described in the table: Specifications Details Value Number of contacts The Base Station internally implements 2 safety relays in serial. Each safety relay has 2 contacts. Logical type - NO Insulation between Q0A and Q0B - SELV insulation between (Q0A1, Q0A2) and (Q0B1, Q0B2) for voltage up to 240 Vac Q0A voltages - Q0B voltages - Q0A, Q0B Maximum Ie current 24...
Safety relays internal wiring: 1 2 Safety relay 1 Safety relay 2 Motion/Auxiliary Relays The motion/auxiliary relay specifications are described in the table: Specifications Details Value Number of motion/auxiliary relays - 12 18 Normally open (N0) relays - 12 (Q1…Q12) 16 (Q1…Q16) Normally open + normally closed (N0+NC) relays - 0 2 (Q17, Q18) Nominal output voltage - Relay type according to EN/IEC 60947-5-1 AC15 DC13 R300 Maximum making and breaking capacities 1 000 000 cycles for NO
Specifications Details Maximum operating rate - Weight - Value ZARB12H ZARB12W ZARB18H ZARB18W 2 Hz 1340 kg (2954 lb.) 1360 kg (3644 lb.) 1430 kg (3831 lb.) 1450 kg (3885 lb.) Power Supply NOTICE INOPERABLE EQUIPMENT The ZARB•H Base Station must be powered with a voltage: From 24 Vac -15% to 48 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%. From 24 Vdc -15% to 48 Vdc +20%.
IN0 The IN0 input specifications are: Static input type Current source logic Compatible only with 2 wiring: Connection of IN0 to one side to the auxiliary contact of the main contactor and connection of S2_S3 output port to the other side of the auxiliary contact of the main contactor. Direct connection to the S2_S3 output.
RADIO Specification RADIO Specification Specification Details Value Frequency of radio communication International frequency range 2.
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
Conformément à la réglementation d’Industrie Canada, les présents émetteurs radio peuvent fonctionner avec une antenne d’un type et d’un gain maximal (ou inférieur) approuvé pour l’émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à l’intention des autres utilisateurs, il faut choisir le type d’antenne et son gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.
Section 2.
Remote Device Specifications Environment Specification Details Value Product certifications - CE, UL/CSA, CCC, Gost Safety certification - TÜV, UL safety Battery life time Conforming to IEC-62133 > 2 years Battery type - LiFePO4 3.
Remote Device Charger Specification Environment 48 Specification Value Location to be used Residential, commercial, and light-industrial environment (IEC 61000-6-3) Product certifications CE, UL/CSA, CCC, Gost Degree of protection IP2x Degree of pollution 2 Operating temperature 10…40 ° C (50…104 ° F) Storage temperature (for 1 year) -20…60 ° C (-4…140 ° F) Primary supply voltage 240 Vac +/-20% 110 Vac +/-20% Secondary output voltage 12 V, SELV voltage Secondary output power 30 W minimu
Section 2.
Base Station Dimensions Dimensions The following figure shows the Base Station dimensions: 50 EIO0000001505 04/2014
Remote Device Dimensions Dimensions The following figure shows the Remote Device dimensions: EIO0000001505 04/2014 51
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Harmony eXLhoist Safety EIO0000001505 04/2014 Chapter 3 Safety Safety What Is in This Chapter? This chapter contains the following sections: Section Topic Page 3.1 Generalities 54 3.2 Description and Safety Function Capability 61 3.3 Functional Safety Function Commissioning 73 3.
Safety Section 3.
Safety Introduction Overview The safety functions incorporated in eXLhoist allow you to develop applications oriented towards protection of people and machinery. Some safety functions are configured with eXLhoist Configuration Software.
Safety Standards and Terminology Overview The technical terms, terminology, and the corresponding descriptions in this manual normally use the terms or definitions in the relevant standards. In the field of Wireless Remote Control System, this includes, but is not limited to, terms such as safety function, safe state, fault, fault reset, failure, error, error message, warning, warning message, and so on. These standards include: IEC 61508 Ed.
Safety Basics Functional Safety Automation and safety engineering are 2 areas that were separate in the past but have recently become more and more integrated. The engineering and installation of complex automation solutions are greatly simplified by integrated safety functions. Usually, the safety engineering requirements depend on the application. The level of requirement results from the risk and the hazard potential arising from the specific application.
Safety Safety standards: SIL - Safety Integrity Level The standard IEC 61508 defines 4 Safety Integrity Levels (SIL) for safety functions. SIL1 is the lowest level and SIL4 is the highest level. A hazard and risk analysis serves as a basis for determining the required SIL. This is used to decide whether the relevant function chain is to be considered as a safety function and which hazard potential it must cover.
Safety The Probability of Failure on Demand (PFD) of low demand operation for different SILs are defined in IEC 61508 are as follows: SIL Average Probability of a Dangerous Failure on Demand of the safety function PFD SIL4 < 10-4 SIL3 ≥ 10-4 to < 10-3 SIL2 ≥ 10-3 to < 10-2 SIL1 ≥ 10-2 to < 10-1 In continuous operation, these changes to the following: SIL Average Frequency of a Dangerous Failure on Demand of the safety function (h-1) PFH SIL4 ≥ 10-9 to < 10-8 SIL3 ≥ 10-8 to < 10-7 SIL2 ≥ 10
Safety PL Probability of a Dangerous Hardware Failure Per Hour b ≥ 3*10-6 to < 10-5 a ≥ 10-5 to < 10-4 HFT - Hardware Fault Tolerance and SFF - Safe Failure Fraction Depending on the SIL for the safety system, the IEC 61508 standard requires a specific HFT in connection with a specific proportion of safe failures SFF. The HFT is the ability of a system to execute the required safety function in spite of the presence of one or more hardware faults.
Safety Section 3.
Safety Wireless Remote Control System Safety Functions Are Part of an Overall System Overview The qualitative and quantitative safety objectives determined by the final application require some adjustments to ensure safe use of the safety functions. The integrator of the Wireless Remote Control System is responsible for these additional changes (for example, managing the mechanical brake on the motor).
Safety Getting and Operating the Safety Function Overview The SISTEMA software allows machine developers and testers of safety-related machine controls to evaluate the safety standard or level of their machine in the context of ISO 13849-1. The tool allows you to model the structure of safety-related control components based on the designated architectures, allowing automated calculation of the reliability standards with various levels of detail, including that of the Performance Level (PL).
Safety E-STOP Overview For general descriptions, refer to E-STOP function (see page 121). The E-STOP is not configurable. The undesired event of the E-STOP function is masking of E-STOP activation. The safe state of the E-STOP function is to open safety relays.
Safety STOP Function Overview For general descriptions, refer to STOP function (see page 123). The undesired event of the STOP function is masking of STOP activation. The safe state of the STOP function is to open safety relays.
Safety Standard Motion & Auxiliary Functions Overview For general descriptions, refer to Standard Motion (see page 131) and Auxiliary functions (see page 133). A relay assignment can be done for the Remote Device motion buttons with the eXLhoist Configuration Software. An UOC relay (see page 105) can be associated to a motion axis (and its motion relays) thanks to the eXLhoist Configuration Software.
Safety Safeguarding Overview For general description, refer to Safeguarding function (see page 107). Safeguarding can be assigned to a motion direction thanks to the eXLhoist Configuration Software. The undesired event of Safeguarding function is the no disabling of motion buttons. Safeguarding limit switches contacts must be NC contacts. The safe state of the Safeguarding function is to open safety relays.
Safety Priority of Safety Functions Overview 68 Priority of safety functions Safety functions 1 E-STOP 2 STOP 3 Safeguarding 4 Standard motion & auxiliary functions EIO0000001505 04/2014
Safety Safe State of the Wireless Remote Control System Overview Safe states of the Base Station are: SAFE-STOP failure: if a failure is detected by the Base Station, the Base Station opens safety relays with a stop category 0 and stops the radio communication with the Remote Device. SAFE-STOP radio: if the Base Station looses the communication with the Remote Device, the Base Station opens the safety relays in stop category 0 or stop category 1 according to the commissioning.
Safety Response Time and Process Safety Time (PST) Overview The maximum Process Safety Time (PST) of STOP function is 550 ms according to IEC 60204-32 Ed.2 §9.2.7.3. This PST of 550 ms is taken into account for all safety functions. The PST allocation is: So 250 ms are allocated for contactors / drives of the hoisting system. The rest (300 ms) is allocated for Wireless Remote Control System.
Safety Legal RFU (Recommendation for Use) Overview According to the machinery directive 2006/42/EC and the amendment - RECOMMENDATION FOR USE n° CNB/M/11.
Safety Summary of the Reliability Study Synthesis of Reliability Study in Configuration 1 Remote Device & 1 Base Station Standard IEC 61508 Ed 2 Safety features SFF per channel -9 -1 PFH (10 h ) E-STOP STOP With auxiliary contact Without UOC UOC 97.8 % 85 % 84.8 % 7.32 7.54 7.57 Type Limit switch Without UOC NC contact UOC 90.1 % 52.3 95 % 51.8 1 91.4 % 0 41.7 % 41.8 % 73.
Safety Section 3.
Safety Safety Parameters and Steps to Configure the Safety Functions Commissioning of Safety Functions The commissioning type of safety function is: Functions UOC delay time Relay assignment Remarks E-STOP - - No commissioning STOP Yes - Safety relays cannot be commissioned Motion & auxiliary functions Yes Yes - Safeguarding - Yes - Some passwords/codes can be configured on the eXLhoist Configuration Software: E-STOP code sequence on the Remote Device Start code sequence on the Remote
Safety Machine Signature Overview The acceptance test for systems with safety integrated functions focuses on validating the functionality of safety integrated monitoring and stop functions configured in the Wireless Remote Control System. The purpose of the test is to verify proper configuration of the defined safety functions and test mechanisms and to examine the response of dedicated monitoring functions to explicit input of values outside the tolerance limits.
Safety Step Action Comment 6 Test the system according to the acceptance test Notify the result of the test in the acceptance result. The acceptance test list becomes the acceptance result once it fulfills with test results. 7 Print, save, and sign the acceptance report. - Acceptance Report eXLhoist Configuration Software and Microsoft® Excel are required to create the acceptance report. The acceptance report is the safety signature of the Wireless Remote Control System.
Safety Section 3.
Safety Maintenance E-STOP By way of preventive maintenance and according to the Recommendation For Use (see page 71), the E-STOP and the STOP function must be activated at least once a month. The Remote Device and the Base Station must be turned off and then on again before carrying out this preventive maintenance.
Safety Base Station or Remote Device Replacement Overview You can replace the Base Station part and the Remote Device part. If you replace the Base Station or the Remote Device configured in Single, you will not lose your safety configuration thanks to the maintenance / device replacement procedure but you need to repeat the acceptance test to avoid incorrect wiring or incorrect behavior of the safety function.
Safety Changing Machine Equipment Overview If you need to change any part of the hoisting system (contactor, drive, …) you must repeat the acceptance test. NOTE: For more product information, see the installation part (see page 81).
Harmony eXLhoist Installation and Wiring EIO0000001505 04/2014 Chapter 4 Installation and Wiring Installation and Wiring What Is in This Chapter? This chapter contains the following sections: Section Topic Page 4.1 Base Station Installation 82 4.2 Base Station Wiring 86 4.3 Functionalities Description 98 4.
Installation and Wiring Section 4.1 Base Station Installation Base Station Installation Base Station Installation Precaution Installation Precaution Example of a recommended Base Station location: Base Station location: The Base Station must be installed vertical, with the cable at the bottom.
Installation and Wiring Consider the wiring limitation and the radio communication limitation to choose the Base Station location. Do not create obstacle between the Base Station and the Remote Device to optimize the radio communication level. The Base Station must not be installed inside closed metal containers. To prevent communication perturbation: Do not place cables or metallic parts in front of the Base Station cover. Do not place obstacles between the Base Station and the Remote Device.
Installation and Wiring WARNING UNINTENDED EQUIPMENT OPERATION Use appropriate safety interlocks where personnel and/or equipment hazards exist. Use the sensor and actuator power supplies only for supplying power to the sensors or actuators connected to the device. Power line must be wired and protected with fuse or thermal magnetic switch (ex: SchneiderElectric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment.
Installation and Wiring Step Action 3 Introduce the 4 screws in the dedicated holes (legend G): 4 Screw the 4 mounting screws. 5 Install the Base Station cover. 6 Screw the 4 screws to fasten the Base Station cover. Use the ZARC09 silent blocs in case of applications with severe vibration constraints.
Installation and Wiring Section 4.
Installation and Wiring Base Station Wiring ZARB•W Wiring procedure: Step Action 1 Unscrew the 4 screws at the bottom of the Base Station. 2 Remove the cover and insert a cable gland. 3 Remove the caps. 4 Introduce the cable through the Base Station dedicated hole. 5 Connect the wires in the dedicated connectors. 6 Screw the cable gland. 7 Install the Base Station cover. 8 Screw the 4 screws to fasten the Base Station cover.
Installation and Wiring ZARB•H The input/output are wired to the connector (except the safeguarding inputs). To connect the Base Station, respect the connector description: If the ZARC03 external antenna is used, refer to the dedicated Instruction Sheet (see page 9). Safeguarding Inputs Safeguarding inputs wiring procedure: Step Action 1 Unscrew the 4 screws at the bottom of the Base Station. 2 Remove the cover and insert a cable gland. 3 Remove the caps of cable gland.
Installation and Wiring Input/Output Possible uses (Depending of the configuration) Q10…Q16 (NO type) Q17, Q18 (NO+NC type) Auxiliary relays (see page 99) Selector (see page 102) UOC (see page 105) Specific relays (see page 109) Power Supply NOTICE INOPERABLE EQUIPMENT The ZARB•H Base Station must be powered with a voltage: From 24 Vac -15% to 48 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%. From 24 Vdc -15% to 48 Vdc +20%.
Installation and Wiring General Wiring Rules The I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2). The I/O and power supply cable lengths should not exceed 20 m (65.6 ft). For more details, refer to Wiring Best Practices (see page 91).
Installation and Wiring Wiring Best Practices Overview This section describes the wiring guidelines and associated best practices to be respected when using the system.
Installation and Wiring Protective Ground (PE) on the Backplane The protective ground (PE) is connected to the conductive backplane by a heavy-duty wire, usually a braided copper cable with the maximum allowable cable section. WARNING IMPROPER GROUNDING CAN CAUSE UNINTENDED EQUIPMENT OPERATION Use cables with insulated shielded jackets for I/O signals. Ground shielded cables for I/O signals at a single point 1. Always comply with local wiring requirements regarding grounding of cable shields.
Installation and Wiring WARNING UNINTENDED EQUIPMENT OPERATION Power line must be wired and protected with fuse or thermal magnetic switch (ex: SchneiderElectric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment. Failure to follow these instructions can result in death, serious injury, or equipment damage. Rules for Screw Terminal Block The following tables show the cable types and wire sizes for a 5.
Installation and Wiring Factory Setting Description General Parameters General Label Parameter Start access sequence (see page 192) Enable: 5, 6, 5, 6 E-STOP RESET sequence (see page 192) Disable Protection Factory setting value Standby Time-out (see page 193) 15 minutes Power saving Time-out (see page 193) 15 minutes Horn duration (see page 193) 2 seconds Configuration File Transfer Password (see page 183) Enable: 5, 6, 5, 6 Detected Applicative Alarms Base Station wiring: Label Wiring d
Installation and Wiring Label Wiring description Factory setting description IN15 Limit switch input (for button 5) When IN15 is activated, the relay 7 is OFF IN16 Limit switch input (for button 5 +7) When IN16 is activated, the relays 7 and 9 are OFF IN17 Limit switch input (for button 6) When IN17 is ON, the relay 8 is OFF IN18 Limit switch input (for button 6 +7) When IN18 is ON, the relays 8 and 9 are OFF IN_COM Common output port (to be connected to the other side of the dry contact co
Installation and Wiring Auxiliary Relays Base Station wiring: General Label Auxiliary relay 10 CC_10 CT_10 Auxiliary relay 11 CC_11 CT_11 Auxiliary relay 12 CC_12 CT_12 Auxiliary relay 13 CC_13 CT_13 Auxiliary relay 14 CC_14 CT_14 Auxiliary relay 15 CC_15 CT_15 Auxiliary relay 16 CC_16 CT_16 Auxiliary relay 17 CC_17 Wiring description Factory setting description Common Selector Relay 10 is ON when the Selector (button 10) is in position 1 or 1+2 Relay 11 is ON when the Selector (button 10) is in po
Installation and Wiring Remote Device: References ZART8L ZART8D ZARB12• Number of buttons 11 (8 configurable) 11 (8 configurable) 15 (12 configurable) Power Supply and PE Base Station wiring: Label Wiring description Factory setting description PE Protected earth ground - AC_Neutral /- Base Station power supply - AC_Phase /+ Safety Base Station wiring: Label Wiring description Factory setting description Q0A_1 Safety relay 1 - Q0A_2 Q0B_1 Safety relay 2 Q0B_2 IN0 Safety loop - S
Installation and Wiring Section 4.
Installation and Wiring Motion/Auxiliary Relays Description The motion/auxiliary relays are switched ON as long as the associated button is pressed. Only up to 6 motion/auxiliary relays activation occurs at the same time. If more than 6 motion/auxiliary relays switching are requested at the same time, then they are actuated in successive switching every 20 ms (except for UOC relays). You can configure the motion/auxiliary relays with the eXLhoist Configuration Software (see page 194).
Installation and Wiring Q10…Q16 motion/auxiliary relay wiring (NO type only) Q17, Q18 auxiliary relay wiring (NO+NC type) WARNING UNINTENDED EQUIPMENT OPERATION Power line must be wired and protected with fuse or thermal magnetic switch (ex: SchneiderElectric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Installation and Wiring Auxiliary Wiring The auxiliary buttons can be used, for example, to manage a: Vacuum/magnetic function (see page 221) Room lighting function (see page 224) Selector switch function (see page 102) Supplementary motion The motion/auxiliary relays output cable length should not exceed 20 m (65.6 ft). Factory Setting For details on factory setting (wiring and configuration), refer to factory setting description (see page 94).
Installation and Wiring Selector Description In SINGLE configuration, the Selector button is associated to 2 relays. With an adapted wiring, these relays enable/disable the motions of the selected device (hook/trolleys). In TANDEM configuration, no relays are associated with the selector button. The button is used to select directly which Base Station are piloted. You can configure the selector with the eXLhoist Configuration Software (see page 194).
Installation and Wiring Detected Applicative Alarm Overview The ZARB18• Base Station implements 6 inputs: IN1…IN6. Different sensors can be connected to these inputs. These inputs are dedicated for applicative alarms. Description The detected applicative alarms are only displayed on the ZART•D Remote Device.
Installation and Wiring Wiring Wiring diagram for the detected applicative alarm devices: 1-6 Detected applicative alarm sensors 104 EIO0000001505 04/2014
Installation and Wiring Unintended Operating Control (UOC) Function Overview The Base Station can manage 3 UOC functions. These relays have temporization that shall correspond to the decelerating time ramp of the drive. After this time, the UOC relay will switch OFF to enable the Safe Torque Off (STO according to EN IEC 61500-5-2) input on the drive. The UOC function allows the Wireless Remote Control System to get a STOP category 1 according to EN60204.
Installation and Wiring General Wiring Rules The I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2). The I/O and power supply cable lengths should not exceed 20 m (65.6 ft). For more details, refer to Wiring Best Practices (see page 91). Wiring Depending on the DRIVE functionality and its application schematic, the UOC relay can be directly connected to the DRIVE Safe Torque Off (STO according to EN/IEC 61500-5-2) input or in serial with a contactor coil.
Installation and Wiring Safeguarding Function Overview The ZARB18• Base Station implement 12 inputs IN7…IN18. These inputs are dedicated for limit switches to provide a protection to the hoist system. Description There are 4 limit switches per axis that allow to: Stop the motion at minimum mechanical position. Disable the high speed of the direction when the hoist system is near the minimum position. Stop the motion at maximum mechanical position.
Installation and Wiring Wiring Wiring diagram for the detected safeguarding devices: 1-6 Limit switches Factory Setting For details on factory setting (wiring and configuration), refer to factory setting description (see page 94).
Installation and Wiring Special Functions Description The Wireless Remote Control System manages 4 specific relays: Relay Description Horn This relay is switched ON during the start procedure, and for a configurable duration. This relay is also switched ON, in START mode, as long as the ON/START/Horn is pressed. Radio link This relay is switched ON as long as a RADIO communication is achieved between the Base Station and its Remote Device.
Installation and Wiring General Wiring Rules The I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2). The I/O and power supply cable lengths should not exceed 20 m (65.6 ft). For more details, refer to Wiring Best Practices (see page 91). Factory Setting For details on factory setting (wiring and configuration), refer to factory setting description (see page 94).
Installation and Wiring Safety Relay IN0 Safety Loop Input The IN0 input is dedicated to check the correct actuator functionality with the auxiliary contact state. The E-STOP function can reach up to SIL 3 level only if all the relevant auxiliary contacts are connected between the IN0 input and the S2_S3 port terminal. The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).
Installation and Wiring Section 4.
Installation and Wiring Customize The Remote Device Overview The Wireless Remote Control System is delivered with a factory configuration. Use the label set to customize the remote buttons in accordance with the motion/auxiliary configuration. For details on factory setting (wiring and configuration), refer to factory setting description (see page 94). You can also stick an empty label above the top side of the Remote Device, and write on it the label of the hoisting system driven by it.
Installation and Wiring First Commissioning Overview The following procedures describe the first commissioning of a Wireless Remote Control System from a pack (Base Station + Remote Device). The installation must be in accordance to the factory setting (see page 94). In other case, refer to eXLhoist Configuration Software (see page 201) and the Discovery procedure description (see page 137).
Installation and Wiring Step 5 Action Press only the ON/START/Horn button more or equal than 1 s. Result: The Remote Device displays the ID list of detected Base Station: 6 Selects the ID of the new Base Station with buttons 5 and 6. 7 Press the button 7 (trigger) to validate. Result: 8 Select the validation cell (check symbol) with buttons 1 and 2.
Installation and Wiring Step 9 Action Press the button 7 (trigger) to validate. Result: The Remote Device proposes to load the Configuration File from the Base Station to the Remote Device. 10 Select the validation cell (check symbol) with buttons 1 and 2. 11 Press the button 7 (trigger) to validate. Result: The Remote Device loads the Configuration File from the Base Station to the Remote Device. 12 Wait for the end of the Configuration File load.
Harmony eXLhoist Using The Wireless Remote Control System EIO0000001505 04/2014 Chapter 5 Using The Wireless Remote Control System Using The Wireless Remote Control System What Is in This Chapter? This chapter contains the following sections: Section Topic Page 5.1 Basic Uses 118 5.2 Functionalities 130 5.3 Discovering 137 5.4 How to Modify the Configuration 140 5.
Using The Wireless Remote Control System Section 5.
Using The Wireless Remote Control System Main Modes Diagram Main Modes Diagram The following diagram presents the main modes of the Wireless Remote Control System: EIO0000001505 04/2014 119
Using The Wireless Remote Control System Power ON Overview The aim is to describe how to power ON the Wireless Remote Control System. Triggering Procedure Step Action 1 Check that the Remote Device is powered OFF. 2 Power ON the Base Station. 3 Press only the ON/START/Horn button more or equal than 1 s. Result: The Remote Device is powered ON. The discovery procedure is automatically launched.
Using The Wireless Remote Control System E-STOP Overview The E-STOP function leads to go to the safe position of the Wireless Remote Control System when the operator presses the E-STOP red mushroom button. In E-STOP mode, the motion/auxiliary relays and the safety relays are OFF. NOTE: The Remote Device cannot go to the E-STOP mode while the E-STOP function is not operational (E-STOP LED is OFF). Triggering Procedure Step Action 1 Press the E-STOP button.
Using The Wireless Remote Control System Release Release procedure: Step Action 1 Verify that there is no more risk conditions. 2 Release the E-STOP button. 3 If an E-STOP restart code sequence is configured: Type the E-STOP restart code sequence with the motion buttons 1…6. Press the button 7 (trigger). Result: The Wireless Remote Control System is in STOP mode (see page 123).
Using The Wireless Remote Control System STOP Overview In STOP mode, the motion/auxiliary relays are disabled and the safety relays are OFF. Triggering Procedure The STOP mode is reached in the following cases: The OFF/STOP button is pressed (the Wireless Remote Control System was previously in START mode). No button pressed for more than the configured time-out (Standby time-out) configured in eXLhoist Configuration Software (see page 191). Wireless connection lost (out of range for example).
Using The Wireless Remote Control System The Base Station execute the following steps: 1 The motion/auxiliary relays are OFF. 2 If configured, the UOC relays are OFF after a pre-configured time delay. 3 The safety relays are OFF. Base Station: Element Description Relays LEDs The STATUS LED is blinking. The POWER LED is ON. The COM LED is blinking. The safety relays are OFF. The motion/auxiliary relays are OFF. The “Radio link” relay is ON. The “Safety relay image” relay is ON.
Using The Wireless Remote Control System START Overview The START mode is the only mode in which: You can command the motions (see page 131). You can command the auxiliary function (see page 133). You can command the horn (see page 136). The safety relays are switched ON. Triggering Procedure Required conditions: The Wireless Remote Control System must be in STOP mode.
Using The Wireless Remote Control System Beacon description in the operating modes: (example with ZART•D) Step Before Power ON Hoisting system signaling ZART•D - STOP mode The motions are not enabled yet. Between STOP mode and START mode: The ZART•D vibrate facility is activated. The Horn sounds for the configured time. The motions are not enabled yet. START mode The motions are enabled.
Using The Wireless Remote Control System Wireless Remote Control System In START Mode Remote Device: Reference Description ZART8L The START LED is ON. The E-STOP LED is ON. ZART•D The START mode symbol is displayed. The E-STOP LED is ON. Base Station: Element Description Relays LEDs The STATUS LED is blinking. The POWER LED is ON. The COM LED is blinking. The safety relays are ON. The motion/auxiliary relays are enabled. The “Radio link” relay is ON.
Using The Wireless Remote Control System Power OFF Overview This function switches OFF the Remote Device. Triggering Procedure Required conditions: The Wireless Remote Control System must be in STOP mode. The "Power OFF function" is triggered in the following cases: The OFF/STOP button is pressed. No button pressed for more than the configured time-out: Auto Standby + Auto-OFF duration time. The Remote Device battery level is low.
Using The Wireless Remote Control System Base Station: Element Description Relays LEDs The STATUS LED is OFF. The POWER LED is ON. The COM LED is OFF. The safety relays are OFF. The motion/auxiliary relays are OFF. The “Radio link” relay is OFF. The “Safety relay image” relay is OFF. Release From this mode, you can: Power ON the Remote Device (see page 120). Charge the Remote Device battery (see page 143).
Using The Wireless Remote Control System Section 5.
Using The Wireless Remote Control System Standard Motion Overview In START mode, the motion buttons activate the associated motion relays that command the hoisting system movements. Triggering Procedure Required conditions: The Wireless Remote Control System must be in START mode (see page 125). Triggering procedure: Step Action 1 Check that the Wireless Remote Control System is in START mode. 2 Press a motion button 1, 1H, 2, 2H, 3, 3H, 4, 4H, 5, 5+7, 6, 6+7 (see page 24).
Using The Wireless Remote Control System Specifics Information In the eXLhoist Configuration Software, you can configure: Motion/auxiliary buttons associated to relays (see page 194). Motion/auxiliary buttons interlocking (see page 198).
Using The Wireless Remote Control System Auxiliary Function Overview In START mode, the auxiliary buttons activate the associated relays to command auxiliary action (for example to command open and close grab). Triggering Procedure Required conditions: The Wireless Remote Control System must be in START mode (see page 125). Triggering procedure: Step Action 1 Check that the Wireless Remote Control System is in START mode.
Using The Wireless Remote Control System Selector Description There are 3 different configurations to use the selector auxiliary button: Bridge selector (3 positions) in TANDEM configuration: to manage 2 bridges by using 2 Base stations. Trolley selector (2 or 3 positions): to manage 2 trolleys with one Base Station. Hook selector (2 positions): to manage 2 hooks with one Base Station. Triggering Procedure Required conditions: The Wireless Remote Control System must be in STOP mode (see page 123).
Using The Wireless Remote Control System In TANDEM configuration, the “Radio link” relay of the selected Base Station switches ON: Relay RADIO link Selector position 1 Bridge 1 Bridge 2 Selector position 1+2 Bridge 1 Bridge 2 Selector position 2 Bridge 1 Bridge 2 Specifics Information At the first Power ON, the Selector position is 1. For further Power ON, the Selector position is the last known Selector position. You can configure the Selector in the eXLhoist Configuration Software (see page 194).
Using The Wireless Remote Control System Horn Overview From STOP mode to START mode, the “Horn” relay is switched ON for a predefined duration time. In START mode, as long as you press the ON/START/Horn button, the “Horn” relay is switched ON. Triggering Procedure Triggering procedure: Step Action 1 Check that the Wireless Remote Control System is in START mode. 2 Press the ON/START/Horn button. Result: The “Horn” relay is switched ON as long as the ON/START/Horn button is pressed.
Using The Wireless Remote Control System Section 5.3 Discovering Discovering Discovering Overview The discovering function is developed to be as automatic as possible. This function manages 2 different tasks: The pairing of the system: association between a Remote Device and a Base Station The Configuration File Upload/Download: this file contains the Wireless Remote Control System configuration information. This function is launched at each Remote Device Power ON.
Using The Wireless Remote Control System Discovering Diagram The following diagram presents the detailed Discovering function: Pairing The pairing is the action to associate a Base Station with a Remote Device. Each Base Station have a unique ID. The pairing test is launched at each Remote Device power ON. As long as the pairing test is OK, the validation procedure is not requested to the operator.
Using The Wireless Remote Control System Configuration File The Configuration File is stored in the Remote Device and in the Base Station. The Configuration File can be created or modified in the eXLhoist Configuration Software (see page 161).
Using The Wireless Remote Control System Section 5.4 How to Modify the Configuration How to Modify the Configuration How to Modify a Configuration Configuration Modification The following procedure describes how to modify the system configuration: Step Action 1 Connect the Remote Device to a PC (see page 165). 2 Start the eXLhoist Configuration Software (see page 178). 3 Create a project (see page 179).
Using The Wireless Remote Control System Configuration File load With a ZART•D After the modification of the configuration with the eXLhoist Configuration Software: Step Action 1 Power ON the Remote Device. Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device. 2 Select the cancel cell (X) with buttons 1 and 2. 3 Press the button 7 (trigger) to validate.
Using The Wireless Remote Control System Step 5 Action If the Configuration File has a transfer password, a padlock is displayed: Enter the Configuration File transfer code with the buttons 1 to 6. The default transfer password is 5, 6, 5, 6. 6 Press the button 7 (trigger) to validate. Result: The Remote Device loads the Configuration File from the Remote Device to the Base Station. 7 Wait for the end of the Configuration File load. Result: The Remote Device goes to STOP mode (see page 123).
Using The Wireless Remote Control System Section 5.5 Remote Device Charge Remote Device Charge Remote Device Charge Required Conditions The Remote Device must only be charged indoor with the ZARC01 charger. The Remote Device must be in STOP mode or Power OFF. The Remote Device temperature range must be 10…60 ° C (50…140 ° F) in case of battery charge. NOTE: At the first commissioning, you must charge the Remote Device for 30 minutes.
Using The Wireless Remote Control System Procedure Step Action 1 Power OFF the Remote Device. 2 On the bottom of the Remote Device, remove the protective cap. 1 2 144 Remote Device battery charge connector Protective cap 3 Connect the charger to the Remote Device battery charge connector. 4 Plug the charger to the dedicated power source.
Using The Wireless Remote Control System Step Action 5 Wait for around 15 minutes. During the charge: ZART8L: the battery LED is flashing. ZART•D: the blinking battery symbol indicates the battery level: The battery is fully charged when: ZART8L: the battery LED is permanently ON. ZART•D: the battery symbol is permanently displayed. For more details, refer to Diagnostic (see page 153). NOTE: The time duration for charge or the Remote Device depends on the ambient temperature.
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Harmony eXLhoist Diagnostic EIO0000001505 04/2014 Chapter 6 Diagnostic Diagnostic What Is in This Chapter? This chapter contains the following sections: Section Topic Page 6.1 Base Station Diagnostic 148 6.2 ZART•D Diagnostic 149 6.
Diagnostic Section 6.1 Base Station Diagnostic Base Station Diagnostic Diagnostic Description The Base Station have 3 LED indicators: LED Color State Description STATUS Green Blinking The Wireless Remote Control System is working properly. OFF Base Station Power OFF or internal fault detected. OFF No communication between the Base Station and the Remote Device. Blinking The communication is established between the Base Station and the Remote Device. OFF Base Station powered OFF.
Diagnostic Section 6.
Diagnostic Diagnostic Mode Overview To test the Wireless Remote Control System configuration, the ZART•D has a specific diagnostic mode display. Procedure to Activate the Diagnostic Mode The diagnostic mode on the ZART•D indicates the inputs and relays states of the Base Station. Step Action 1 Go to STOP mode (see page 123). 2 Simultaneously press the buttons 1 and 2, and release immediately. 3 Less than 5 seconds later, simultaneously press the buttons 3 and 4. 4 Release the buttons 3 and 4.
Diagnostic Procedure to Leave the Diagnostic Mode Step Action 1 Power OFF the Remote Device EIO0000001505 04/2014 151
Diagnostic Radio Communication Indicator ZART•D Display ZART•D radio communication level with the Base Station High Medium Low No radio communication 152 EIO0000001505 04/2014
Diagnostic Battery Level of the Remote Device ZART•D Display Description Battery charge level is high Battery charge level is medium Battery charge level is low This display occurs at least 10 minutes before the Remote Device cannot properly work. In addition, the Remote Device vibrate facility is activated for 1 second.
Diagnostic E-STOP LED Description E-STOP LED 154 Description Permanently ON E-STOP is operational and not triggered. Blinking at a frequency of 1 Hz. E-STOP is operational and triggered. Permanently OFF E-STOP is not operational.
Diagnostic Applicative Alarms Signals Overview Some devices can be connected to the ZARB18• Base Station to provide detected applicative alarms signals that can be displayed in the ZART•D. ZART•D When applicative alarms signals come from ZARB18• Base Station, the ZART•D Remote Device involves a symbol display and 3 seconds of vibration every 10 minutes as long as the alarm signal is active.
Diagnostic Detected Failure Displays ZART•D The ZART•D Remote Device can display the following symbols: Display 156 Status Description Blinking Configuration File download failure detected Blinking Configuration File upload failure detected Blinking Remote Device failure detected Blinking Remote Device battery charge failure detected EIO0000001505 04/2014
Diagnostic Section 6.3 ZART8L Diagnostic ZART8L Diagnostic ZART8L LED Diagnostic Overview This section describes the ZART8L Display LEDs (see page 28).
Diagnostic Label Status A OFF B ON C Normal blink D Fast blink E Flash step 1 F Flash step 2 G Reverse flash step 1 Start LED Label Status Description B ON The system is in START mode with radio operational C Normal blink Radio not established or START mode not yet confirmed F Reverse flash step 1 A password has not yet been provided & validated (either for before START, or after unlocking the E-Stop before START) D Fast blink Wrong Configuration File E Flash step 1 The Rem
Diagnostic Charger ZARC01 connected Once the Remote Device is connected to the battery charger, the battery LED flashes 3 times (E label = FLASH_STEP_1).
Diagnostic Configuration file download: During the transfer of a Configuration File (from the Remote Device to the Base Station): The START LED is in status E = Flash step 1 The “2” LED is in status F = Flash step 2 Remote device reset: When you press the reset button : until the “1” and “2” LED comes in the following status: The “1” LED is in status E = Flash step 1 The “2” LED is in status A = OFF E-STOP LED Label 160 Status Description B ON E-STOP is operational and not triggered.
Harmony eXLhoist eXLhoist Configuration Software EIO0000001505 04/2014 Chapter 7 eXLhoist Configuration Software eXLhoist Configuration Software What Is in This Chapter? This chapter contains the following sections: Section Topic Page 7.1 Introduction to eXLhoist Configuration Software 162 7.2 User Interface 168 7.3 Project Management 175 7.
eXLhoist Configuration Software Section 7.
eXLhoist Configuration Software What is eXLhoist Configuration Software? Introduction eXLhoist Configuration Software is a graphic user interface allowing you to manage the configuration of the Wireless Remote Control System.
eXLhoist Configuration Software Conventions The following typographic conventions are used in this operation guide. 164 Format Represents Bold For user input, enter words or phrases shown in bold as they appear. Menu names and options, commands and toolbar names, and dialog box names and options are also shown in bold type. UPPER CASE Keyboard names, combinations, and sequences are shown in all uppercase letters. For example, the keyboard shortcut for creating a new application is CTRL+N.
eXLhoist Configuration Software Connect a Remote Device to the PC Introduction The connection is made using the RJ45 to USB converter cable. It is recommended to Power OFF the Remote Device before connecting it to the PC Description The figure illustrates the connection to a personal computer: 1 2 3 Personal computer USB to RJ45 converter cable: TCSMCNAM3M002P Remote Device NOTICE INOPERABLE EQUIPMENT Always connect the communication cable to the PC before connecting it to the device.
eXLhoist Configuration Software As long as the Remote Device is connected to the PC: ZART•D: a dedicated screen is displayed ZAR8L: The Start LED is flashing.
eXLhoist Configuration Software Installation Introduction The software can be downloaded from www.schneider-electric.com. It must be installed via an administrator account. Prerequisites eXLhoist Configuration Software requires the following minimal configuration: Dual core processor RAM: 2 GB Required disk space: 2 GB Windows® XP SP3 32 bits / 7 Pro 32 bits Installation Process To install eXLhoist Configuration Software, follow the steps below: Step 1 Action Double-click the program file (setup.
eXLhoist Configuration Software Section 7.
eXLhoist Configuration Software Starting Screen Introduction The eXLhoist Configuration Software starting window is displayed at software launching. It provides easy access to the main functions: Create a new project. Open an existing project. Connect a Remote Device. Description The illustration shows the eXLhoist Configuration Software starting screen: Button Description Create a Project Allows you to create a new project with default values.
eXLhoist Configuration Software Main Window Introduction The eXLhoist Configuration Software main window provides access to menus and commands, windows and toolbars, and views of an application.
eXLhoist Configuration Software Status Bar Introduction The status bar is a panel at the bottom of the main window that displays information about the application and the connected device. The status bar can be turned on or off by selecting View → Status Bar from the menu bar.
eXLhoist Configuration Software Toolbar Introduction The toolbar is a panel at the top of the main window which provides access to the main commands using icons. The toolbar can be turned on or off by selecting View →Toolbar from the menu bar. Description The illustration shows the eXLhoist Configuration Software toolbar: 172 Element Description 1 Go to Start Page: Displays the start page, any opened project must be closed. If the project is not saved, a dialog box asks to save the project.
eXLhoist Configuration Software Menu Bar Introduction The menu bar is a panel at the top of the main window which provides access to the command menus. Description The illustration shows the eXLhoist Configuration Software menu bar: Menu Description File Available to launch file related operations (New, Open, Export, Print, Save, Close, and so on). View Available to toggle the toolbar and status bar visibility. Communication Available to manage the communication-related operation.
eXLhoist Configuration Software Workspace Introduction The eXLhoist Configuration Software workspace provides access to the connected remote parameters.
eXLhoist Configuration Software Section 7.
eXLhoist Configuration Software Diagram Uses Cases The main use cases of the eXLhoist Configuration Software are: Create a project. Open an existing project. Open a new project using data from remote connected. Save project. Close project. Generate the configuration documentation to export in “.pdf” file. Transfer configuration from PC to Remote Device.
eXLhoist Configuration Software The diagram illustrates the use cases: EIO0000001505 04/2014 177
eXLhoist Configuration Software Starting and Exiting eXLhoist Configuration Software Starting eXLhoist Configuration Software The installation procedure for eXLhoist Configuration Software creates one or more of the following options for starting the software, depending on selections made during installation. Select one of the following options to start eXLhoist Configuration Software: Double-click the eXLhoist Configuration Software icon on the Windows® desktop.
eXLhoist Configuration Software Creating a Project Overview As shown in the eXLhoist Configuration Software diagram, there are 3 ways to start a project: Create a new project with default values (see page 179). Open an existing project (see page 180). Create a new project with the configuration stored in a connected Remote Device (see page 180). These 3 ways can be realized form the starting screen but also from the main menu.
eXLhoist Configuration Software Open an Existing Project Follow the procedure to open an existing project from your PC: Step Action 1 From the starting screen, click Open a project button. Note: From the main menu, select File →Open. 2 A browser window is displayed. Select the project file (“.xpf”). 3 Click Open. 4 If the project file is locked, a window is displayed. Enter the project password (see page 184). Click Enter. The project window is activated.
eXLhoist Configuration Software Step Action 4 If the configuration in the Remote Device has a transfer Configuration File password, a window is displayed. Enter the Transfer Password (see page 183) with the keyboard of the PC. Click Enter. 5 Wait during the transfer. Note: A progress bar is displayed during the transfer. 6 If the project file is locked, a window is displayed. Enter the project password (see page 184). Click Enter. The project window is activated.
eXLhoist Configuration Software Edit a Connection Overview Follow the procedure to modify the communication settings for the connected device: Step Action 1 Connect a Remote Device to the PC (see page 165). 2 From the main menu, select Communication →Edit Connection. 3 A window is displayed: Select the COM Port. 182 4 Click Test. 5 If the communication is not established with the Remote Device, click Cancel and modify the Modbus protocol settings.
eXLhoist Configuration Software Project Passwords Management Overview You can configure 2 passwords to the project: The transfer password of the Configuration File The project password Transfer Password The transfer password is asked before each Configuration File transfer.
eXLhoist Configuration Software Project Password The project password is asked before opening a locked project. Follow the procedure to create or modified the project password: Step Action 1 From the main menu, select File →Password →Project Password. Result: A window is displayed. 2 To modify an existing password, enter the previous password in the Old Password fields. 3 Enter the new project password in the New Password and in the Confirm Password fields.
eXLhoist Configuration Software Load the Configuration into the Remote Device How To ... Follow the procedure to load the configuration from the PC to the Remote Device: Step Action 1 Connect a Remote Device to the PC (see page 165). 2 Create or open a project. 3 From the main menu, select Communication →Store to device. 4 If asked, enter the transfer password. 5 Wait during the transfer.
eXLhoist Configuration Software Save a Project How To ... Follow the procedure to save the project file on the PC: Step Action 1 From the main menu, select File →Save. Result: A browser window is displayed. 2 Choose the directory. 3 Click Save. It is possible to change the name of the project file by selecting File →Save as.
eXLhoist Configuration Software Export to PDF How To ... Follow the procedure to export the configuration to a PDF file: Step Action 1 From the main menu, select File →Export →Export to PDF. Result: A browser window is displayed. 2 Choose the directory and the name of the export file. 3 Click Export. Result: The export file is created. 4 A question window asks you to open or not the export file. Click Yes to open the export file. Click No to go back to the project workspace.
eXLhoist Configuration Software Section 7.
eXLhoist Configuration Software Device Identity Overview From this tab, you can read generic information from the Remote Device: EIO0000001505 04/2014 189
eXLhoist Configuration Software Description At the activation, the fields are clear. Click the Read button to display generic information coming from the connected Remote Device. If there is no Remote Device connected, you are informed by a popup and all fields are cleared. Field Description Reference Remote Device reference. Firmware Version Firmware version of the Remote Device. Format xxx.yyy (where xxx is major version and yyy is minor version).
eXLhoist Configuration Software Parameters Overview In this tab, you can configure the Wireless Remote Control System parameters.
eXLhoist Configuration Software Identification Setting You can select the Wireless Remote Control System configuration between: SINGLE TANDEM You must enter the Base Station ID: Format: 00 80 F4 0X XX XX (0X XX XX is an hexadecimal value from 0 00 00 to 3 FF FF). This ID can be read on the Base Station. Click Label checkbox to enable the label management. Select in the listbox a label number (0…999). This label number is displayed on the ZART•D to identify the selected Base Station/Bridge.
eXLhoist Configuration Software Standby Time-out The Remote Device goes automatically from START mode to STOP mode if no buttons are pressed during the Standby Time-out delay. You can modify the duration: 1…60 minutes. The factory setting value is 15 minutes. Power saving Time-out When the Wireless Remote Control System is in STOP mode due to Standby Time-out, if no button is pressed during this Power saving Time-out, the Remote Device automatically power OFF. You can modify the duration: 1…300 minutes.
eXLhoist Configuration Software Relay Assignment Overview In this tab, you can: Configure the motion buttons. Configure a selector. Configure the auxiliary buttons. Configure UOC function. Configure the limit switches. Configure the special functions.
eXLhoist Configuration Software Restriction Due To Remote Device This tab is automatically modified according to the selected/connected Remote Device: Reference Disable relay column Disable limit switches group Disable buttons rows 13...18 Yes 12…15+7 ZART8L ZART8D - - 12…15+7 ZART12D - - - Generic Description The main use of this tab is to configure the association between the buttons and the relays.
eXLhoist Configuration Software In TANDEM configuration: In this configuration, no any relays are used. The selector is used to select Base Station to be piloted. Step Action 1 Select, in the N° Button combobox, the button to be used as selector. The Use a Selector checkbox is checked and not modifiable. The Number of position field is set to 3 and is not modifiable. The relay assignment is the same for the 2 Base stations.
eXLhoist Configuration Software Safeguarding Function Configuration The Safeguarding function configuration consists in enable/disable the limit switches.
eXLhoist Configuration Software Interlocking Overview In this tab, you can configure the buttons combinations that cannot operate simultaneously. Step Action 1 Click a cell to interlock (or not) 2 buttons (or buttons combinations). Result: When the buttons are interlocked, the empty cell has now an associated symbol . Example of the factory setting: The button 1 and 2 are associated to the same axis, for the opposites directions. The button 1 must not operate while the button 2 is pressed.
eXLhoist Configuration Software Detected Applicative Alarms Overview In this tab, you can configure the Applicative Alarm states. The Base Station can provide detected alarms information to the ZART•D. Voltage free sensors can be connected to Base Station. Step Action 1 Click High or Low to select the active state of each alarm. With a NO type switch, select High. For more information, refer to Special functions description (see page 103).
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Harmony eXLhoist Maintenance / Device Replacement EIO0000001505 04/2014 Chapter 8 Maintenance / Device Replacement Maintenance / Device Replacement What Is in This Chapter? This chapter contains the following sections: Section Topic Page 8.1 Maintenance 202 8.2 Device Replacement 203 8.
Maintenance / Device Replacement Section 8.1 Maintenance Maintenance Regular Cleaning Remote Device Cleaning When the surface or the frame of the display gets dirty, soak a soft cloth in water with a neutral detergent, wring the cloth tightly, and wipe the display. NOTICE EQUIPMENT DAMAGE Do not use paint thinner, organic solvents, or a strong acid compound to clean the equipment. Failure to follow these instructions can result in equipment damage.
Maintenance / Device Replacement Section 8.2 Device Replacement Device Replacement Overview The Configuration File management allows some device replacement, without tool.
Maintenance / Device Replacement Base Station Replacement New Base Station Replacement Follow the procedure to replace a Base Station by a new one: Step 204 Action 1 Execute a Remote Pairing Reset (see page 211). 2 Install the new Base Station. 3 Power ON the new Base Station. 4 Place yourself with the Remote Device to an appropriate distance from the Base Station (around 10 m (32.8 ft)). 5 Press only the ON/START/Horn button on the Remote Device more or equal than 1 s.
Maintenance / Device Replacement Step 9 10 Action Press the button 7 (trigger) to validate. Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device. Select the cancel cell (X) with buttons 1 and 2. 11 Press the button 7 (trigger) to validate. 12 The Remote Device propose to load the Configuration File from the Remote Device to the Base Station. Select the validation cell (check symbol) with buttons 1 and 2.
Maintenance / Device Replacement Step 13 Action If the Configuration File has a transfer password, a padlock is displayed: Enter the Configuration File transfer code with the buttons 1 to 6. The default transfer password is 5, 6, 5, 6. 14 Press the button 7 (trigger) to validate. Result: The Remote Device loads the Configuration File from the Remote Device to the Base Station. 15 Wait for the end of the Configuration File load.
Maintenance / Device Replacement ZART•D Replacement Replacement of a ZART•D by an out-of-the-box One Procedure to replace an out of work ZART•D by an out-of-the-box one: Step Action 1 Power ON the Base Station. 2 Place yourself with the Remote Device to an appropriate distance from the Base Station (around 10 m (32.8 ft)). 3 Press only the ON/START/Horn button on the Remote Device more or equal than 1 s.
Maintenance / Device Replacement Step Action 7 Press the button 7 (trigger) to validate. Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device. 8 Select the validation cell (check symbol) with buttons 1 and 2. 9 Press the button 7 (trigger) to validate. Result: The Remote Device loads the Configuration File from the Base Station to the Remote Device. 10 Wait for the end of the Configuration File load.
Maintenance / Device Replacement Replacement of a ZART•D by an Already Configured One Replacement of an out of work ZART•D by an already configured one: Step Action 1 Do a Remote Factory Reset (see page 211). 2 Execute the procedure Replacement of an out of Work ZART•D by a New One (see page 207).
Maintenance / Device Replacement ZART8L Device Replacement Replacement of an ZART8L Procedure to replace an out of work ZART8L: Step Action 1 Connect the Remote Device to a PC (see page 165). 2 Start the eXLhoist Configuration Software (see page 178). 3 Open an existing project (see page 180). 4 Select Communication →Store to Device. 5 Wait for the end of the Configuration File load in the Remote Device. 6 Disconnect the Remote Device to the PC. 7 Power ON the Base Station.
Maintenance / Device Replacement Section 8.3 Remote Device Resets Remote Device Resets Remote Device Resets Procedure Step Action 1 Power ON the Remote Device. 2 On the rear of the Remote Device, unscrew the 2 screws. 3 Remove the cover. 4 Press and maintain the reset button for the appropriate duration (see page 212).
Maintenance / Device Replacement Remote Device rear view: 1 2 3 Cover RJ45 connector Reset button Reset Information Title t = Reset button Remote Device reaction duration press Simple reset t<5s Remote Device reboot. Pairing reset 5 s ≤ t < 20 s Remote Device reboot. Erase in the remote memory the stored Base Station ID. The remote is no Factory reset t > 20 s Remote Device reboot. Erase in the remote memory the stored Base Station ID.
Harmony eXLhoist EIO0000001505 04/2014 Appendices EIO0000001505 04/2014 213
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Harmony eXLhoist Architecture Examples EIO0000001505 04/2014 Appendix A Architecture Examples Architecture Examples What Is in This Chapter? This chapter contains the following topics: Topic Page Tested Architectures 216 Vacuum/Magnetic Application Example 221 Room Lighting Application Example 224 EIO0000001505 04/2014 215
Architecture Examples Tested Architectures Overview Schneider Electric provides the basis of tested architecture. You can adapt these architectures to your individual requirements. NOTE: the architectures specified have been tested under actual service conditions. Your specific application requirements may be different from those assumed for these projects. In that case, you have to adapt the architecture to your particular needs.
Architecture Examples Description Schneider Electric has tested some possible architectures: No. Hoisting Trolley Translation E-STOP STOP Motion Stop category According To EN 61508 EN 13849 1 2 Contactor 3 4 ATV71 Contactor Contactor SIL2/Cat 3 SIL3/Cat 4 ATV32 ATV32 EN 61508 EN 13849 SIL3/Cat 4 EN60204 Cat 0 SIL1/Cat 2 SIL3/Cat 4 Cat 1 Stop category depends on the UOC function/wiring (see page 105). E-Stop and Stop SIL level depends on the IN0 and S2_S3 wiring (see page 111).
Architecture Examples Safety Case 2 S1 is a wired E-STOP SIL2; The E-STOP of the Remote Device is SIL3.
Architecture Examples Safety Case 3 S1 is a wired E-STOP SIL2; The E-STOP of the Remote Device is SIL3.
Architecture Examples Safety Case 4 S1 is a wired E-STOP SIL2; The E-STOP of the Remote Device is SIL3.
Architecture Examples Vacuum/Magnetic Application Example Description A possible use of auxiliary buttons is a Vacuum/Magnetic function. Vacuum/Magnetic Description Triggering “Vacuum/Magnetic ON“ button is assigned to 1 relay. When the operator presses the “Vacuum/Magnetic ON” button, the magnetic is activated through the associated relay. Releasing To release the load, simultaneously press ”Vacuum/Magnetic OFF 1” and “Vacuum/Magnetic OFF 2” buttons.
Architecture Examples Wiring Example V_M_H1 V hold command magnetic 48…230 Vac V_M_H2 V hold power magnetic 48…230 Vac 222 EIO0000001505 04/2014
Architecture Examples NOTE: The Magnetic OFF flash is ON only in the 2 following cases: When the operator presses at least one of the Magnetic OFF buttons. If one the Magnetic OFF relay is welded. In this case, a maintenance action shall be done (Otherwise it is enough to press the other Magnetic OFF button for releasing the load). The power supply choice is the OEM responsibility. It depends on the risk analysis.
Architecture Examples Room Lighting Application Example Description It is possible to manage room lighting applications. An auxiliary button commands an impulse relay on the room lighting circuit. Configuration There is no specific configuration needed. You have to associate an auxiliary button to a relay. Wiring Example NOTE: Schneider Electric offers modular impulse relays which are bistable switches designed to control load power mainly for lighting applications.
Harmony eXLhoist Glossary EIO0000001505 04/2014 Glossary A AWG (American wire gauge) The standard that specifies wire section sizes in North America C CCF (Common Cause of Failure) CSA (Canadian standards association) The Canadian standard for industrial electronic equipment in hazardous environments. D DTM (Device Type Manager) Classified into 2 categories: Device DTMs connect to the field device configuration components. CommDTMs connect to the software communication components.
Glossary F FE (Functional Earth) A common grounding connection to enhance or otherwise allow normal operation of electrically sensitive equipment (also referred to as functional ground in North America). In contrast to a protective Earth (protective ground), a functional earth connection serves a purpose other than shock protection, and may normally carry current.
Glossary M MAC address (Media Access Control address) A unique 48-bit number associated with a specific piece of hardware. The MAC address is programmed into each network card or device when it is manufactured. MTTF (Mean TIme To Failure) N NC (Normally Closed) A contact pair that closes when the actuator is de-energized (no power is applied) and opens when the actuator is energized (power is applied).
Glossary R RJ45 A standard type of 8-pin connector for network cables. S SELV (Safety Extra Low Voltage) A system that follows IEC 61140 guidelines for power supplies is protected in such a way that voltage between any 2 accessible parts (or between 1 accessible part and the PE terminal for class 1 equipment) does not exceed a specified value under normal conditions or under inoperable conditions.
