Schneider Electric Lexium 62 ILM Hardware Guide

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Lexium 62 ILM

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Lexium 62 ILM

Hardware Guide

Original instructions

02/2020

EIO0000001351.07

www.schneider-electric.com

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. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.

You agree not to reproduce, other than for your own personal, noncommercial use, all or part of this document on any medium whatsoever without permission of Schneider Electric, given in writing. You also agree not to establish any hypertext links to this document or its content. Schneider Electric does not grant any right or license for the personal and noncommercial use of the document or its content, except for a non-exclusive license to consult it on an "as is" basis, at your own risk. All other rights are reserved.

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components.

When devices are used for applications with technical safety requirements, the relevant instructions must be followed.

Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results.

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Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1 Specific Safety Information . . . . . . . . . . . . . . . . . . . . . . . 13

Product Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 Connection Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 Distribution Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 ILM Integrated Servo Drive . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 ILM Digital I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lexium 62 ILM Safety Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ILM Daisy Chain Connector Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 Engineering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1 Electromagnetic Compatibility, EMC . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic Compatibility, EMC . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Control Cabinet Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Degree of Protection (IP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical and Climatic Environmental Conditions in the Control

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Cooling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Information about Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information about Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESD Protection Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions for UL / CSA Compliant Use . . . . . . . . . . . . . . . . . . . . . . .

Fusing the Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains Line Reactor (Choke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection of the Lexium 62 Power Supply . . . . . . . . . . . . . . . . . . . .

Leakage (Touch) Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual Current Operated Protective Device. . . . . . . . . . . . . . . . . . .

14 18 20

22 24 27 29 31 34 36 38

42 42 46 47

48 49 51 52 53 55 56 58 60 61 62 63 64 65

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3.4 Functional Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process Minimizing Risks Associated with the Machine . . . . . . . . . . .

Designated Safety Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup, Installation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Perform Muting with the Optional Modules DIS1 . . . . . . . . . . . . . . . . .

Application Proposals for Hardware-Based Safety Functions . . . . . . .

Application Proposals for Software-Based Safety Functions . . . . . . . .

Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 67 69 77 79 82 85 86 87 89 90 91 93 93

Chapter 4 Installation and Maintenance . . . . . . . . . . . . . . . . . . . . . . 97

4.1 Prerequisites for Installation and Maintenance . . . . . . . . . . . . . . . . . .

Prerequisites for Maintenance and Installation . . . . . . . . . . . . . . . . . .

4.2 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grinding the Holding Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing the Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring the Lexium 62 Connection Module in Linear or Tree Topologies Wiring from the Lexium 62 Connection Module in a Daisy Chain

Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Maintenance, Repair, Cleaning, Replacement Equipment Inventory. .

Prerequisites for Maintenance, Repair, and Cleaning . . . . . . . . . . . . .

Fuse Replacement Lexium 62 Connection Module . . . . . . . . . . . . . . .

Machine Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Equipment Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Replacing Components and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for Replacing Components and Cables . . . . . . . . . . . . .

Replacement of the Lexium 62 Connection Module . . . . . . . . . . . . . .

Replacement of the Lexium 62 Distribution Box . . . . . . . . . . . . . . . . .

Replacement of the Lexium 62 ILM Integrated Servo Drive . . . . . . . .

98 98

99 100 101 103 104 108 114

120 124 125 127 131 132 133 134 135 138 141 145

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Chapter 5 Indicators and Control Elements. . . . . . . . . . . . . . . . . . . 149

Indicators of the Lexium 62 Power Supply . . . . . . . . . . . . . . . . . . . . .

Indicators of the Lexium 62 Connection Module . . . . . . . . . . . . . . . . .

Indicators of the Lexium 62 Distribution Box . . . . . . . . . . . . . . . . . . . .

Indicators of the Lexium 62 ILM Integrated Servo Drive . . . . . . . . . . .

150 153 155 157

Chapter 6 Electrical Power Connections . . . . . . . . . . . . . . . . . . . . . 161

Electrical Connections for the Lexium 62 Power Supply . . . . . . . . . . .

Electrical Connections for the Lexium 62 Connection Module . . . . . .

Electrical Connections for the Lexium 62 Distribution Box . . . . . . . . .

Electrical Connections for the Lexium 62 ILM Integrated Servo Drive

Electrical Connections for the ILM Daisy Chain Connector Box . . . . .

162 168 174 177 179

Chapter 7 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Standards and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical and Electrical Data for the Lexium 62 Power Supply . . . .

Mechanical and Electrical Data for the Lexium 62 Connection Module Mechanical and Electrical Data for the Lexium 62 Distribution Box . . Mechanical and Electrical Data for the

ILM Daisy Chain Connector Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical and Electrical Data for the Lexium 62 ILM Integrated Servo

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical and Electrical Data for the ILM070 Servo Motor . . . . . . .

Mechanical and Electrical Data for the ILM100 Servo Motor . . . . . . .

Mechanical and Electrical Data for the ILM140 Servo Motor . . . . . . .

Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Shaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Holding Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Arrangement and Degree of Protection. . . . . . . . . . . . . . . .

Torque / Speed Characteristic Curves . . . . . . . . . . . . . . . . . . . . . . . .

186 187 188 191 194

197

202 205 208 211 214 215 217 219 220

Chapter 8 Lexium 62 ILM Digital I/O Module. . . . . . . . . . . . . . . . . . 227

Lexium 62 ILM Digital I/O Module - Description . . . . . . . . . . . . . . . . .

Lexium 62 ILM Digital I/O Module - Technical Data . . . . . . . . . . . . . .

Lexium 62 ILM Digital I/O Module - Installation. . . . . . . . . . . . . . . . . .

Lexium 62 ILM Digital I/O Module - Electrical Connections. . . . . . . . .

Lexium 62 ILM Digital I/O Module - Wiring . . . . . . . . . . . . . . . . . . . . .

228 229 231 234 238

Chapter 9 Lexium 62 ILM Safety Module . . . . . . . . . . . . . . . . . . . . 239

Lexium 62 ILM Safety Module - Description . . . . . . . . . . . . . . . . . . . .

Lexium 62 ILM Safety Module - Technical Data . . . . . . . . . . . . . . . . .

Lexium 62 ILM Safety Module - Installation. . . . . . . . . . . . . . . . . . . . .

240 241 243

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Chapter 10 Hybrid Connector HCN-2 Adapter . . . . . . . . . . . . . . . . . . 247

Hybrid Connector HCN-2 Adapter - Description . . . . . . . . . . . . . . . . .

Hybrid Connector HCN-2 Adapter - Technical Data . . . . . . . . . . . . . .

Hybrid Connector HCN-2 Adapter- Installation . . . . . . . . . . . . . . . . . .

Hybrid Connector HCN-2 Adapter - Electrical Connections. . . . . . . . .

Hybrid Connector HCN-2 Adapter - Dimensions . . . . . . . . . . . . . . . . .

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

248 249 251 253 255

257

259 261 263

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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, service, 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.

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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.

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About the Book

At a Glance

Document Scope

Read and understand the material contained in this manual before you work on Lexium 62 ILM drive for the first time. Take particular note of the chapter

(see page 13) (see page 20)

A copy of this manual must be available for personnel who work with the Lexium 62 ILM drive. This manual is to help you use the capabilities of the Lexium 62 ILM drive safely and properly. Follow the instructions within this manual to help:

 Reduce risks  Reduce repair costs and downtime of the Lexium 62 ILM components.  Increase the service life of the Lexium 62 ILM components.  Increase reliability of the Lexium 62 ILM components.

Validity Note

This document has been updated for the release of EcoStruxureTM Machine Expert V1.2. The technical characteristics of the devices described in the present document also appear online.

To access the information online, go to the Schneider Electric home page

electric.com

Specific Safety Information

. Only those persons who meet the criteria described in are allowed to work with the Lexium 62 ILM components.

Qualification of Personnel

www.schneider-

Specific Safety Information

Chapter 1

Specific Safety Information

Overview

This chapter contains important safety information regarding working with the Lexium 62 ILM.

What Is in This Chapter?

This chapter contains the following topics:

Product Related Information 14 Intended Use 18 Qualification of Personnel 20

Topic Page

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Specific Safety Information

Product Related Information

Overview

Health and safety risks arising from the Lexium 62 ILM have been reduced. However residual risks remain, since the Lexium 62 ILM components work with electrical voltage and electrical currents as well as initiation of movement that may be hazardous depending on your machine design.

If activities involve residual risks, a safety message is made at the appropriate points. This includes potential hazard(s) that may arise, their possible consequences, and describes preventive measures to avoid the hazard(s).

Electrical Parts

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

 Disconnect all power from all equipment including connected devices prior to removing any

covers or doors, or installing or removing any accessories, hardware, cables, or wires.

 Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in

the non-energized position.

 Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge.  Measure the voltage on the DC bus with a properly rated voltage sensing device and verify

that the voltage is less than 42.4 Vdc.

 Do not assume that the DC bus is voltage-free when the DC bus LED is off.  Block the motor shaft to prevent rotation prior to performing any type of work on the drive

system.

 Do not create a short-circuit across the DC bus terminals or the DC bus capacitors.  Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a

proper ground connection exists before applying power to the unit.

 Use only the specified voltage when operating this equipment and any associated products.

Failure to follow these instructions will result in death or serious injury.

DANGER

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ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

 Operate electrical components only with a connected protective ground (earth) cable.  After the installation, verify the secure connection of the protective ground (earth) cable to all

electrical devices to ensure that connection complies with the connection diagram.

 Before enabling the device, safely cover the live components to prevent contact.  Do not touch the electrical connection points of the components when the module is

energized.

 Provide protection against indirect contact.  Connect and disconnect cables and terminals only after you have verified that the power has

been removed from the system.

Failure to follow these instructions will result in death or serious injury.

Assembly and Handling

This product has a leakage (touch) current greater than 3.5 mA. If the protective ground connection is interrupted, a hazardous leakage (touch) current may flow if the housing is touched.

INSUFFICIENT GROUNDING

 Use a protective ground copper conductor with at least 10 mm

ground copper conductors with the same or larger cross section of the conductors supplying the power terminals.

 Verify compliance with all local and national electrical code requirements as well as all other

applicable regulations with respect to grounding of all equipment.

Failure to follow these instructions will result in death or serious injury.

DANGER

Specific Safety Information

(AWG 6) or two protective

WARNING

CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING

 Observe the general construction and safety regulations for handling and assembly.  Use appropriate mounting and transport equipment and use appropriate tools.  Prevent clamping and crushing by taking appropriate precautions.  Cover edges and angles to protect against cutting damage.  Wear appropriate protective clothing (for example, protective goggles, protective boots,

protective gloves).

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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Specific Safety Information

Hazardous Movements

There can be different sources of hazardous movements:

 No, or incorrect, homing of the drive  Wiring or cabling errors  Errors in the application program  Component errors  Error in the measured value and signal transmitter

NOTE: Provide for personal safety by primary equipment monitoring or measures. Do not rely only on the internal monitoring of the drive components. Adapt the monitoring or other arrangements and measures to the specific conditions of the installation in accordance with a risk and error analysis.

UNAVAILABLE OR INADEQUATE PROTECTION DEVICE(S)

 Prevent entry to a zone of operation with, for example, protective fencing, mesh guards,

protective coverings, or light barriers.

 Dimension the protective devices properly and do not remove them.  Do not make any modifications that can degrade, incapacitate, or in any way invalidate

protection devices.

 Before accessing the drives or entering the zone of operation, bring the drives and the motors

they control to a stop.

 Protect existing workstations and operating terminals against unauthorized operation.  Position EMERGENCY STOP switches so that they are easily accessible and can be reached

quickly.

 Validate the functionality of EMERGENCY STOP equipment before start-up and during

maintenance periods.

 Prevent unintentional start-up by disconnecting the power connection of the drive using the

EMERGENCY STOP circuit or using an appropriate lock-out tag-out sequence.

 Validate the system and installation before the initial start-up.  Avoid operating high-frequency, remote control, and radio devices close to the system

electronics and their feed lines, and perform, if necessary, an EMC validation of the system.

Failure to follow these instructions will result in death or serious injury.

DANGER

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Drive systems may perform unanticipated movements because of incorrect wiring, incorrect settings, incorrect data or other errors.

UNINTENDED MOVEMENT OR MACHINE OPERATION

 Carefully install the wiring in accordance with the EMC requirements.  Do not operate the product with undetermined settings and data.  Perform comprehensive commissioning tests that include verification of configuration settings

and data that determine position and movement.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

PELV Circuits

ELECTRIC SHOCK DUE TO INADEQUATE PROTECTIVE SEPARATION Only connect devices, electrical components, or lines to the signal voltage connectors of these

products that feature a sufficient, protective separation from the connected circuits in accordance with the standards (IEC 61800-5-1: Adjustable speed electrical power drive systems - safety requirements).

Failure to follow these instructions will result in death or serious injury.

Specific Safety Information

WARNING

DANGER

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Specific Safety Information

Intended Use

Installation

Install and operate this equipment in a control cabinet (enclosure) appropriately rated for its intended environment and secured by a keyed or tooled locking mechanism.

The Lexium 62 ILM and the Lexium 62 Distribution Box are intended for the installation in a machine.

Provide for Protective Measures

Before installing the device, provide for appropriate protective devices in compliance with local and national standards. Do not commission components without appropriate protective devices. After installation, commissioning, or repair, test the protective devices used.

Perform a risk evaluation concerning the specific use before operating the product and take appropriate safety measures.

UNINTENDED EQUIPMENT OPERATION Ensure that a risk assessment is conducted and respected according to EN/ISO 12100 during

the design of your machine. Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

If circumstances occur that affect the safety or cause changes to the operating behavior of the Lexium 62 ILM components, then immediately shut down the Lexium 62 ILM components and contact your Schneider Electric representative.

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Use Original Equipment Only

Use only the accessories and mounting parts specified in the documentation and no third-party devices or components that have not been expressly approved by Schneider Electric.

There are no user-serviceable parts in the Lexium 62 ILM system. Do not attempt to modify the Lexium 62 ILM in any way. Refer to Schneider Electric for all repairs and replacements.

UNINTENDED EQUIPMENT OPERATION

 Only use software and hardware components approved by Schneider Electric for use with this

equipment.

 Do not attempt to service this equipment outside of authorized Schneider Electric service

centers.

 Update your application program every time you change the physical hardware configuration.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

Environment Restrictions

The components must not be used in the following environments:

 In hazardous (explosive) atmospheres  In mobile, movable, or floating systems  In life support systems  In domestic appliances  Underground

This equipment has been designed to operate outside of any hazardous location. Only install this equipment in zones known to be free of a hazardous atmosphere.

Specific Safety Information

WARNING

DANGER

POTENTIAL FOR EXPLOSION Install and use this equipment in non-hazardous locations only. Failure to follow these instructions will result in death or serious injury.

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Specific Safety Information

Qualification of Personnel

Target Audience for This Manual

Electrical equipment must 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.

Qualified Person

A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation, and has received safety training to recognize and avoid the hazards involved.

The qualified personnel must be able to detect possible hazards that may arise from parameterization, changing parameter values and generally from mechanical, electrical, or electronic equipment. The qualified personnel must be familiar with the standards, provisions, and regulations for the prevention of industrial accidents, which they must observe when working on the drive system.

Designated Safety Functions

Qualified personnel that work with designated safety functions must be trained according to the complexity of the machines and the requirements of the ISO 13849-1. The training has to include the production process and the relation between the designated safety function and the machine.

Qualification guidelines are available in the following publication:

Commitment: Competency Guidelines for Safety-Related System Practitioners

IEEE Publications, ISBN 0 85296 787 X, 1999.

Safety, Competency and

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Lexium 62 ILM System Overview EIO0000001351 02/2020

System Overview

Chapter 2

System Overview

What Is in This Chapter?

This chapter contains the following topics:

System Overview 22 Lexium 62 Power Supply 24 Lexium 62 Connection Module 27 Lexium 62 Distribution Box 29 Lexium 62 ILM Integrated Servo Drive 31 Lexium 62 ILM Digital I/O Module 34 Lexium 62 ILM Safety Module 36 ILM Daisy Chain Connector Box 38

Topic Page

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System Overview

The control system consists of several components, depending on its application. PacDrive 3 system overview:

(1) EcoStruxure Machine Expert Software (2) Safety Logic Controller according to IEC 61508:2010 and EN ISO 13849:2008

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Lexium 62 ILM system overview:

1 Lexium 62 Connection Module 2 Lexium 62 Distribution Box 3 Lexium 62 ILM Integrated Servo Drive 4 Lexium 62 ILM with Safety Module 5 Hybrid Cable

System Overview

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System Overview

Lexium 62 Power Supply

Overview

Product Description

The central Lexium 62 Power Supply, using a common DC bus, supplies the connected Lexium 62 servo drive(s) with the required power. For further information, refer to:



Installation and Maintenance (see page 97)



Indicators of the Lexium 62 Power Supply (see page 150)



Electrical Connections for the Lexium 62 Power Supply (see page 162)



Mechanical and Electrical Data for the Lexium 62 Power Supply (see page 188)

References

Product Reference Power supply LXM62PD20A11000

LXM62PD84A11000

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Type Code

Item Meaning Product

family Size 62 = Lexium 62 Type P = Power Module Peak

current Variants A = Power Supply Module Options 1 = 1 or 3 Phases x 208...480 Vac Hardware

release Internal 0 = Serial production Customer 00 = Standard Type code

(example)

Technical Nameplate

The technical nameplate is located laterally on housing.

System Overview

LXM = Lexium

D84 = 84 A D20 = 20 A

LXM 62 P D84 A 1 1 0 00

Label Meaning LXM62PDxxxxxxx Device type and Unicode Input ac/dc Input voltage and/or input current (rated- and/or peak

Output dc Output voltage and output current (rated and/or peak

IP20 Degree of protection Symbols This field displays the symbols of declarations and

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value per input)

value per output)

certifications

System Overview

Logistic Nameplate

The technical nameplate is located on top of the housing.

Label Meaning LXM62PDxxxxxxx Device type and Unicode 2528044067 Serial number RS:01 Hardware revision DOM Date of manufacture Symbols This field displays the symbols of declarations and

certifications

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Lexium 62 Connection Module

Overview

The Lexium 62 Connection Module simplifies the wiring of the devices. With the Lexium 62 Connection Module you can connect up to 45 servo drives.

Product Description

System Overview

The Lexium 62 Connection Module supplies the Lexium 62 ILMs with DC voltage from the DC bus via a hybrid cable or a power cable (daisy chain wiring). Additionally, the Lexium 62 Connection Module provides the Inverter Enable and Sercos interface. For further information, refer to:



Installation and Maintenance (see page 97)



Indicators of the Lexium 62 Connection Module (see page 153)



Electrical Power Connection of the Lexium 62 Connection Module (see page 168)



Mechanical and Electrical Data for the Lexium 62 Connection Module (see page 191)

References

Product Reference Lexium 62 Connection Module ILM62CMD20A000

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System Overview

Type Code

Item Meaning Product family ILM = Integrated Lexium Servo Module Size 62 = Lexium 62 Type CM = Connection Module Power

(cont. DC Bus current)

Variants A Internal 0 = Serial production Customer 00 = Standard Type code

(example)

Technical Nameplate

The technical nameplate is located laterally on housing.

Label Meaning ILM62CMxxxxxxx Device type and Unicode Input dc Input voltage and/or input current (rated- and/or peak

Output ac/dc Output voltage and output current (rated and/or peak

IP20 Degree of protection Symbols This field displays the symbols of declarations and

D20

ILM 62 CM D20 A 0 00

value per input)

value per output)

certifications

Logistic Nameplate

The technical nameplate is located on top of the housing.

Label Meaning ILM62xxxxxxxxxx Device type and Unicode 2528044067 Serial number RS:01 Hardware revision DOM Date of manufacture Symbols This field displays the symbols of declarations and

certifications

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Lexium 62 Distribution Box

Overview

Product Description

The highlights:

 1...4 connections for Lexium 62 ILMs or daisy chain lines or further Lexium 62 distribution

boxes.

 Pre-assembled hybrid cables or power cables (Daisy Chain wiring).

System Overview

The Lexium 62 Distribution Box is the link between Lexium 62 Connection Module and Lexium 62 ILM. Depending on the number of drives, 1 to 4 Lexium 62 ILMs or daisy chain lines can be connected. When operating more than four drives, expand the system by using more Lexium 62 distribution boxes. For further information, refer to:



Installation and Maintenance (see page 97)



Indicators of the Lexium 62 Distribution Box (see page 155)



Electrical Connections for the Lexium 62 Distribution Box (see page 174)



Mechanical and Electrical Data for the Lexium 62 Distribution Box (see page 194)

References

Product Reference Lexium 62 Distribution Box ILM62DB4A000 Sercos bridge plug VW3E6023

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System Overview

Type Code

Item Meaning Product family ILM = Integrated Lexium Servo Module Size 62 = Lexium 62 Type DB = Distribution Box Hybrid outputs 4 Variants A Internal 0 Customer 0 Type code (example) ILM 62 DB 4 A000

Technical Nameplate

The technical nameplate is located laterally on housing:

Label Meaning ILM62DBxxxxx Device type and Unicode Input dc Input voltage and/or input current (rated- and/or peak

Output ac/dc Output voltage and output current (rated and/or peak

IP65 Degree of protection Symbols This field displays the symbols of declarations and

value per input)

value per output)

certifications

Logistic Nameplate

Label Meaning ILM62DBxxxxx Device type and Unicode 2328234578 Serial number RS:01 Hardware revision DOM Date of manufacture

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Lexium 62 ILM Integrated Servo Drive

Overview

Product Description

The Lexium 62 ILMs are available in three different flange sizes:

 ILM070 (70 mm / 2.76 in.)  ILM100 (100 mm / 3.94 in.)  ILM140 (140 mm / 5.51 in.)

The Lexium 62 ILMs have been derived from the Schneider Electric SH3 family of motors, and therefore share many characteristics. For instance, when it comes to mounting the motor, the Lexium 62 ILMs are equivalent.

The highlights:

 Compact design  3.5 times peak torque  Integrated Sercos interface  High-resolution single or multi-turn encoder  Degree of protection IP65 (depending on the reference and/or options)

System Overview

The Lexium 62 ILM combines motor, power stage, and digital servo controller for an axis in a spacesaving housing. Due to its compact design with the integrated drive, it is suitable for decentralized, distributed architectures. It is available with singleturn or multi-turn encoders, and simplifies configuration with the aid of the electronic nameplate in the Lexium 62 ILM. For further information, refer to:



Installation and Maintenance (see page 98)



Indicators of the Lexium 62 ILM Integrated Servo Drive (see page 157)



Electrical Connections for the Lexium 62 ILM Integrated Servo Drive (see page 177)



Mechanical and Electrical Data for the Lexium 62 ILM Integrated Servo Drive (see page 202)

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System Overview

References

Device Reference Lexium 62 ILM Integrated Servo Drive

Type Code

Item Meaning Product family ILM = Integrated Lexium Servo Module Flange size 070 = 70 mm / 2.76 in.

Number of stacks

Winding type P = Standard

Shaft

(see page 215)

Encoder

(see page 214)

Holding brake

(see page 217)

Variants 0 Internal 0 = Standard production Costumer 00 = Standard Type code

(example)

 ILM0701P  ILM0702P  ILM0703P  ILM1001P  ILM1002P  ILM1003P  ILM1401P  ILM1401M  ILM1402P

100 = 100 mm / 3.94 in. 140 = 140 mm / 5.51 in.

1 = 1 Stack 2 = 2 Stacks 3 = 3 Stacks

M = Optimized in terms of torque (available only with ILM1401)

0 = Smooth shaft, without shaft seal 1 = Parallel key, without shaft seal 2 = Smooth shaft, with shaft seal, IP65 3 = Parallel key, with shaft seal, IP65

1 = Absolute single-turn 128 SinCos periods per revolution 2 = Absolute multi-turn 128 SinCos periods per revolution

A = Without holding brake F = With holding brake

ILM 070 1 P 0 1 A 0 0 00

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Technical/Logistic Nameplate

Label Meaning ILMxxxxxxxxxxxx Device type, see type code SN Serial number Input 1 Rated voltage and rated current of the power supply Input 2 Rated voltage and rated current of the electronics Type rating Degree of protection of the housing in accordance with NEMA 250 and

HW Hardware version SW Software version IPxx Degree of protection Th-Cl Insulation material class of the motor M0 Standstill torque Mmax Peak torque nN Nominal speed of rotation DOM Date of manufacture Symbols This field displays the symbols of declarations and certifications.

System Overview

UL 50.

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System Overview

Lexium 62 ILM Digital I/O Module

Overview

Option Module for Lexium 62 ILM Integrated Servo Drive.

Product Description

Reference

Product Reference Digital I/O Module VW3E702100000

Type Code

Lexium 62 ILM Digital I/O Module with 8 digital inputs or outputs. For further information, refer to the chapter

ILM 62 Digital I/O Module (see page 227)

Lexium

Item Meaning Product family VW3 = Integrated Lexium Size E = PacDrive 3 Type 7 = Option Modules Drawing reference 021 = I/O Option Module for

Internal 00000 Type code (example) VW3 E 7 021 00000

Lexium 62 ILM 022 = Safety Option Module for Lexium 62 ILM

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Technical/Logistic Nameplate Description

Label Meaning ILM62-iSH-DIO8 I/O module Device type and Unicode VW3E702100000 Commercial reference 2910229412 Serial number DOM Date of manufacture HW Hardware version FW Firmware version

System Overview

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System Overview

Lexium 62 ILM Safety Module

Overview

Option module for Lexium 62 ILM integrated servo drive.

Product Description

Reference

Product Reference Safety Module VW3E702200000

Lexium 62 ILM Safety Module manages the safe motion functions via Sercos bus.

 Safe Torque off (STO)  Safe Stop 1 (SS1)  Safe Operating Stop (SOS)  Safe Stop 2 (SS2)  Safe Maximum Speed (SMS)  Safely-Limited Speed (SLS)  Safe Direction Indication (SDI)

For further information, refer to the chapter

62 ILM Safety Module (see page 239)

Lexium

Type Code

Item Meaning Product family VW3 = Integrated Lexium Size E = PacDrive 3 Type 7 = Option Modules Drawing reference 021 = I/O Option Module for

Lexium 62 ILM 022 = Safety Option Module for

Lexium 62 ILM Internal 00000 Type code (example) VW3 E 7 022 00000

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Technical/Logistic Nameplate Description

Label Meaning Lexium 62 ILM safety option module Device type and Unicode VW3E702200000 Commercial reference 2910171253 Serial number DOM Date of manufacture HW Hardware version FW Firmware version

System Overview

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System Overview

ILM Daisy Chain Connector Box

Overview

Product Description Type A The ILM Daisy Chain Connector Box is mounted on

Type B Power (DC bus voltage/24 V/Inverter Enable signals)

Type C

a Lexium 62 ILM in order to enable a daisy chain wiring. The Lexium 62 ILMs can be either directly connected to the Lexium 62 Distribution Box or via a Lexium 62 Connection Module. Refer to

Wiring from the Lexium 62 Connection Module in a Daisy Chain Topology (see page 120)

When connecting via a Lexium 62 Distribution Box, a larger number of drives can be connected.

and Sercos signals are distributed via separate cables. Each Lexium 62 ILM must be extended by a Daisy Chain Connector Box (refer to

(see page 108)

Box is used, then up to four daisy chain lines can be connected to it. If several Lexium 62 distribution boxes are used, then from the first Lexium 62 Distribution Box up to and including the second last Lexium 62 Distribution Box respectively up to three daisy chain lines and on the last Lexium 62 Distribution Box up to four daisy chain lines can be connected. A daisy chain line can consist of up to nine Lexium 62 ILMs.

). If only one Lexium 62 Distribution

Mounting

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For further information, refer to:



The connection between the Lexium 62 ILMs is established as follows (refer to Wiring from the Lexium 62 Connection Module in a daisy chain topology

 Power cable for power distribution (DC bus voltage/24V/Inverter Enable signals) with an M23

 Sercos cable for distribution of the Sercos signals via M12 connector

Reference

Product Reference ILM Daisy Chain Connector Box

Type Code

Item Meaning Product

family Size 62 = Integrated Lexium 62 Type DC = Daisy Chain Connector Box Series A = Power at back, Sercos at bottom (ILM070, ILM100,

Internal 0 = Serial production Customer 00 = Standard Type code

(example)

System Overview

Electrical Connections for the ILM Daisy Chain Connector Box (see page 179) Mechanical and Electrical Data for the ILM Daisy Chain Connector Box (see page 197)

(see page 120)

connector

 ILM62DCA000  ILM62DCB000  ILM62DCC000

ILM = Integrated Lexium Servo Module

ILM140) B = Power at bottom, Sercos at left and right (ILM070) C = Power at bottom, Sercos at left and right (ILM100) Z = Protection cap for the last M23 connector

ILM 62 DC A 0 00

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System Overview

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Lexium 62 ILM Engineering EIO0000001351 02/2020

Engineering

Chapter 3

Engineering

What Is in This Chapter?

This chapter contains the following sections:

Section Topic Page

3.1 Electromagnetic Compatibility, EMC 42

3.2 Control Cabinet Planning 46

3.3 Information about Wiring 51

3.4 Functional Safety 66

3.5 Special Conditions 93

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Engineering

Electromagnetic Compatibility, E MC

Section 3.1

Electromagnetic Compatibility, EMC

Electromagnetic Disturbances of Signals and Devices

This product meets the EMC requirements according to the standard IEC 61800-3 if the measures described in this manual are implemented during installation.

Signal interference can cause unexpected responses of the drive and of other equipment in the vicinity of the drive.

WARNING

SIGNAL AND EQUIPMENT INTERFERENCE

 Only operate the drive with the specified external mains filter.  Install the wiring in accordance with the EMC requirements described in the present

document.

 Verify compliance with the EMC requirements described in the present document.  Verify compliance with all EMC regulations and requirements applicable in the country in

which the product is to be operated and with all EMC regulations and requirements applicable at the installation site.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

ELECTROMAGNETIC DISTURBANCES OF SIGNALS AND DEVICES Use proper EMC shielding techniques to help prevent unintended device operation in accordance

with the standard IEC 61800-3. Failure to follow these instructions can result in death, serious injury, or equipment damage.

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These types of devices are not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if used in such a network.

RADIO INTERFERENCE Do not use these products in domestic electrical networks. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Layout Control Cabinet (Enclosure)

The prerequisite for compliance with the specified limit values is an EMC compatible layout. Depending on the application, the following measures can improve the EMC-dependent values:

EMC measures Objective Use galvanized or chromium-plated sub plates, bond

metallic parts across large surface areas, remove paint layer from contact surfaces.

Ground control cabinet (enclosure), door, and sub plates by using grounding strips or grounding cables

with a cross-section of 10 mm Supplement switch devices such as contactors,

relays, or magnetic valves with interference suppression combinations or spark suppressor elements (for example, diodes, varistors, RC elements).

Fit power and control components separately. Reduces mutual interference.

(AWG 6).

Engineering

WARNING

Good conductivity by surface area contact.

Reduce emission.

Reduces mutual interference.

Shielded Cables

EMC measures Objective Connect large surface areas of cable shields, use

cable clamps and ground straps. Ground shields of digital signal wires at both ends by

connecting them to a large surface area or via conductive connector housings.

Ground shield of analog signal cables directly on the device (signal input), insulate the shield at the other cable end or ground the same through a capacitor, such as 10 nF.

EIO0000001351 02/2020 43

Reduce emission.

Reduce interference action on signal cables, reduce emissions.

Reduce grounding loops by low frequency interferences.

Engineering

Cable Installation

EMC measures Objective Do not route fieldbus cables and signal wires in a

single cable duct together with lines with DC and AC voltages of more than 60 V. (Fieldbus cables, signal lines, and analog lines may be in the same cable duct) Recommendation: Use separate cable ducts at least 20 cm (7.84 in) apart.

Keep cables as short as possible. Do not install unnecessary cable loops, use short cables from the central grounding point in the control cabinet to the external ground connection.

Use equipotential bonding conductors (stranded wire of equal potential at all grounding locations connected to an equipotential grounding plane) in the following cases: wide-area installations, different voltage supplies, and installation across several buildings.

Use stranded wire potential equalization conductor. Discharging of high frequency interference currents. If motor and machine are not connected in a

conducting fashion, for example, due to an insulated flange or a connection not across a full surface, the motor must be grounded via a grounding cable with a

minimum 4 mm grounding strip with a length as short as possible.

Use twisted pair for 24 Vdc signals. Reduce interference action on signal cables, reduce

(AWG 11) cross-section or a

Reduces mutual interference.

Reduces capacitive and inductive interference.

Reduces current in the cable shield, reduces emissions.

Reduce emissions, increase interference resistance.

emissions.

Power Supply

EMC measures Objective Operate product on mains with grounded neutral

point. Use surge arrester if there is a risk of overvoltage. Reduces the risk of damage caused by overvoltage.

Enables effectiveness of mains filter.

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Additional Measures for Improving the EMC

Depending on the respective application, the following measures may lead to an EMC compatible layout:

EMC measures Objective Upstream connection of mains line reactor (choke) Reduction of the harmonic network oscillations,

Upstream connection of external mains filters Improvement of the EMC limit values. Special EMC-appropriate layout, for example, within

an enclosed control cabinet complete with 15 dB attenuation of the interferences emitted

Engineering

extension of the service life of the product.

Improvement of the EMC limit values.

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Engineering

Control Cabinet Planning

Section 3.2

Control Cabinet Planning

What Is in This Section?

This section contains the following topics:

Degree of Protection (IP) 47 Mechanical and Climatic Environmental Conditions in the Control Cabinet 48 Using Cooling Units 49

Topic Page

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Degree of Protection (IP)

Overview

Install components such that a degree of protection corresponding to the actual operational environment is set up.

For more information on the degree of protection of the component, refer to

(see page 187)

The following ambient conditions may damage the components:

 Oil  Moisture  Electromagnetic interference  Ambient temperature  Metal dust deposits

UNINTENDED EQUIPMENT OPERATION

 Observe and conform to ambient temperatures, storage temperatures and transport

temperatures of the individual components as specified in the operating manuals of the components.

 Prevent the formation of moisture during the operation, storage and transport of individual

components.

 Conform to the vibration and shock requirements specified in the operating manuals for the

components when operating, storing and transporting system components.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

Engineering

Ambient Conditions

WARNING

EIO0000001351 02/2020 47

Engineering

Mechanical and Climatic Environmental Conditions in the Control Cabinet

Overview

Step Action

1 Observe the climatic and mechanical ambient conditions.

For more information on the general climatic and mechanical environmental conditions according to IEC 60721, refer to

2 Verify the technical data of the device whether the permitted deviations (for example, higher

shock load or higher temperature) are specified.

Ambient Conditions (see page 187)

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Using Cooling Units

Installing a Cooling Unit

How to proceed when installing a cooling unit:

Step Action

1 Position the cooling units so that no condensate drips out of the cooling unit onto electronic

components or is sprayed by the cooling air flow. 2 Provide specially designed control cabinets for cooling units on the top of the control cabinet. 3 Design the control cabinet so that the cooling unit fan cannot spray any accumulated condensate

onto the electronic components when it restarts after a pause. 4 When using cooling units, use only well-sealed control cabinets so that warm, humid outside air,

which causes condensation, does not enter the cabinet. 5 When operating control cabinets with open doors during commissioning or maintenance, ensure

that the electronic components are at no time cooler than the air in the control cabinet after the

doors are shut, in order to avoid any condensation. 6 Continue to operate the cooling unit even when the system is switched off, so that the

temperature of the air in the control cabinet and the air in the electronic components remains the

same. 7 Set cooling unit to a fixed temperature of 40 °C or lower (104 °F). 8 For cooling units with temperature monitoring, set the temperature limit to 40 °C (104 °F) so that

the internal temperature of the control cabinet does not fall below the external air temperature.

Engineering

WARNING

UNINTENDED EQUIPMENT OPERATION Follow the installation instructions such that the condensation from the cooling unit can not enter

electrical equipment. Failure to follow these instructions can result in death, serious injury, or equipment damage.

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Engineering

Installing a cooling unit

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Information about Wiring

Section 3.3

Information about Wiring

What Is in This Section?

This section contains the following topics:

General Information about Wiring 52 Cable Characteristics 53 ESD Protection Measures 55 Conditions for UL / CSA Compliant Use 56 Fusing the Mains Connection 58 Mains Contactor 60 Mains Filter 61 Mains Line Reactor (Choke) 62 Connection of the Lexium 62 Power Supply 63 Leakage (Touch) Current 64 Residual Current Operated Protective Device 65

Engineering

Topic Page

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Engineering

General Information about Wiring

Overview

Use only Schneider Electric approved devices in your application, and especially Schneider Electric pre-fabricated cables, wherever and whenever possible.

For further information, refer to Use an appropriate torque indication or screwdriver for tightening connections. Observe and implement the following points when wiring:

1. Observe the minimum cross-sections of the cables necessary for the load carrying capacity of the equipment being connected.

2. Verify the integrity of cable shields to ensure continuity to ground.

3. Ensure that there is a proper, equipotential connection to ground for all interconnected equipment.

4. Ensure connection of the motors to the machine ground.

5. Eliminate any ground loops.

6. Do not disconnect cable connection terminals when under power.

7. Ensure that all ground connections have sufficient surface area continuity.

8. Do not interchange motor phases.

9. Do not interchange encoder connections.

10.Connect the hybrid or power cable connections and the Sercos cable connections to the Lexium 62 Connection Module according to the connection diagram of the machine manufacturer. For information on the different cable type refer to

11.Do not interchange the emergency stop circuits. This has to be observed especially when two different safety-related circuits are used for axis A and axis B of the Lexium 62 Double Drive.

If, for example, two parallel conductors are shown as coming from one point, you may not run just one conductor and then branch it off at a later point. If it is wired this way, induction loops (interference emitters and antennas) as well as interfering potential shifts may occur.

Cable Characteristics (see page 53)

DANGER

INCORRECT OR UNAVAILABLE GROUNDING Remove paint across a large surface at the installation points before installing the devices (bare

metal connection). Failure to follow these instructions will result in death or serious injury.

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Cable Characteristics

Overview

Cable characteristics of the hybrid cable:

Property Value Hybrid cable voltage isolation 1000 V Maximum continuous current

Temperature range -40...+80 °C / -40...+176 °F Cable diameter 14.8 ± 0.3 mm (0.58 ± 0.012 in.) Bending radius Five x diameter (fixed routing)

Sheath PUR, oil resistant, halogen-free

The hybrid cable (daisy chain wiring) is drag chain capable. Cable characteristics of the power cable (daisy chain wiring):

Property Value Voltage isolation 1000 V Maximum continuous current

Temperature range -40...+80 °C / -40...+176 °F (fixed routing)

Cable diameter 11.7 ± 0.3 mm (0.45 ± 0.012 in.) Bending radius 5 x diameter (fixed routing)

Sheath PUR, oil resistant, halogen-free, flame-retardant

Engineering

 DC Bus: 20 A  24 Vdc: 20 A

10 x diameter (mobile, 5 million bending cycles)

 DC Bus: 20 A  24 Vdc: 20 A

-25...+80 °C / -13...+176 °F (mobile)

10 x diameter (mobile, 5 million bending cycles)

The power cable (daisy chain wiring) is drag chain capable.

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Engineering

Cable characteristics of the Sercos cable (daisy chain wiring):

Property Value Voltage isolation 300 V Temperature range -20...+60 °C / -4...+140 °F Cable diameter 6.7 ± 0.2 mm (0.26 ± 0.008 in.) Bending radius 5 x diameter (fixed routing)

Sheath PUR, halogen-free, flame-retardant Cable type and shielding CAT6 with S/FTP (Sercos III)

10 x diameter (mobile, 5 million bending cycles)

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ESD Protection Measures

General

Observe the following instructions to help avoid damages due to electrostatic discharge:

ELECTROSTATIC DISCHARGE

 Do not touch any of the electrical connections or components.  Prevent electrostatic charges, for example, by wearing appropriate clothing.  If you must touch circuit boards, do so only on the edges.  Remove existing static charge by touching a grounded, metallic surface.

Failure to follow these instructions can result in equipment damage.

Engineering

NOTICE

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Engineering

Conditions for UL / CSA Compliant Use

General

If you use the Lexium 62 ILM system in accordance with UL or CSA standards, you must additionally, aside from the installation requirements stated in the present document, meet the following conditions:

 Install the “open type equipment” Lexium 62 ILM system at a maximum surrounding air

temperature of 40 °C / 55 °C with derating.

 Only connect the power supply to a mains supply with a maximum short circuit current of 22 kA

or, alternatively, take appropriate measures according to UL508A SB4 in the supply circuit of the control cabinet to limit the short circuit current to 22 kA maximum. This does not apply to operation in accordance with CSA 22.2 No. 14. Here, it is only permissible to operate the device for a maximum short circuit current of 5 kA.

 Use devices only in connection with a Lexium 62 Power Supply.  To protect the power supply, use a class J fuse according to UL248 with a maximum fuse rating

of 60 A / 600 Vac.

 Only use hybrid connection cable approved by Schneider Electric and comply with the

requirements of NFPA 79.

Short-Circuit Current Rating (SCCR)

Only connect the Lexium 62 Drive System to a mains supply network not exceeding the nonoperational case of SCCR (Short Circuit Current Rating) from following table, or take appropriate measures according to UL 508 A SB4 in the supply (feeder) circuit of the control cabinet to limit the short circuit current to a value below the least SCCR of those devices you are using from the following table.

NOTE: The opening of the branch-circuit protective device (fuses in the case of UL conformance, or any circuit breaker) may be an indication that an invalid condition has been interrupted. To reduce the risk of fire or electric shock, current-carrying parts and other components of the controller must be examined and replaced if damaged. If burnout of the current element of an overload relay occurs, the complete overload relay must be replaced.

DANGER

FIRE, ELECTRIC SHOCK OR ARC FLASH Examine and replace if necessary any current-carrying parts or other controller components in

the case of mains- or branch-circuit protection activation. Failure to follow these instructions will result in death or serious injury.

According to CSA 22.2 No.14, only a short circuit current rating of 5 kA is permissible. NOTE: Line reactors according to UL 508 A (SB 4.2.1 Exception No. 1) are not required to have a

short-circuit current rating (SCCR).

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Notes on Wiring

 For the wiring of the Lexium 62 Power Supply, use at least 60 °C (140 °F) / 75 °C (167 °F)

copper conductors.

 Choose the cross-section according to the load of the system and selected overload protection

in your application. Consider the applicable cross section for the terminal blocks according to following tables: For Lexium 62 Power Supply

Engineering

Connection Torque [Nm] / [lbf in]

CN1 2.5 / 22 N/A CN5 N/A 0.5...16 / 20...6 CN6 N/A 0.75...16 / 18...6 CN7 N/A 0.2...6 / 24...10 CN4 N/A 0.5...1.5 / 20...16 (1) To protect the Lexium 62 Power Supply, use a Class J fuse according to UL 248 with a maximum fuse

rating of 60 A / 600 Vac.

DC Bus Coupling

When using the DC bus connection on CN7 of the Lexium 62 Power Supply, ensure that the current is limited to 35 A via this connection with an appropriate fuse or circuit breaker.

Connection cross section [mm²] / [AWG]

(1)

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Engineering

Fusing the Mains Connection

General

This data is only valid for fusing the mains connection of each Lexium 62 Power Supply module:

 Protect the power supply against any short-circuit and overload using appropriate measures.  Set the overload protection depending on the permanent current of the device:

 Lexium 62 Power Supply (LXM62PD84A11000) maximum of 40 A (3-phase),  Lexium 62 Power Supply (LXM62PD20A11000) maximum of 10 A (3-phase).

NOTE: The opening of the branch-circuit protective device (fuses in the case of UL conformance, or any circuit breaker) may be an indication that an abnormal condition has been interrupted. To reduce the risk of fire or electric shock, current-carrying parts and other components of the system should be examined and replaced if damaged. If burnout of the current element of an overload relay occurs, the complete overload relay must be replaced. In any and all cases, determine the source of the opening of the branch-circuit protection before re-applying power to the system.

FIRE, ELECTRIC SHOCK OR ARC FLASH Examine and replace if necessary any current-carrying parts or other motor control components

in the case of mains- or branch-circuit protection activation. Failure to follow these instructions will result in death or serious injury.

DANGER

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Allowable Combinations

Combine mains contactor and motor protection switch for protection of a Lexium 62 Power Supply as follows:

Engineering

Mains current DC bus

current (with mains lines reactor)

16 A ≤ 8 A 1-phase Circuit breaker iC60N,

20 A ≤10 A 1-phase Circuit breaker iC60N,

9.5 A ≤ 10 A 3-phase TeSys Model U LUB12 with

12 A ≤ 12.5 A 3-phase – TeSys Model U LUB12 with

18 A ≤19 A 3-phase – TeSys Model U LUB32 with

32 A ≤ 33.5 A 3-phase – TeSys Model U LUB32 with

40 A ≤ 42 A 3-phase – Mains contactor

Connection type Protection Lexium 62

Power Supply (LXM62PD20A11000)

characteristic C, 16 A

characteristic C, 20 A

LUCA12BL

Protection Lexium 62 Power Supply (LXM62PD84A11000)

–

LUCA12BL

LUCA18BL

LUCA32BL

LC1D40ABD motor protection switch GV3P40

Limit the external 24 Vdc supply to the Lexium 62 Power Supply module with adequate means to 50 A.

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Mains Contactor

General

The selection of the mains contactor must be in accordance with the protection requirements of the mains line.

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Mains Filter

Overview

The products described in the present document meet the EMC requirements in accordance with the standard IEC/EN 61800-3, if the EMC measures described in this manual are complied with during the installation. The values are based on the reference application specified in the manual. Refer to Electromagnetic Compatibility, EMC

The connected cable length and the number of connected motors has no significant influence on the grid-bound emitted interference. Thus, no external mains filter is required when only the Lexium 62 ILM related components are used.

In the case of a mixed system using the Lexium 62 Servo Drives combined with the Lexium 62 ILM components, the selection of the external mains filter depends on the devices installed in the control cabinet and the motor supply cables. The hybrid cable or power cable (with daisy chain wiring) of the Lexium 62 ILM is not considered as motor supply cables.

NOTE: For additional information on mains filtering, contact your Schneider Electric representative.

(see page 42)

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Mains Line Reactor (Choke)

Overview

A mains line reactor (choke) is required for the application. A mains line reactor is necessary to reduce the harmonics of the mains current. The mains line reactor must have at least 4% voltage drop at rated load.

With UL/CSA Certification

Mains line reactor with UL / CSA certification:

 Schneider Electric: VPM05D100000 for architectures up to 10 A  Schneider Electric: VPM05D250000 for architectures up to 25 A  Schneider Electric: VPM05D500000 for architectures up to 50 A  Schneider Electric: VW3A4551 for architectures up to 4 A  Schneider Electric: VW3A4552 for architectures up to 10 A  Schneider Electric: VW3A4553 for architectures up to 16 A  Schneider Electric: VW3A4554 for architectures up to 30 A  Schneider Electric: VW3A4555 for architectures up to 60 A

A shielded version of the connection cables is not required. NOTE: Verify that the rated current of the mains line reactor is above preset overload protection of

the protective device.

Correlation Between Mains Current and DC Bus Current (3-Phase Operation)

The mains current is approximately the same as the DC bus current and corresponds to the current of the mains line reactor. For the design of the mains line reactor, use a dimensioning of the mains current of 100% to 110% of the DC bus current.

Mains Line Reactor and External Mains Filter

If a mains line reactor and an external mains line reactor are required, the mains line reactor and external mains filter must be arranged according to the following illustrations for EMC reasons.

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Connection of the Lexium 62 Power Supply

Overview

Connection of a Lexium 62 Power Supply

Engineering

NOTE: The 24 Vdc supply input current must be limited to 50 A, which can be realized by a 50 A fuse as shown above. In particular, a 50 A fuse is mandatory if a passive 24 Vdc power supply is used.

For further information, refer to

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Fusing the Mains Connection (see page 58)

Engineering

Leakage (Touch) Current

Overview

Application Per Lexium 62 Connection

Module

Typical (400V, 50Hz) < 9mA < 18mA ≤141mA

Per Lexium 62 Distribution Box

Per Lexium 62 Power Supply

NOTE: If the leakage (touch) current is too high for the respective application, use an isolating transformer on the mains supply.

This product has a leakage (touch) current greater than 3.5 mA. If the protective ground connection is interrupted, a hazardous leakage (touch) current may flow if the housing is touched.

DANGER

INSUFFICIENT GROUNDING

 Use a protective ground copper conductor with at least 10 mm

ground copper conductors with the same or larger cross section of the conductors supplying the power terminals.

 Verify compliance with all local and national electrical code requirements as well as all other

applicable regulations with respect to grounding of all equipment.

Failure to follow these instructions will result in death or serious injury.

(AWG 6) or two protective

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Residual Current Operated Protective Device

Using Residual Current Protective Devices

When using a residual current protective device in combination with the Lexium 62 Drive System, certain conditions and restrictions must be considered. As a dc current component in the ground conductor may result from insulation damage or direct contact, residual current circuit-breakers of type A or AC may not be triggered and therefore must not be used. Moreover, during system power-up and also in normal operation the Lexium 62 Drive System can generate a significant leakage (touch) current

(see page 64)

protective device. Consequently, observe the following when using residual current protective devices in combination

with the Lexium 62 Drive System:

 Only use universal current sensitive residual current circuit-breaker of type B.  Use residual current protective devices with a latent time to prevent unintended triggering at

system power-up.

 Consider the leakage (touch) current of the Lexium 62 Drive System in normal operation when

selecting the triggering threshold of the residual current protective device.

 If no residual current protective device or only a device with a high current threshold can be

installed, appropriate other measures must be applied to provide protection against electrical

shock and fire hazard

which may lead to unintended triggering of a residual current

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Functional Safety

Section 3.4

Functional Safety

What Is in This Section?

This section contains the following topics:

Process Minimizing Risks Associated with the Machine 67 Designated Safety Function 69 Setup, Installation and Maintenance 77 Perform Muting with the Optional Modules DIS1 79 Application Proposals for Hardware-Based Safety Functions 82 Application Proposals for Software-Based Safety Functions 85 Commissioning 86 Best Practices 87 Maintenance 89 Physical Environment 90 Safety Standards 91

Topic Page

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Process Minimizing Risks Associated with the Machine

General

The goal of designing machines safely is to protect people. The risk associated with machines with electrically controlled drives comes chiefly from moving machine parts and electricity itself.

Only you, the user, machine builder, or system integrator can be aware of all the conditions and factors realized in the design of your application for the machine. Therefore, only you can determine the automation equipment and the related safeties and interlocks which can be properly used, and validate such usage.

Hazard and Risk Analysis

Based on the system configuration and utilization, a hazard and risk analysis must be carried out for the system (for example, according to ISO 12100 or ISO 13849-1). The results of this analysis must be considered when designing the machine, and subsequently applying safety-related equipment and safety-related functions. The results of your analysis may deviate from any application examples contained in the present or related documentation. For example, additional safety components may be required. In principle, the results from the hazard and risk analysis have priority.

WARNING

NON-CONFORMANCE TO SAFETY FUNCTION REQUIREMENTS

 Specify the requirements and/or measures to be implemented in the risk analysis you perform.  Verify that your safety-related application complies to applicable safety regulations and

standards.

 Make certain that appropriate procedures and measures (according to applicable sector

standards) have been established to help avoid hazardous situations when operating the machine.

 Use appropriate safety interlocks where personnel and/or equipment hazards exist.  Validate the overall safety-related function and thoroughly test the application.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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The ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General principle for design describes an iterative process for the selection and design of safety-related parts of controllers to reduce the risk to the machine to a reasonable degree:

To perform risk assessment and risk minimization according to ISO 12100, proceed as follows:

1. Defining the boundary of the machine.

2. Identifying risks associated with the machine.

3. Assessing risks.

4. Evaluating risks.

5. Minimizing risks by:

6. Designing safety-related controller parts (SRP/CS, Safety-Related Parts of the Control System)

To design the safety-related controller parts in an interactive process, proceed as follows:

Step Action 1 Identify necessary safety functions that are executed via SRP/CS (Safety-Related Parts of the

2 Determine required properties for each safety function. 3 Determine the required performance level PL

4 Identify safety-related parts executing the safety function. 5 Determine the performance level PL of the afore-mentioned safety-related parts. 6 Verify the performance level PL for the safety function (PL ≥ PL

7 Verify if all requirements have been met (validation).

 Intrinsically safe design  Protective devices  User information (see ISO 12100)

in an interactive process.

Control System).

Additional information is available on

www.schneider-electric.com

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Designated Safety Function

Functional Description

With the Inverter Enable function (IE), you can bring drives to a defined safe stop. This Inverter Enable function relates to the components

 Lexium 62 Connection Module  Lexium 62 Distribution Box  Lexium 62 ILM Integrated Servo Drive

In the sense of the relevant standards, the requirements of the stop category 0 (Safe Torque Off, STO) and stop category 1 (Safe Stop 1, SS1) can be met. Both categories lead to a torque-free motor while SS1 takes this state after a predefined time. As a result of the hazard and risk analysis, it may be necessary to choose an additional brake as a safety-related option (for example, for hanging loads).

With the optionally available Lexium 62 ILM Safety Module it is also possible to realize the extended safety functions such as Safety Limited Speed (SLS) in connection with the SLC100/200 FS and the associated software EcoStruxure Machine Expert - Safety.

UNINTENDED EQUIPMENT OPERATION

 Make certain that no hazards can arise for persons or material during the coast down period

of the axis/machine.

 Do not enter the zone of operation during the coast down period.  Ensure that no other persons can access the zone of operation during the coast down period.  Use appropriate safety interlocks where personnel and/or equipment hazards exist.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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WARNING

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Designated Safety Function Safe Torque Off (STO)

The Inverter Enable function relates to Lexium 62 Connection Module, Lexium 62 Distribution Box and Lexium 62 ILM, hereinafter referred to as Lexium 62 Drive System.

The function is selected via a signal (pair) at the input of the Lexium 62 Connection Module (2), which is forwarded to all drives (7) of the Lexium 62 Connection Module network. The supply voltage (AC) does not need to be interrupted

The graphic shows the Lexium 62 Drive System with emergency stop:

1 Control cabinet 2 Contactor 3 Lexium 62 Connection Module 4 Emergency stop switch 5 Safety switching device (for example Preventa XPS AV) 6 Lexium 62 ILM Integrated Servo Drive 7 Lexium 62 Distribution Box 8 Logic Motion Controller

Operating Principle

The Inverter Enable function switches off the motor torque. It is sufficient to set a logical zero at the function input. There is no need to interrupt the power supply. Standstill, however, is not monitored.

Defined Safe State

Inverter Enable is synonymous with "Safe Torque Off (STO)" according to IEC 61800-5-2:2007. This torque-free state is automatically entered when errors are detected and is therefore the defined safe state of the drive.

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Mode of Operation

The safety-related circuit with Inverter Enable was developed to minimize wear on the mains contactor. When the stop or the emergency stop button is activated, the mains contactor is not switched off. The defined safe stop is achieved by removing the “InverterEnable” for the optocouple in the power stage. Thus, the PWM signals cannot control the power stage so that a startup of the drives is prevented (pulse pattern lock).

You can use the Inverter Enable function to implement the control function “Stopping in case of emergency” (IEC 60204-1) for stop categories 0 and 1. Use an appropriate external safety-related circuit to prevent the unintended restart of the drive after a stop, as required in the machine directive.

Stop Category 0

In stop category 0 (Safe Torque Off, STO), the drive coasts to a stop (provided there are no external forces operating to the contrary). The STO safety-related function is intended to help prevent an unintended start-up, not stop a motor, and therefore corresponds to an unassisted stop in accordance with IEC 60204-1.

In circumstances where external influences are present, the coast down time depends on physical properties of the components used (such as weight, torque, friction, and so on), and additional measures such as mechanical brakes may be necessary to help prevent any hazard from materializing. That is to say, if this means a hazard to your personnel or equipment, you must take appropriate measures (refer to

Hazard and Risk Analysis (see page 67)

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WARNING

UNINTENDED EQUIPMENT OPERATION

 Make certain that no hazards can arise for persons or material during the coast down period

of the axis/machine.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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Stop Category 1

For stops of category 1 (Safe Stop 1, SS1) you can request a controlled stop via the Logic Motion Controller (LMC). The controlled stop by the LMC is not safety-relevant, nor monitored, and does not perform as defined in the case of a power outage or if an error is detected. The final switch off in the defined safe state is accomplished by switching off the "Inverter Enable" input. This has to be implemented by using an external safety-related switching device with safety-related delay (see

Application Proposal (see page 85)

Independent of the safety function, the detectable errors not affecting the safety function are recognized by the controller, thus avoiding the drive from starting by switching off the mains contactor. Contactor K2 prevents the mains contactor from being switched on.

Execute Muting

To execute muting, determine the muting reaction time for switching off, that is, without the Inverter Enable function, within the application.

Should a response time be required because of the risk assessment of the machine, the total response time of the machine has to be taken into account. That is to say, the components related to the safety functions from the sensor to the drive shaft or the driven mechanics have to be considered. The determined reaction time must correspond to the results of the hazard and risk analysis.

UNINTENDED EQUIPMENT OPERATION

 Verify that the maximum response time corresponds to your risk analysis.  Be sure that your risk analysis includes an evaluation for the maximum response time.  Validate the overall function with regard to the maximum response time and thoroughly test

the application.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

Proceed as follows to disable the Inverter Enable function:

Step Action

1 You can deactivate the Inverter Enable function by using the optional module DIS1

2 In order to use the optional module DIS1, you must define the configuration with the parameter

(see page 79)

Result:The defined safe state can only be achieved if the power is removed from the power supply.

InverterEnableConfig of the Lexium 62 ILM in the motion controller configuration.

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Engineering

If the software configuration does not match the physical configuration of the Lexium 62 ILM, then the diagnostic message 8978 InverterEnableConfig invalid with Ext. diagnostic = x(HW)!=y(Cfg) is triggered. The drive is disabled as long as the configuration is incorrect. The detected error can only be acknowledged if the set InverterEnableConfig corresponds to the physical

configuration. The deactivation of the Inverter Enable function can be used to divide the drives on a Lexium 62 Connection Module in two groups if it is technically not possible to use two Lexium 62 Connection Module for the two groups in the existing machine.

The axes without Inverter Enable function become torque-free via the mains contactor and come to a stop.

If only some of the drives attached to a Lexium 62 Connection Module are to be put in the defined safe state, this can be achieved by the configuration of the drives. This can be of interest, for example, for maintenance procedures. If an optional module DIS1 is set, then the Inverter Enable signal is ignored.

To implement the emergency stop, the supply voltage on the Lexium 62 Power Supply must be interrupted:

1 Control cabinet 2 Emergency stop switch 3 Safety switching device (for example Preventa XPS AV) 4 Contactor 5 Switch: Operating mode (normal/maintenance) 6 Lexium 62 Connection Module 7 Lexium 62 ILM Integrated Servo Drive 8 Lexium 62 Distribution Box 9 Logic Motion Controller

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Extended Safety-Related Functions - Operating Principle

The safety concept is based upon the general consideration that the required safety-related travel movement is performed by the controller and the drive. The safety system monitors the correct execution of the motion, and if it is not respected the safety system initiates the required fall-back level (for example the defined safe state).

An example for Safe Limited Speed (SLS) is as follows: A light curtain is connected to a safety-related digital input. As soon as a person enters the

protected zone passing the light curtain, a corresponding information is transmitted to the Safety Logic Controller (SLC) and the LMC via the Sercos bus. After that the LMC initiates an adequate travel movement, for example by using decelerating and then moving slowly. After an adjustable delay time this slow movement is monitored by Lexium 62 ILM Safety Module. Upon exceeding an adjustable threshold value (for example, high velocity), the required fall-back level is entered, for example, the defined safe state.

Application of safety-related function SLS:

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Extended Safety-Related Functions - Inverter Enable via Hardware Input

The Lexium 62 ILM Safety Module has been primarily developed to realize the extended safety functions, however, it still can be accessed using the usual hardware input for the Inverter Enable of the Lexium 62 Drive System. If only this is to be used, the device still needs to be configured and parameterized by using the software. If it is hardwired, the Safe Torque Off (STO) function can be triggered via this input or the Sercos bus. The Lexium 62 ILM Safety Module can be configured to ignore the hardware input. In this case, the Safe Torque Off (STO) function can only be activated upon a request over the Sercos bus. Otherwise, if the hardware input is not ignored then both requests (hardware input and Sercos bus) are verified and the Safe Torque Off (STO) function is triggered if one or both requests are active. The default configuration is not to ignore the hardware input.

Extended Safety-Related Functions - Defined Safe State

The defined safe state of the device is characterized by the following features:

 The drive is torque-free, which is equivalent to Safe Torque Off (STO) according to IEC 61800-

5-2.

 There is no safety-related communication from the drive via the Sercos bus.

This state is automatically entered when errors are detected.

Validity of the Safety Case

The safety case for the Inverter Enable function of the Lexium 62 ILM is identified and defined by the standards listed in

Safety Standards (seepage91)

. The safety case for the designated safety function of the Lexium 62 ILM system applies to the following hardware codes, which can be found examining the appropriate software object in EcoStruxure Machine Expert

Machine Expert, Programming Guide)

Engineering

(see EcoStruxure

Unicode Hardware code ILM 070/xx xxxxxxxxx1xx, xxxxxxxxx2xx ILM 100/xx xxxxxxxxx1xx, xxxxxxxxx2xx ILM140/xx xxxxxxxxx1xx, xxxxxxxxx2xx DIS1 1 ILM62CM xxxxxx1xx, xxxxxx2xx ILM62DB xxxxxx1xx

Device Hardware code VW3E702200000 011A1110

For questions on this, contact your Schneider Electric representative.

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Interface and Control

The Inverter Enable function is operated via the switching thresholds of the InverterEnable-input (IE_p1/IE_p2 at Pin1/Pin2, IE_n1/IE_n2 at Pin3/Pin4) of the Lexium 62 Connection Module.

 Maximum downtime: 500 µs at U  Maximum test pulse ratio: 1 Hz

 STO active: -3 V ≤ U  Power stage active: 15 V ≤ U

For information on the technical data and electrical connections, refer to the chapter

Data (see page 185)

> 20 V with dynamic control

IEX

≤ 5 V

≤ 30 V

Technical

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Setup, Installation and Maintenance

Prevent Possible Unintended Operation and Avoid Overvoltage

The following measures avoid overvoltages and help prevent possible unintended equipment operation through conductive pollution or parts falling into the device:

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

 Install Lexium 62 Connection Module in a control cabinet or housing with a minimum IP 54

rating.

 Comply with the clearances and creepage distances according to EN 50178.  Lexium 62 ILM Integrated Servo Drive must only be operated with 24 Vdc power supplies

certified according to EN 60950 or EN 50178.

Failure to follow these instructions will result in death or serious injury.

NOTE: These power supply units do not deliver an overvoltage over 120 Vdc for more than 120 ms or no permanent overvoltage over 60 Vdc.

Only operate the drive system with approved, specified cables, accessories and replacement equipment by Schneider Electric.

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DANGER

ELECTRIC SHOCK OR ARC FLASH Do not use non-Schneider Electric approved cables, accessories or any type of replacement

equipment. Failure to follow these instructions will result in death or serious injury.

Avoid Unintentional Restart

The unintentional restart of the equipment must be avoided by appropriate means, depending on your particular application.

DANGER

UNINTENTIONAL RESTART OF THE MOTOR

 Ensure that a restart of the motor is not possible after a return of power or the tripping of a

functional safety device unless preceded by a deliberate enable signal from the system.

 Ensure that the enable signal meets the specified safety criteria.

Failure to follow these instructions will result in death or serious injury.

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Encoder Connection When Using Extended Safety-Related Functions

Lexium 62 ILM Safety Module enables the use of extended, position-dependent and/or velocitydependent safety-related functions.

DANGER

INOPERABLE SAFETY FUNCTION

 Observe the specified maximum configuration (number of devices, network structure and

cable length), or else a voltage drop of the Inverter Enable signal will occur over the cable length and therefore the system will be in the defined safe state continuously.

 Connect per Lexium 62 Connection Module a maximum of 45 Lexium 62 ILMs.

Failure to follow these instructions will result in death or serious injury.

For more information on the dimensions of the maximum system extension for

structure or tree structure or daisy chain structure (see page 120)

Wiring in line

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Perform Muting with the Optional Modules DIS1

Overview

Implementation of Emergency stops combining hardwired control of supply power with the Inverter Enable function:

Lexium 62 ILM Maintenance Emergency stop Parameter InverterEnableConfig

Lexium 62 ILM without DIS1

Lexium 62 ILM with DIS1

How to Install the Optional Modules DIS1

You cannot use the option modules DIS1 and Lexium 62 ILM Safety Module together.

Step Action

1 Remove power to the Lexium 62 Power Supply during the installation of the optional module

2 Remove the transparent cover plate on the motor. 3 Remove plugged in jumpers J1 and J2:

Torque-free motor Torque-free motor Standard/1

– Torque-free motor Off/0

DIS1.

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Step Action

4 Connect the optional module DIS1 by inserting it into the contact pin, as shown in the following

graphic:

5 Replace the transparent cover plate on the motor and secure it.

How to Disassemble the Optional Module DIS1

Step Action

1 Remove power to the Lexium 62 Power Supply during the installation of the optional module

DIS1. 2 Remove the transparent cover plate on the motor. 3 Remove the optional module DIS1.

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Step Action

4 Reconnect the jumpers J1 and J2.

5 Replace the transparent cover plate on the motor and secure it.

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Application Proposals for Hardware-Based Safety Functions

How to Implement the Safe Stop Category 1 (SS1)

Refer to the schematic EL-1122-05-xx: Inverter Enable circuit Lexium 62 Connection Module / Lexium 62 ILM using the Logic Motion Controller LMC•00C with safety switch device for an emergency stop circuit.

NOTE:

 All application proposals provide for a protected Inverter Enable-wiring (control cabinet IP54)

from the safety-related switch device to the Lexium 62 Connection Module, as wiring issues need to be ruled out.

 Protection against automatic restart must be provided by the external safety-related switch

device.

NOTE: The mains contactor in the circuit suggestion EL-1122-05-xx is not necessary for functional safety purposes. It is, however, used in the application proposal for the device protection of the Lexium 62 Power Supply or the components connected to it.

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EL-1122-05-xx Sheet 1:

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EL-1122-05-xx Sheet 2:

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Application Proposals for Software-Based Safety Functions

How to Use the Inverter Enable via Hardware or Extended Safety Functions

Proceed as follows to use the Inverter Enable via hardware or extended safety functions using the Lexium 62 ILM Safety Module:

Step Action

1 Perform the assembly for Lexium 62 ILM Safety Module. 2 Configure the safety-related network. 3 Adjust the parameters, in particular the prioritization of Inverter Enable via hardware and STO

via the bus.

4 Program the EcoStruxure Machine Expert - Safety application.

NOTE: Observe the information on the parameters and the EcoStruxure Machine Expert - Safety in the EcoStruxure Machine Expert online help.

Further information on the parameters and the EcoStruxure Machine Expert - Safety Software can be found in the EcoStruxure Machine Expert online help.

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Commissioning

General

Step Action

1 Carry out a functional test of the STO function for all drives that need the safety function. 2 Especially verify the correct application of the axes without Inverter Enable function. 3 Complete installation in accordance with the EMC regulations and further specifications in the

4 Afterwards, commission the drive systems.

NOTE: When using the extended safety functions, the Lexium 62 ILM Safety Module must be configured, parameterized, and programmed according to the EcoStruxure Machine Expert online help and the EcoStruxure Machine Expert - Safety online help.

device operating manuals.

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Best Practices

General

At machine start-up, the connected drives are usually hidden from sight of the machine operator and cannot be monitored directly.

UNSUPERVISED MACHINE START-UP Only start the machine if there are no persons within the zone of operation of moving machine

components. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Verify Connections

Step Action

1 Verify all terminals, connectors, and other connections on all system components for correct

2 Only use robust connectors and secure fixings. 3 Verify the protective earth ground (24 Vdc PELV (Protective Extra Low Voltage) supply. 4 Verify the wiring of the safety function to the axes to avoid an interchange of the ie_sig and

5 Use coded connectors (refer to chapter

6 Use only appropriate transport packaging to forward or return individual devices.

WARNING

and firm fit.

ie_ref inputs as well as the 24 V supply.

commissioning test (refer to chapter

Information about Wiring (see page 51)

Commissioning (see page 86)

Engineering

) and perform a

DANGER

ELECTRIC SHOCK DUE TO INADEQUATE PROTECTIVE SEPARATION Only connect devices, electrical components, or lines to the signal voltage connectors of these

Failure to follow these instructions will result in death or serious injury.

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External Forces

The defined safe state of the motor is the torque-free output shaft. If external forces act upon the output shaft, it will not necessarily maintain its position. In any case, the motor will coast to an unassisted stop. This coast down time depends on physical properties of the components used (such as weight, torque, friction, and so on), and additional measures such as mechanical brakes may be necessary to help prevent any hazard from materializing. If the torque-free defined safe state is inappropriate for your application where external forces may move the output shaft as determined by your risk assessment, implement other external safety-related measures.

UNINTENDED EQUIPMENT OPERATION

 Make certain that no hazards can arise for persons or material during the coast down period

of the axis/machine.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

Hanging and Pulling Loads

UNINTENDED AXIS MOVEMENT

 Do not use the internal holding brake as a safety-related measure.  Only use certified external brakes as safety-related measures.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

If the suspension of hanging / pulling loads is a safety objective for the machine, then you can only achieve this objective by using an appropriate external brake as a safety-related measure.

NOTE: The drive does not provide its own safety-related output to connect an external brake to use as a safety-related measure.

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Maintenance

General

The Inverter Enable function has been designed for a defined lifetime that does not require to verify the safety-related function, nor any specific maintenance requirements. After this lifetime

(see page 91)

the aging of the component. If you want to ensure the functional safety after this period, you need to replace the device that includes the safety function.

NOTE: Subject the product to a complete function test after replacement. The following applies for Lexium 62 ILM Safety Module. In addition to the LED state, data of the Safety Logger is also available in the EcoStruxure Machine

Expert Logic Builder. These are provided for information only and must not be used for safetyrelated diagnostics.

For information about initial start-up and maintenance, refer to the chapter

Maintenance (see page 97)

Engineering

has elapsed, a statement about the Inverter Enable function cannot be made due to

Installation and

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Physical Environment

General

The system is not protected against physical or chemical sources of damage by any design features, such as:

 toxic,  explosive,  corrosive,  highly reactive, or  inflammable types.

This equipment has been designed to operate outside of any hazardous location. Only install this equipment in zones known to be free of a hazardous atmosphere.

POTENTIAL FOR EXPLOSION Install and use this equipment in non-hazardous locations only. Failure to follow these instructions will result in death or serious injury.

UNINTENDED EQUIPMENT OPERATION

 Observe and conform to ambient temperatures, storage temperatures and transport

temperatures of the individual components as specified in the operating manuals of the components.

 Prevent the formation of moisture during the operation, storage and transport of individual

components.

 Conform to the vibration and shock requirements specified in the operating manuals for the

components when operating, storing and transporting system components.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

DANGER

WARNING

The Lexium 62 Power Supply and the Lexium 62 Connection Module must only be installed in an electrical equipment enclosure (for example, in a control cabinet). The electrical equipment enclosure must be lockable by using a key or tool

The Lexium 62 ILM and the Lexium 62 Distribution Box are intended for installation in a machine.

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Safety Standards

Overview

The designated safety functions have been designed and tested for functional safety according to the following standards

 IEC 61508:2010  IEC 61800-5-2:2007  EN ISO 13849-1:2008  IEC 62061:2005

An independent assessment was performed by TÜV Nord. According to the above listed standards, the figures for the devices for using the Inverter Enable

function are as follows:

Engineering

Standard characteristics Lexium 62 Connection

Module

SFF (IEC 61508)

99% 99.9% 99%

Lexium 62 ILM Lexium 62 ILM with installed

Lexium 62 ILM Safety Module

Safe failure fraction HFT (IEC 61508)

111

Hardware Fault Tolerance Type (IEC 61508) A A B SIL (IEC 61508)

333 Safety Integrity Level SILCL (IEC 62061) Safety Integrity Level claim limit

PFH (IEC 61508)

-9

1.3*10

/h 0.08*10-9/h 1.6*10-9/h

Probability of Dangerous Failures per Hour

PL (cat) (EN ISO 13849-1)

e (4) e (4) e(4) Performance Level (Category)

MTTFd (EN ISO 13849-1)

881 years 14487 years 320 years Mean Time to Dangerous Failure

Lexium 62 Distribution Box: The elimination from consideration of certain errors within the safety-related parts of the control system, known as Fault Exclusion within various IEC, ISO, NFPA and ANSI standards, has been applied because clearances and creepage standards have been respected in the product. The plug-in connectors have been included in the PFH figures of Lexium 62 Connection Module and Lexium 62 ILM.

NOTE: The values specified are rounded individually and are therefore not a result of a conversion by for

example, PFH in MTTFd or the comparative tables from EN ISO 13849-1:2008.

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Engineering

Standard characteristics Lexium 62 Connection

Module

DC (EN ISO 13849-1)

99% 99% 99%

Lexium 62 ILM Lexium 62 ILM with installed

Lexium 62 ILM Safety Module

Diagnostic Coverage Lifetime 20 years 20 years 20 years Maximum reaction time

5 ms 5 ms 10 ms between the request and execution of the designated safety function

Maximum reaction time

5 ms 5 ms 10 ms before the detection of safety-related errors

Maximum reaction time

Not applicable Not applicable 10 ms between exceeding the threshold values of extended safety functions and the initiation of substitute reactions

NOTE: The values specified are rounded individually and are therefore not a result of a conversion by for

example, PFH in MTTFd or the comparative tables from EN ISO 13849-1:2008.

Standard characteristics - Lexium 62 ILM Safety Module

Standard characteristics Lexium 62 ILM Safety Module

MTTFd (EN ISO 13849-1)

Mean Time to Dangerous Failure [years] Use of SLS (Safely Limited Speed (SLS)) etc. – ... with Sick Stegmann encoder SKM36 250 ... with Sick Stegmann encoder SKS36 250

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Special Conditions

Section 3.5

Special Conditions

Low Air Pressure

Description

If the installation altitude exceeds the specified rated installation altitude, the performance of the entire system is reduced.

Low Air Pressure - Lexium 62 Power Supply

Power reduction at increased installation altitude (Lexium 62 Power Supply):

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Low Air Pressure - Lexium 62 Connection Module

Power reduction at increased installation altitude (Lexium 62 Connection Module):

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Low Air Pressure - Lexium 62 ILM

Power reduction at increased installation altitude (Lexium 62 ILM at 8 kHz clock frequency of power stage):

NOTE: Multiply the values with the nominal current at 40 °C / 104 °F in order to calculate the maximum current value, depending on the required installation altitude.

Engineering

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5 Lexium 62 ILM Installation and Maintenance EIO0000001351 02/2020

Installation and Maintenance

Chapter 4

Installation and Maintenance

What Is in This Chapter?

This chapter contains the following sections:

Section Topic Page

4.1 Prerequisites for Installation and Maintenance 98

4.2 Commissioning 99

4.3 Maintenance, Repair, Cleaning, Replacement Equipment Inventory 124

4.4 Replacing Components and Cables 134

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Installation and Maintenance

Prerequisites for Installation and Maintenance

Section 4.1

Prerequisites for Installation and Maintenance

Prerequisites for Maintenance and Installation

General Information

Proceed with care during the following steps in order to help to avoid the following points:

 Injuries and material damage  Incorrect installation and programming of components  Incorrect operation of components  Use of non-authorized cables or modified components

WARNING

INCORRECT INSTALLATION Ensure a correct installation and maintenance of the system according to this manual. Failure to follow these instructions can result in death, serious injury, or equipment damage.

The Lexium 62 ILMs (drive/motor combination) have been derived from the Schneider Electric SH3 family of motors, and therefore share many characteristics. However, when it comes to mounting the motor, the Lexium 62 ILMs are equivalent to the SH3 motors. Refer to the

Servo motor, User Guide (see SH3 Servo Motor, User Guide)

Lexium 62 ILMs. The correspondence between the Lexium 62 ILMs and the SH3 motors are as follows:

SH3 -

for details of installing the

Lexium 62 ILM SH3 motor ILM070 SH3070 ILM100 SH3100 ILM140 SH3140

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Commissioning

Section 4.2

Commissioning

What Is in This Section?

This section contains the following topics:

Prerequisites for Commissioning 100 Preparing Commissioning 101 Grinding the Holding Brake 103 Preparing the Control Cabinet 104 Mounting 108 Wiring the Lexium 62 Connection Module in Linear or Tree Topologies 114 Wiring from the Lexium 62 Connection Module in a Daisy Chain Topology 120

Installation and Maintenance

Topic Page

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Installation and Maintenance

Prerequisites for Commissioning

Prerequisites

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

 Disconnect all power from all equipment including connected devices prior to removing any

covers or doors, or installing or removing any accessories, hardware, cables, or wires.

 Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in

the non-energized position.

 Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge.  Measure the voltage on the DC bus with a properly rated voltage sensing device and verify

that the voltage is less than 42.4 Vdc.

 Do not assume that the DC bus is voltage-free when the DC bus LED is off.  Block the motor shaft to prevent rotation prior to performing any type of work on the drive

system.

 Do not create a short-circuit across the DC bus terminals or the DC bus capacitors.  Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a

proper ground connection exists before applying power to the unit.

 Use only the specified voltage when operating this equipment and any associated products.

Failure to follow these instructions will result in death or serious injury.

DANGER

100

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

 Operate electrical components only with a connected protective ground (earth) cable.  After the installation, verify the secure connection of the protective ground (earth) cable to all

electrical devices to ensure that connection complies with the connection diagram.

 Before enabling the device, safely cover the live components to prevent contact.  Do not touch the electrical connection points of the components when the module is

energized.

 Provide protection against indirect contact.  Connect and disconnect cables and terminals only after you have verified that the power has

been removed from the system.

Failure to follow these instructions will result in death or serious injury.

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Schneider Electric Lexium 62 ILM Hardware Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Lexium 62 ILM

Table of Contents

Safety Information

About the Book

Specific Safety Information

Product Related Information

Intended Use

Qualification of Personnel

System Overview

System Overview

Lexium 62 Power Supply

Lexium 62 Connection Module

Lexium 62 Distribution Box

Lexium 62 ILM Integrated Servo Drive

Lexium 62 ILM Digital I/O Module

Lexium 62 ILM Safety Module

ILM Daisy Chain Connector Box

Engineering

Electromagnetic Compatibility, E MC

Electromagnetic Compatibility, EMC

Control Cabinet Planning

Degree of Protection (IP)

Mechanical and Climatic Environmental Conditions in the Control Cabinet

Using Cooling Units

Information about Wiring

General Information about Wiring

Cable Characteristics

ESD Protection Measures

Conditions for UL / CSA Compliant Use

Fusing the Mains Connection

Mains Contactor

Mains Filter

Mains Line Reactor (Choke)

Connection of the Lexium 62 Power Supply

Leakage (Touch) Current

Residual Current Operated Protective Device

Functional Safety

Process Minimizing Risks Associated with the Machine

Designated Safety Function

Setup, Installation and Maintenance

Perform Muting with the Optional Modules DIS1

Application Proposals for Hardware-Based Safety Functions

Application Proposals for Software-Based Safety Functions

Commissioning

Best Practices

Maintenance

Physical Environment

Safety Standards

Special Conditions

Low Air Pressure

Installation and Maintenance

Prerequisites for Installation and Maintenance

Prerequisites for Maintenance and Installation

Commissioning

Prerequisites for Commissioning