Schneider Electric France L Isle d Espagnac ZART ZART REMOTE use a Bluetooth module User Manual USERS MANUAL

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EIO0000001505.00www.schneider-electric.comHarmony eXLhoistEIO0000001505 04/2014Harmony eXLhoistWireless Remote Control SystemUser Guide04/2014

2EIO0000001505 04/2014 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. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric.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.Failure to observe this information can result in injury or equipment damage.© 2014 Schneider Electric. All rights reserved.

EIO0000001505 04/2014 3Table of ContentsSafety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7About the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Chapter 1 Wireless Remote Control System. . . . . . . . . . . . . . . . . 13Wireless Remote Control System Overview . . . . . . . . . . . . . . . . . . . . 14Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Parts Identification and Main Features . . . . . . . . . . . . . . . . . . . . . . . . 20Certifications and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Chapter 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352.1 Base Station Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Base Station Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37RADIO Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.2 Remote Device Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Remote Device Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Remote Device Charger Specification. . . . . . . . . . . . . . . . . . . . . . . . . 482.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Base Station Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Remote Device Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Chapter 3 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533.1 Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Standards and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573.2 Description and Safety Function Capability. . . . . . . . . . . . . . . . . . . . . 61Wireless Remote Control System Safety Functions Are Part of an Overall System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Getting and Operating the Safety Function . . . . . . . . . . . . . . . . . . . . . 63E-STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64STOP Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Standard Motion & Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . 66Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Priority of Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4EIO0000001505 04/2014Safe State of the Wireless Remote Control System . . . . . . . . . . . . . . 69Response Time and Process Safety Time (PST) . . . . . . . . . . . . . . . . 70Legal RFU (Recommendation for Use) . . . . . . . . . . . . . . . . . . . . . . . . 71Summary of the Reliability Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723.3 Functional Safety Function Commissioning . . . . . . . . . . . . . . . . . . . . . 73Safety Parameters and Steps to Configure the Safety Functions . . . . 74Machine Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753.4 Functional Safety Requirements for Maintenance . . . . . . . . . . . . . . . . 77Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Base Station or Remote Device Replacement. . . . . . . . . . . . . . . . . . . 79Changing Machine Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Chapter 4 Installation and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . 814.1 Base Station Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Base Station Installation Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . 824.2 Base Station Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Base Station Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Wiring Best Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Factory Setting Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 944.3 Functionalities Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Motion/Auxiliary Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Detected Applicative Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Unintended Operating Control (UOC) Function . . . . . . . . . . . . . . . . . . 105Safeguarding Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Special Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114.4 Remote Device Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Customize The Remote Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113First Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Chapter 5 Using The Wireless Remote Control System . . . . . . . 1175.1 Basic Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Main Modes Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Power ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E-STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Power OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

EIO0000001505 04/2014 55.2 Functionalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Standard Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Auxiliary Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1365.3 Discovering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Discovering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1375.4 How to Modify the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140How to Modify a Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405.5 Remote Device Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Remote Device Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Chapter 6 Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1476.1 Base Station Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1486.2 ZART•D Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Radio Communication Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Battery Level of the Remote Device . . . . . . . . . . . . . . . . . . . . . . . . . . 153E-STOP LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Applicative Alarms Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Detected Failure Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1566.3 ZART8L Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157ZART8L LED Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Chapter 7 eXLhoist Configuration Software . . . . . . . . . . . . . . . . . 1617.1 Introduction to eXLhoist Configuration Software . . . . . . . . . . . . . . . . . 162What is eXLhoist Configuration Software? . . . . . . . . . . . . . . . . . . . . . 163Connect a Remote Device to the PC. . . . . . . . . . . . . . . . . . . . . . . . . . 165Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1677.2 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Starting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Workspace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

6EIO0000001505 04/20147.3 Project Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Starting and Exiting eXLhoist Configuration Software . . . . . . . . . . . . . 178Creating a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Edit a Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Project Passwords Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183Load the Configuration into the Remote Device . . . . . . . . . . . . . . . . . 185Save a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Export to PDF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1877.4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188Device Identity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Relay Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Detected Applicative Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Chapter 8 Maintenance / Device Replacement . . . . . . . . . . . . . . . 2018.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Regular Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2028.2 Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Base Station Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204ZART•D Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207ZART8L Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2108.3 Remote Device Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Remote Device Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Appendix A Architecture Examples . . . . . . . . . . . . . . . . . . . . . . . . . 215Tested Architectures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Vacuum/Magnetic Application Example . . . . . . . . . . . . . . . . . . . . . . . 221Room Lighting Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . 224Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

EIO0000001505 04/2014 7Safety InformationImportant InformationNOTICERead these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

8EIO0000001505 04/2014PLEASE NOTEElectrical 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.

EIO0000001505 04/2014 9About the BookAt a GlanceDocument ScopeThis manuel describes how to use the Wireless Remote Control System.Validity NoteThe technical characteristics of the devices described in this document also appear online. To access this information online:The characteristics that are presented in this manual should be the same as those characteristics that appear online. In line with our policy of constant improvement, we may revise content over time to improve clarity and accuracy. If you see a difference between the manual and online information, use the online information as your reference.Related DocumentsStep Action1 Go to the Schneider Electric home page www.schneider-electric.com.2 In the Search box type the reference of a product or the name of a product range.Do not include blank spaces in the model number/product range.To get information on grouping similar modules, use asterisks (*).3 If you entered a reference, go to the Product datasheets search results and click on the reference that interests you.If you entered the name of a product range, go to the Product Ranges search results and click on the product range that interests you.4 If more than one reference appears in the Products search results, click on the reference that interests you.5 Depending on the size of your screen, you may need to scroll down to see the data sheet.6 To save or print a data sheet as a .pdf file, click Download XXX product datasheet.Title of Documentation Reference NumberInstruction Sheet System XARS8L HRB57247Instruction Sheet System XARS•D HRB57248Instruction Sheet Accessory Charger HRB57251Instruction Sheet Accessory Soft & Cables HRB57273Instruction Sheet Accessory Shoulder Harness HRB57274

10 EIO0000001505 04/2014You can download these technical publications and other technical information from our website at www.schneider-electric.com.Product Related InformationInstruction Sheet Accessory Remote Holder HRB57277Instruction Sheet Accessory Rubber Protection EAV52994Instruction Sheet Accessory Pad & Trigger EAV52985Instruction Sheet Accessory External Antenna EAV59906Title of Documentation Reference NumberDANGERHAZARD OF 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, connectors or wires except under the specific conditions specified in this user guide.Always use a properly rated voltage sensing device to confirm that the power is off.Unplug the power cable from both the equipment and the power supply.Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the equipment.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.WARNINGUNINTENDED EQUIPMENT OPERATIONDo not open the Remote Device.Do not replace internal parts of the Base Station.After a Base Station power off, wait until the STATUS LED becomes OFF (around 20 seconds) before removing the cover.Always comply with the local requirements regarding installation and use of the hoisting devices.Failure to follow these instructions can result in death, serious injury, or equipment damage.

EIO0000001505 04/2014 11Battery Warning NotesCarefully read all instructions in this user guide, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it.For more information, contact us at www.schneider-electric.com or contact your local reseller.WARNINGUNINTENDED EQUIPMENT OPERATIONOnly use software approved by Schneider Electric for use with this equipment.Update your application program every time you change the hardware configuration.Failure to follow these instructions can result in death, serious injury, or equipment damage.NOTE: To increase the system security, it is recommended to use Configuration File transfer password.WARNINGEXPLOSION, FIRE, OR CHEMICAL HAZARDElectric devices that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility in accordance with national law.In case of electrolyte leak from battery, use adapted safety equipment and put the device in a sealed package. If you come into contact with electrolyte, immediately thoroughly wash the involved parts with clear water and call medical assistance.Do not incinerate the device.Do not drop or hit the device.Do not use a damaged device.The Remote Device battery is a 1Ah LiFePO4 battery. Do not replace it by yourself. In case of Remote Device battery malfunction or for any maintenance, contact us at www.schneider-electric.com or contact your local reseller.Failure to follow these instructions can result in death, serious injury, or equipment damage.NOTE: Advice to improve battery life:Charge the battery before device requires it.Charge the battery with room temperature within 10…40 °C (50…104 °F).Charge the battery once in every six months if you do not use it for a long time.

12 EIO0000001505 04/2014

EIO0000001505 04/2014 13Harmony eXLhoistWireless Re mote Control SystemEIO0000001505 04/2014Wireless Re mote Control SystemChapter 1Wireless Remote Control SystemWhat Is in This Chapter?This chapter contains the following topics:Topic PageWireless Remote Control System Overview 14Package Contents 19Parts Identification and Main Features 20Certifications and Standards 29Accessories 33

Wireless Remote Control System14 EIO0000001505 04/2014Wireless Remote Control System OverviewOverviewThe Harmony™ eXLhoist range of wireless remote control systems is an operator control station used in hoisting and material handling applications.The Wireless Remote Control System is based on 2 types of devices:Remote Device (or transmitter), which is the operator command device to interface with the machine.Base Station (or receiver), which is hardwired to the machine. It receives control commands from the Remote Device and transmits information to the operator.The Wireless Remote Control System is a combination of these devices which communicate by radio transmission.Radio CommunicationEach Base Station have a unique ID managed by Schneider Electric. It permits up to 50 single systems working at same time without perturbation in a 100 x 100 meter area.

Wireless Remote Control SystemEIO0000001505 04/2014 15Main ApplicationsExample of overhead traveling crane:Type DescriptionSINGLE With 1 trolleyThe Remote Device controls one trolley.1 Remote Device2 Trolley3 Base Station4 Electrical cabinet

Wireless Remote Control System16 EIO0000001505 04/2014SINGLE With 2 trolleysBy using the selector button, the Remote Device separately controls the trolley 1, trolley 1+2 or the trolley 2.1 Remote Device2 Trolley 13 Trolley 24 Base Station5 Electrical cabinetType Description

Wireless Remote Control SystemEIO0000001505 04/2014 17SINGLEWith 2 hooksBy using the selector button, the Remote Device separately controls the hook 1 or the hook 2.1 Remote Device2 Hook 13 Hook 24 Base Station5 Electrical cabinetType Description

Wireless Remote Control System18 EIO0000001505 04/2014*: TANDEM mode will be available on Q4 2014TANDEM*By using the selector button, the Remote Device separately controls the bridge 1, bridge 1+2 or the bridge 2.1 Remote Device2 Base Station 13 Bridge 14 Base Station 25 Bridge 26 Electrical cabinetsType Description

Wireless Remote Control SystemEIO0000001505 04/2014 19Package ContentsOverviewApplicable items included in the package:1 Base Station2 Remote Device3 Set of labels to customize the Remote Device buttons4 Instruction Sheet5 Charger of the Remote Device battery (only in starting kits)6 Shoulder belt for the Remote Device (only in starting kits)

Wireless Remote Control System20 EIO0000001505 04/2014Parts Identification and Main FeaturesWireless Remote Control System OverviewThe Wireless Remote Control System is a combination of 2 kinds of devices:Base Station:Remote Device:Therefore, 3 levels of complexity for Wireless Remote Control System: NOTE: Extended and complex systems (XARS•D) can support TANDEM mode (see page 15).Starting kits: References ZARB12W ZARB12H ZARB18W ZARB18HConnectors Cable gland for wires Industrial plug type Cable gland for wires Industrial plug typeNo. of inputs 0 18No. of relays 12 18Features ZART8L ZART8D ZART12DNumber of configurable buttons 8 8 12Operator interface LEDs Display DisplayComplexity level description ReferenceWireless Remote Control SystemRemote Device Base StationBasic system:For simple applications, which include up to 2 auxiliary buttonsXARS8L12W ZART8L ZARB12WXARS8L12H ZART8L ZARB12HExtended system:For adapted applications which include up to 2 auxiliary buttonsXARS8D18W ZART8D ZARB18WXARS8D18H ZART8D ZARB18HComplex system:For complex applications which include up to 6 auxiliary buttonsXARS12D18W ZART12D ZARB18WXARS12D18H ZART12D ZARB18HReferenceStarting Kit System AccessoriesXARSK8L12W XARS8L12W ZARC01 + ZARC02XARS8KL12H XARS8L12H ZARC01 + ZARC02XARS8KD18W XARS8D18W ZARC01 + ZARC02

Wireless Remote Control SystemEIO0000001505 04/2014 21Base Station Parts Identification XARS8KD18H XARS8D18H ZARC01 + ZARC02XARSK12D18W XARS12D18W ZARC01 + ZARC02XARSK12D18H XARS12D18H ZARC01 + ZARC02ReferenceStarting Kit System AccessoriesSide DescriptionFrontZARB•WFrontZARB•H

Wireless Remote Control System22 EIO0000001505 04/2014 Rear without the coverPart DescriptionA M12 for external antenna (covered by cap)B Status LEDsC M20 for the safeguarding function input wires (covered by cap)D 62 pins connector (covered by cap)E M25 for output wires (covered by cable gland)F M25 for detected applicative alarms input wires (covered by cap)G 4 holes for standard mounting on support (covered by cap)Side Description

Wireless Remote Control SystemEIO0000001505 04/2014 23Base Station Main Features References ZARB12W ZARB12H ZARB18W ZARB18HRadio communication YesExternal antenna connector YesConnectors Cable gland for wiresIndustrial plug typeCable gland for wiresIndustrial plug typeQ0 safety relays outputs 2 (Q0_A, Q0_B)IN0 / S2_S3 feedback loop terminals for mirror contacts from safety actuator1Configurable inputs for detected applicative alarms0 6 (IN1…IN6)Inputs dedicated for safeguarding function0 12 (IN7…IN18)Motion & auxiliary standard relays12 (Q1…Q12) 18 (Q1…Q18)Power supply 24…240 V ac/dc 24…48 V ac/dc 24…240 V ac/dc 24…48 V ac/dcCurrent consumption AC: 535…250 mA, 50/60 HzDC: 328…44 mAAC: 535…312 mA, 50/60 HzDC: 328…155 mAAC: 535…250 mA, 50/60 HzDC: 328…44 mAAC: 535…312 mA, 50/60 HzDC: 328…155 mASystem earthing TN, TT, ITQ0_A contact voltage 24…240 V ac/dc 24…48 V ac/dc 24…240 V ac/dc 24…48 V ac/dcQ0_B contact voltageMotion / auxiliary contact voltage used by groupMotion / auxiliary contact group Q1…Q3Q4…Q6Q7…Q9Q10…Q12Q1…Q3Q4…Q6Q7…Q9Q10…Q12Q13…Q16Motion / auxiliary relay in NO+NC type- Q17, Q18

Wireless Remote Control System24 EIO0000001505 04/2014Remote Device Front View Parts Identification ZART8LZART8D ZART12D

Wireless Remote Control SystemEIO0000001505 04/2014 25 Remote Device Rear View Parts Identification1 Cover2 RJ45 connector3 Reset buttonPart Description1, 1H, 2, 2H, 3, 3H, 4, 4H, 5, 6 Motion buttons7 Trigger button8 OFF/STOP button9 ON/START/Horn button10,11,12,13,14,15 Auxiliary buttons

Wireless Remote Control System26 EIO0000001505 04/2014Remote Device Bottom Display Parts Identification1 Remote Device battery charge connector2 Protective plug3 E-STOP buttonDANGEROBSTRUCTED PUSH-BUTTON MOTIONEnsure push-button will fully operate.Failure to follow these instructions will result in death or serious injury.

Wireless Remote Control SystemEIO0000001505 04/2014 27ZART•D Display Parts Identification1 Battery level2 Radio communication level3 Operating status4 Bridge label5 Detected applicative alarms6 Selector status7 E-STOP LED

Wireless Remote Control System28 EIO0000001505 04/2014ZART8L Display Parts Identification1 Battery level LED2 START LED3 Selector LEDs4 E-STOP LEDRemote Device Functionalities Description ZART8L ZART8D ZART12DNumber of configurable buttons 8 8 12OFF/STOP button YesON/START/Horn button YesMotion & Stop function YesSelector 2 or 3 positions (1, 1+2, 2) YesE-STOP function YesOptional E-STOP reset code sequence YesOptional START code sequence YesOptional automatic STOP function after a time-out YesOptional automatic Power OFF function after a time-out YesInformation LEDs Yes NoDisplay function No YesVibrate facility function in case of detected applicative alarms No YesEmbedded accelerometer Yes

Wireless Remote Control SystemEIO0000001505 04/2014 29Certifications and StandardsEnvironmentThe Wireless Remote Control System devices are compliant with:WEEE, directive 2002/96/ECREACH, regulation 1907/2006RoHS, directive 2011/65/EUOverall StandardsLocal Standards and CertificationsSchneider Electric submitted this product for independent testing and qualification by third party listing agencies.Criteria LevelPrinciples of design for safety EN IEC 60204-1EN ISO 13849-1EN ISO 13849-2EN IEC 62061EN IEC 61508EN ISO 13850Specific standards for hoisting applications EN IEC 60204-32EN 13557Low voltage equipment EN IEC 61010-1EN IEC 60947-5-1EN IEC 60947-5-4EN IEC 60947-5-5Electromagnetic compatibility IEC 61000-6-2Transmission frame format EN 60870-5-1Criteria DescriptionCE marking Machinery directive 2006/42/ECLow voltage directive 2006/95/ECEMC directive 2004/108/ECR&TTE directive 1999/05/EC Low voltage equipment EN 50178European specific standards for hoisting applicationsEN 13557EN 12077-2EN 15011European specific standards for hoisting machinesEN 15011 (overhead traveling cranes)EN 14439 (tower cranes)EN 14492 (block hoists and winches)

Wireless Remote Control System30 EIO0000001505 04/2014Radio Frequencies CertificationThe eXLhoist devices have obtained, or in the process of obtaining, the radio frequency conformity delivered by the following certification organisms: Countries certifications (electrical devices)CCCUL508 for base + UL functional safetyCSA C22-2 n°14GostC-tickKCUS-specific standards for safety UL 1998 (Covered by IEC 61508)UL 991Canadian specific standards for safetyCSA 22.2 N°0.8 (Covered by UL 991)Standards for radio frequencies ETSI EN 301 489 -1 ETSI EN 301 489 -3ETSI EN 301 489-17 ETSI EN 300 440-2ETSI EN 300 328 FCC part 15RSS GEN issue 3RSS 210 issue 8ARIB STD-T81Criteria DescriptionCertification organism Certification organism countryCertification marksCNC ArgentineRCM Australia/New-ZealandSee on the deviceANATEL Brazil See on www.schneider-electric.com.IC Canada See on the deviceSUBTEL Chili See on the device

Wireless Remote Control SystemEIO0000001505 04/2014 31SRRC China SRRC See on the deviceSDPPI IndonesiaTechnical Conformity Mark Japan See on the deviceSIRIM Malaysia See on the deviceCOFETEL Mexico See on the deviceictQATAR QatarEAC Russia See on the deviceIDA SingaporeICASA South Africa See on the deviceKCC South Korea See on the deviceNCC Taiwan See on the deviceNTC SDoC Thailand See on www.schneider-electric.com.Certification organism Certification organism countryCertification marks

Wireless Remote Control System32 EIO0000001505 04/2014TRA United Arab EmiratesFCC USA See on the deviceCertification organism Certification organism countryCertification marks

Wireless Remote Control SystemEIO0000001505 04/2014 33AccessoriesBase Station Accessories Remote Device Accessories Reference DescriptionZARC03 External antenna for Base Station:The use of this accessory allows an increase of the radio range in severe environment conditions.ZARC05 Connector plug female with cable 1.5 m (4.92 ft) for ZARB•HZARC06 Cable gland kit with wire grommetsZARC09 Kit silent bloc:Use this accessory in case of applications with severe vibration constraints.NSYAEFTB Optional mounting:Use this accessory for external mounting on support (x4).To be assembled on box before mounting on support.ZARC12 Connector plug female with cable 3 m (9.84 ft) for ZARB•HZARC18 Connector plug female with cable 5 m (16.4 ft) for ZARB•HReference DescriptionZARC01 ChargerZARC02 Shoulder beltZARC04 HolderZARC07 Kit of adhesive labels in B/W for Remote DeviceZARC08 Kit of adhesive labels in color for Remote Device and hoisting systemZARC20 Kit of pad and triggerZARC21 Rubber protection

Wireless Remote Control System34 EIO0000001505 04/2014

EIO0000001505 04/2014 35Harmony eXLhoist EIO0000001505 04/2014SpecificationsChapter 2SpecificationsWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page2.1 Base Station Specifications 362.2 Remote Device Specifications 462.3 Dimensions 49

36 EIO0000001505 04/2014Base Stat ion SpecificationsSection 2.1Base Station SpecificationsWhat Is in This Section?This section contains the following topics:Topic PageBase Station Specifications 37RADIO Specification 43

EIO0000001505 04/2014 37Base Station SpecificationsEnvironmentThe Base Station specifications are described in the table:Specifications Details ValueZARB•H ZARB•WProduct certifications - CE, UL/CSA, CCC, GostEnvironment - RoHS compliantLife time - 10 yearsDegree of protection - IP65Degree of pollution - 3Operating temperature For 24…48 V ac/dc power supply-25…70 °C (-13…158 °F)For 48…130 V ac/dc power supply- -25…70 °C (-13…158 °F)For 130…240 V ac/dc power supply- -25…50 °C (-13…122 °F)Storage temperature (for 1 year) - -40…70 °C (-40…158 °F)Corrosive atmosphere withstandsIEC-60721-3-3 Level 3C2 on H2S / SO2 / NO2 / Cl2Fire withstands Power on parts 960 °C 30s / 30s according to IEC 60695-2-10 and IEC-60695-2-11Other parts 650 °C 30s / 30s according to IEC 60695-2-10 and IEC-60695-2-11Salt mist IEC 60068.2.52 Severity 2Operating humidity range - 0...97%Storage humidity range - 0...97%Altitude Operation Storage0...2000 m (0...6561.7 ft)0...3000 m (0...9842.5 ft)Vibration resistance IEC-60068-2-6Use NSYAEFTB silent bloc in case of applications with severe vibration constraints10…55 Hz, amplitude 0.75 mm,Acceleration 9.8 m/s² (1 gn)Shock resistance According to IEC 60068-2-27 147 m/s² (15 gn), for 11 msPower supply Over voltage category-OVC2Voltage dips IEC-61000-4-11 10 msResistance to electrostatic dischargesIEC 61000-4-2 4 kV on contact8kV in air

38 EIO0000001505 04/2014Safety SpecificationsThe main safety specifications are described in the table:Resistance to radiated fields IEC 61000-4-3 10 V/mImmunity to fast transient IEC 61000-4-4 Power line: 4 kV (direct)Outputs: 4 kV (direct)Inputs: 2 kV (coupling)Surge immunity IEC 61000-4-5 between the ground and power supply wires (Common mode)2kVIEC 61000-4-5 between the power supply wires (Differential mode)1kVImmunity to conducted magnetic fields Conforming to IEC-61000-4-6 10 V from 150 kHz to 80 MHzEmission disturbances Conducted & radiated disturbancesClass BSpecifications Details ValueZARB•H ZARB•WSpecifications Details ValueSafety relays functionSafety specificationsAccording to IEC 61508 Ed2 Up to SIL3 capabilityAccording to IEC 62061 Ed1 Up to SIL3 CL capabilityEN ISO 13849-1 Up to performance level “e”Up to category 4Stop category according to IEC 60204-32Category 0Motion relays functionSafety specificationsAccording to IEC 61508 Ed2 SIL1 capabilityAccording to IEC 62061 Ed 1 SIL1 CL capabilityEN ISO 13849-1 Performance level “c”Category 1Stop category according to IEC 60204-32Category 0 or 1IN7...IN18 safeguarding inputs According to IEC 61508 Ed2 SIL1 capabilityAccording to IEC 62061 Ed 1 SIL1 CL capabilityEN ISO 13849-1 Performance level “c”Category 1Stop category according to IEC 60204-32Category 0 or 1

EIO0000001505 04/2014 39Safety RelaysThe safety relays specifications are described in the table:Specifications Details ValueZARB•H ZARB•WNumber of contacts The Base Station internally implements 2 safety relays in serial. Each safety relay has 2 contacts.2Logical type - NOInsulation between Q0A and Q0B- SELV insulation between (Q0A1, Q0A2) and (Q0B1, Q0B2) for voltage up to 240 VacQ0A voltages - Up to 48 Vac 24...240 VacQ0B voltages -Q0A, Q0BMaximum Ie current 24...240 Vac-4A6ARelay type according to EN/IEC 60947-5-1 AC15 C300 B300DC13 - R300Maximum making and breaking capacities (100.000 cycles)AC15 / AC current according to EN/IEC 60947-5-1 24 Vac 0.75 A48 Vac 0.38 A120 Vac - 0.15 A240 Vac - 0.08 AInrush 450 VAMaintained 45 VAMaximum making and breaking capacities (100.000 cycles)DC13 / DC current according to EN/IEC 60947-5-1 24 Vdc 0.6 A48 Vdc 0.3 A120 Vdc - 0.12 A240 Vdc - 0.06 AMake 14.4 VABreakMinimum output current The minimum current is compatible with the STO Schneider Electric drive input impedance of 1.5 kΩ which means a current of 24 V/1.5 kΩ= 16 mA.10 mA / 24 Vdc

40 EIO0000001505 04/2014Safety relays internal wiring:1 Safety relay 12 Safety relay 2Motion/Auxiliary RelaysThe motion/auxiliary relay specifications are described in the table:Specifications Details ValueZARB12H ZARB12W ZARB18H ZARB18WNumber of motion/auxiliary relays - 12 18Normally open (N0) relays - 12 (Q1…Q12) 16 (Q1…Q16)Normally open + normally closed (N0+NC) relays- 0 2 (Q17, Q18)Nominal output voltage - 24…48 V ac/dc ±20%24…240 V ac/dc ±20%24…48 V ac/dc ±20%24…240 V ac/dc ±20%Relay type according to EN/IEC 60947-5-1 AC15 B300DC13 R300Maximum making and breaking capacities 1 000 000 cycles for NO contacts500 000 cycles for NC contacts AC15 / AC current according to EN/IEC 60947-5-1 24 Vac 1.08 A48 Vac 0.54 A120 Vac - 0.22 A - 0.22 A240 Vac - 0.11 A - 0.11 AInrush 260 VAMaintained 26 VAMaximum making and breaking capacities 1 000 000 cycles for NO contacts500 000 cycles for NC contactsDC13 / DC current according to EN/IEC 60947-5-1 24 Vdc 0.1 A48 Vdc 0.05 A120 Vdc - 0.02 A - 0.02 A240 Vdc - 0.01 A - 0.01 AMake 5 VABreak 5 VAMinimum output current 6.8 mA with 24 Vdc voltage6.8 mAMaximum operating rate - 2 Hz

EIO0000001505 04/2014 41Power SupplyProtective Earth GroundThe PE must be connected to the machine to protect against maloperation due to earth faults (IEC 60204-1, Protection against maloperation due to earth faults).The PE must be connected to the machine ground (IEC 60204-1, protection against electric shock). If not then the Base Station inputs voltage (IN_COM, S2_S3, IN0…IN18) could increase to a dangerous voltage because of the possible static electricity induced by the machine motions. Maximum operating rate - 2 HzWeight - 1340 kg(2954 lb.)1360 kg(3644 lb.)1430 kg(3831 lb.)1450 kg(3885 lb.)Specifications Details ValueZARB12H ZARB12W ZARB18H ZARB18WNOTICEINOPERABLE EQUIPMENTThe ZARB•H Base Station must be powered with a voltage:From 24 Vac -15% to 48 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%.From 24 Vdc -15% to 48 Vdc +20%.The ZARB•W Base Station must be powered with a voltage:From 24 Vac -15% to 240 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%.From 24 Vdc -15% to 240 Vdc +20%.Failure to follow these instructions can result in equipment damage.WARNINGUNINTENDED EQUIPMENT OPERATIONConnect the Base Station protective earth ground connection to the machine ground.Failure to follow these instructions can result in death, serious injury, or equipment damage.

42 EIO0000001505 04/2014IN0The IN0 input specifications are:Static input typeCurrent source logicCompatible only with 2 wiring:Connection of IN0 to one side to the auxiliary contact of the main contactor and connection of S2_S3 output port to the other side of the auxiliary contact of the main contactor.Direct connection to the S2_S3 output.20 mA typical pulsed input currentIN1…IN18The IN1 to IN18 input specifications are:Static input typeCurrent source logicCompatible only with 2 wiring:Connection of INi (i=1…18) in one side of a dry contact and connection of IN_COM output to the other side of the dry contact.No INi (i=1…18) connection.20 mA typical pulsed input currentResponse TimeYou shall choose the contactors/drives in such way that the process safety time shall be less than 550 ms maximum to be in accordance with the IEC 60204-32.Input/Output Maximum response time (ms)E-STOP 300STOP 300Motion/Auxiliary 300Selector 300Input 300

EIO0000001505 04/2014 43RADIO SpecificationRADIO Specification FCC USA and IC Canada Compliance StatementThis device complies with part 15 of the FCC Rules and Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation.Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions suivantes : 1) l’appareil ne doit pas produire de brouillage, et 2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en compromettre le fonctionnement.Specification Details ValueFrequency of radio communicationInternational frequency range 2.4 GHzNumber of working systems in the same area- Up to 50 systems in a 100 x 100 meter areaRadio range In free field Up to 100 m (328 ft)In industrial environment Up to 50 m (164 ft) typicalAntenna (Possible ZARC03 external antenna use) InternalWorking channel selectionNo impact for the customer (during installation, use and maintenance)Up to 40 channelsID - MAC address reserved by Schneider Electric

44 EIO0000001505 04/2014Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:Reorient or relocate the receiving antenna.Increase the separation between the equipment and receiver.Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.Consult the dealer or an experienced radio/TV technician for help.The base complies with FCC’s radiation exposure limits set forth for an uncontrolled environment under the following conditions: 1) This equipment should be installed and operated such that a minimum separation distance of 20 cm is maintained between the radiator (antenna) and user’s/nearby person’s body at all times. 2) This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.The remote device with it’s antenna complies with FCC’s radiation exposure limits set forth for an uncontrolled environment. To maintain compliance, follow the instructions below: 1) This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter. 2) Avoid direct contact to the antenna, or keep contact to a minimum while using this equipment.Under Industry Canada regulations, these radio transmitters may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that necessary for successful communication. These radio transmitters (IC:7002CZARB and IC:7002CZART) have been approved by Industry Canada to operate with the antenna type ZARC03 with the maximum permissible gain and required antenna impedance. Any other antenna types having a gain greater than the maximum gain indicated for that type, are strictly prohibited for use with this device.

EIO0000001505 04/2014 45Conformément à la réglementation d’Industrie Canada, les présents émetteurs radio peuvent fonctionner avec une antenne d’un type et d’un gain maximal (ou inférieur) approuvé pour l’émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à l’intention des autres utilisateurs, il faut choisir le type d’antenne et son gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.) ne dépasse pas l’intensité nécessaire à l’établissement d’une communication satisfaisante. Les présents émetteurs radio (identifier IC:7002CZARBo and IC:7002CZARTo) ont été approuvé par Industrie Canada pour fonctionner avec le type d’antenne ZARC03 ayant un gain admissible maximal et l’impédance requise. D’autres types d’antenne non dont le gain est supérieur au gain maximal indiqué, sont strictement interdits pour l’exploitation de l’émetteur.Any changes or modifications not expressly approved by Schneider Electric could void the user’s authority to operate the equipment.Product referenceMaximum gain of internal antenna (dB)Maximum gain of external antenna (dB)(including cable)Allowed impedance (Ω)ZART8L 4.5 – 50ZATL8D 5.5ZART12DZARB12H 4.5 1ZARB12WZARB18HZARB18W

46 EIO0000001505 04/2014Remote De vice Specif icationsSection 2.2Remote Device SpecificationsWhat Is in This Section?This section contains the following topics:Topic PageRemote Device Specifications 47Remote Device Charger Specification 48

EIO0000001505 04/2014 47Remote Device SpecificationsEnvironment Specification Details ValueProduct certifications - CE, UL/CSA, CCC, GostSafety certification - TÜV, UL safetyBattery life time Conforming to IEC-62133 > 2 yearsBattery type - LiFePO4 3.3 V / 1 AhMechanical life Motion buttons 5 000 000 cyclesMechanical life Auxiliary buttons 5 000 000 cyclesTemperature Storage (for 1 year) -20…45 °C (-4…113 °F)Operating -20…60 °C (-4…140 °F)Relative humidity Operating/Storage -25…60 °C (-13…140 °F), 0%...95%, without condensationCorrosive atmospheres resistanceIEC 60721-3-3 Level of 3C2 on H2S / SO2 / NO2 / Cl2Degree of protection - IP65 and NEMA type 4Altitude OperationStorage0...2000 m (0...6561.7 ft)0...3000 m (0...9842.5 ft)Vibration resistance Conforming to IEC 60068-2-6 10…55 Hz, amplitude 0.75 mm, acceleration 15 gnShock resistance Conforming to IEC 60068-2-27 100 gnMechanical protection - BumperResistance to electrostatic dischargesConforming to IEC 61000-4-2 4 kV on contact8kV in airResistance to radiated fields Conforming to IEC 61000-4-3 10 V/mImmunity to fast transient Conforming to IEC 61000-4-4 1 kV, on power supplyImmunity to power frequency magnetic field - 30 A/m minimumMechanical materials - Bumper in onflex materialHousing visibility - Green colorWeight - 594 g (21 oz)

48 EIO0000001505 04/2014Remote Device Charger SpecificationEnvironment Specification ValueLocation to be used Residential, commercial, and light-industrial environment (IEC 61000-6-3)Product certifications CE, UL/CSA, CCC, GostDegree of protection IP2xDegree of pollution 2Operating temperature 10…40 °C (50…104 °F)Storage temperature (for 1 year) -20…60 °C (-4…140 °F)Primary supply voltage 240 Vac +/-20%110 Vac +/-20%Secondary output voltage 12 V, SELV voltageSecondary output power 30 W minimum

EIO0000001505 04/2014 49Dimensio nsSection 2.3DimensionsWhat Is in This Section?This section contains the following topics:Topic PageBase Station Dimensions 50Remote Device Dimensions 51

50 EIO0000001505 04/2014Base Station DimensionsDimensionsThe following figure shows the Base Station dimensions:

EIO0000001505 04/2014 51Remote Device DimensionsDimensionsThe following figure shows the Remote Device dimensions:

52 EIO0000001505 04/2014

EIO0000001505 04/2014 53Harmony eXLhoistSafetyEIO0000001505 04/2014SafetyChapter 3SafetyWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page3.1 Generalities 543.2 Description and Safety Function Capability 613.3 Functional Safety Function Commissioning 733.4 Functional Safety Requirements for Maintenance 77

Safety54 EIO0000001505 04/2014GeneralitiesSection 3.1GeneralitiesWhat Is in This Section?This section contains the following topics:Topic PageIntroduction 55Standards and Terminology 56Basics 57

SafetyEIO0000001505 04/2014 55IntroductionOverviewThe safety functions incorporated in eXLhoist allow you to develop applications oriented towards protection of people and machinery.Some safety functions are configured with eXLhoist Configuration Software.Integrated safety functions provide the following benefits:Additional standards-compliant safety functionsNo need for external safety devicesReduced wiring effort and space requirementsReduced costsThe eXLhoist is compliant with the requirements of the standards in terms of implementation of safety functions.

Safety56 EIO0000001505 04/2014Standards and TerminologyOverviewThe technical terms, terminology, and the corresponding descriptions in this manual normally use the terms or definitions in the relevant standards.In the field of Wireless Remote Control System, this includes, but is not limited to, terms such as safety function, safe state, fault, fault reset, failure, error, error message, warning, warning message, and so on. These standards include:IEC 61508 Ed.2 series: Functional safety of electrical/electronic/programmable electronic safety-related systemsIEC 62061 Ed.1.0: Safety of machinery - Functional safety of safety-related electrical, electronic, and programmable electronic control systemsEN ISO 13849-1 & 2 Safety of machinery - Safety related parts of control systemsEC Declaration of ConformityThe EC declaration of conformity for the machine directive 2006/42/EC can be obtained on www.schneider-electric.com.Functional Safety CertificationThe integrated safety functions are compatible with:EN 15011: 2011EN 14492-2: 2009EN 14439: 2009EN 13557: 2008IEC 60204-1: 2009IEC 60204-32: 2008The listed standards set out safety-related considerations of Wireless Remote Control System safety related in terms of the framework of the ISO13849-1 and ISO13849-2 standards.The defined safety functions are:SIL1, SIL2, and SIL3 capability in compliance with the IEC 61508 Ed.2 series.Performance Level c, d, and e in compliance with ISO 13849-1.Compliant with category 2, 3, and 4 of European standard ISO 13849-1.Also refer to Safety Function Capability (seepage61).The safety demand operating mode is considered to be high demand or continuous mode of operation according to the IEC 61508-1 standard.The functional safety certificate is accessible on www.schneider-electric.com.

SafetyEIO0000001505 04/2014 57BasicsFunctional SafetyAutomation and safety engineering are 2 areas that were separate in the past but have recently become more and more integrated.The engineering and installation of complex automation solutions are greatly simplified by integrated safety functions.Usually, the safety engineering requirements depend on the application.The level of requirement results from the risk and the hazard potential arising from the specific application.IEC 61508 StandardThe standard IEC 61508 functional safety of electrical/electronic/programmable electronic safety-related systems covers the safety-related function.Instead of a single component, an entire function chain (for example, from a sensor through the logical processing units to the actuator) is considered as a unit.This function chain must meet the requirements of the specific safety integrity level as a whole.Systems and components that can be used in various applications for safety tasks with comparable risk levels can be developed on this basis.ISO13849 Standard or IEC62061 StandardDesigners can follow either EN ISO 13849-1 or EN 62061 to demonstrate conformity with the Directive 2006/42/EC on machinery. These 2 new standards consider not only whether a fault will occur, but also how likely it is to occur.This means that there is a quantifiable, probabilistic element in compliance: machine builders must be able to determine whether their safety circuit meets the required Safety Integrity Level (SIL) or Performance Level (PL). Panel builders and designers should be aware that manufacturers of the components used in safety circuits (such as safety detection components, safety logic solvers, and output devices like contactors) must provide detailed data on their products.

Safety58 EIO0000001505 04/2014Safety standards:SIL - Safety Integrity LevelThe standard IEC 61508 defines 4 Safety Integrity Levels (SIL) for safety functions.SIL1 is the lowest level and SIL4 is the highest level.A hazard and risk analysis serves as a basis for determining the required SIL.This is used to decide whether the relevant function chain is to be considered as a safety function and which hazard potential it must cover.PF - Probability of FailureThe standard IEC 61508 defines SIL using requirements grouped into 2 broad categories: hardware safety integrity and systematic safety integrity. A device or system must meet the requirements for both categories to achieve a given SIL.The SIL requirements for hardware safety integrity are based on a probabilistic analysis of the device. To achieve a given SIL, the device must meet targets for the maximum probability of dangerous failure and a minimum Safe Failure Fraction. The concept of “dangerous failure” must be rigorously defined for the system in question, normally in the form of requirement constraints whose integrity is verified throughout system development. The actual targets required vary depending on the likelihood of a demand, the complexity of the devices, and types of redundancy used.

SafetyEIO0000001505 04/2014 59The Probability of Failure on Demand (PFD) of low demand operation for different SILs are defined in IEC 61508 are as follows:In continuous operation, these changes to the following:A function is considered as "on demand" if the demand rate is lower than one activation per year. Otherwise, the function is considered as "High demand or continuous operation".The hazards of a control system must be identified then analyzed in a risk analysis. These risks are gradually mitigated until their overall contribution to the hazard is deemed to be acceptable. The tolerable level of these risks is specified as a safety requirement in the form of a target probability of a dangerous failure over a given period, stated as a discrete SIL level.PL - Performance LevelThe standard IEC 13849-1 defines 5 Performance Levels (PL) for safety functions."a" is the lowest level and "e" is the highest level.5 levels (a, b, c, d, and e) correspond to different values of average probability of dangerous failure per hour.SIL Average Probability of a Dangerous Failure on Demand of the safety functionPFDSIL4 < 10-4SIL3 ≥ 10-4 to < 10-3SIL2 ≥ 10-3 to < 10-2SIL1 ≥ 10-2 to < 10-1SIL Average Frequency of a Dangerous Failure on Demand of the safety function (h-1)PFHSIL4 ≥ 10-9 to < 10-8SIL3 ≥ 10-8 to < 10-7SIL2 ≥ 10-7 to < 10-6SIL1 ≥ 10-6 to < 10-5PL Probability of a Dangerous Hardware Failure Per Houre≥ 10-8 to < 10-7d≥ 10-7 to < 10-6c≥ 10-6 to < 3*10-6

Safety60 EIO0000001505 04/2014HFT - Hardware Fault Tolerance and SFF - Safe Failure FractionDepending on the SIL for the safety system, the IEC 61508 standard requires a specific HFT in connection with a specific proportion of safe failures SFF.The HFT is the ability of a system to execute the required safety function in spite of the presence of one or more hardware faults.The SFF of a system is defined as the ratio of the rate of safe failures to the total failure rate of the system.According to IEC 61508, the maximum achievable SIL of a system is partly determined by the HFT and the SFF of the system.IEC 61508 distinguishes 2 types of subsystem (type A subsystem, type B subsystem).These types are specified on the basis of criteria which the standard defines for the safety-relevant components.Systematic Safety Integrity & Detect Fault Avoidance MeasuresSystematic errors in the specifications, in the hardware and the software, usage faults and maintenance faults in the safety system must be avoided to the maximum degree possible. To reach these requirements, IEC 61508 specifies a number of measures for fault avoidance that must be implemented depending on the required SIL. These measures for fault avoidance must cover the entire life cycle of the safety system, that is, from design to decommissioning of the system.b≥ 3*10-6 to < 10-5a≥ 10-5 to < 10-4PL Probability of a Dangerous Hardware Failure Per HourSFF HTFType A subsystem Type B subsystem012012< 60% SIL1 SIL2 SIL3 ---- SIL1 SIL260% ... < 90% SIL2 SIL3 SIL4 SIL1 SIL2 SIL390% ... < 99% SIL3 SIL4 SIL4 SIL2 SIL3 SIL4≥ 99% SIL3 SIL4 SIL4 SIL3 SIL4 SIL4

SafetyEIO0000001505 04/2014 61Description and Safety Function CapabilitySection 3.2Description and Safety Function CapabilityWhat Is in This Section?This section contains the following topics:Topic PageWireless Remote Control System Safety Functions Are Part of an Overall System 62Getting and Operating the Safety Function 63E-STOP 64STOP Function 65Standard Motion & Auxiliary Functions 66Safeguarding 67Priority of Safety Functions 68Safe State of the Wireless Remote Control System 69Response Time and Process Safety Time (PST) 70Legal RFU (Recommendation for Use) 71Summary of the Reliability Study 72

Safety62 EIO0000001505 04/2014Wireless Remote Control System Safety Functions Are Part of an Overall SystemOverviewThe qualitative and quantitative safety objectives determined by the final application require some adjustments to ensure safe use of the safety functions. The integrator of the Wireless Remote Control System is responsible for these additional changes (for example, managing the mechanical brake on the motor).

SafetyEIO0000001505 04/2014 63Getting and Operating the Safety FunctionOverviewThe SISTEMA software allows machine developers and testers of safety-related machine controls to evaluate the safety standard or level of their machine in the context of ISO 13849-1. The tool allows you to model the structure of safety-related control components based on the designated architectures, allowing automated calculation of the reliability standards with various levels of detail, including that of the Performance Level (PL).The eXLhoist libraries are available from www.schneider-electric.com.

Safety64 EIO0000001505 04/2014E-STOPOverviewFor general descriptions, refer to E-STOP function (see page 121).The E-STOP is not configurable.The undesired event of the E-STOP function is masking of E-STOP activation.The safe state of the E-STOP function is to open safety relays.For a SIL3 PLe E-STOP, auxiliary contact of contactors must be mechanically linked. Contactors shall be compliant with:EN 60947-4-1:2010 Annex F (preferred) - Requirements for auxiliary contact linked to power contact (mirror contact), orEN 60947-5-1:2004 Annex L - Special prescription for elements with contact mechanically linked.In order to be compliant with the Common Cause of Failure (CCF), wiring of redundant contactors or drives must be by different path. The standard E-STOP function of eXLhoist is limited to a stop category 0 according to IEC 60204-32. If some applications require an E-STOP function with a stop category 1, then a safety relay type Preventa XPS ATE or XPS AV or similar must be used.In order to justify of the safety category 4 according to ISO13849-1, an automatic diagnostic is realized on IN0 terminal thanks to the S2_S3 terminal (Pulsed 12 V). An external supply of IN0 input cannot be used.E-STOP function is a passive stop (function activated when an invalid frame is detected).Function Installation IEC 60204-32 IEC 61508 IEC 62061 ISO 13849STOP categorySIL SIL CL Safety categoryPLE-STOP With auxiliary contact loop between S2_S3 and IN0Category SIL3 SIL3 CL Safety categoryPL eWithout auxiliary contact loop between S2_S3 and IN0SIL2 SIL2 CL Safety categoryPL d

SafetyEIO0000001505 04/2014 65STOP FunctionOverviewFor general descriptions, refer to STOP function (seepage123).The undesired event of the STOP function is masking of STOP activation.The safe state of the STOP function is to open safety relays.STOP function is a passive stop (function activated when an invalid frame is detected).Function Installation IEC 60204-32 IEC 61508 IEC 62061 ISO 13849STOP categorySIL SIL CL Safety categoryPLSTOP No UOC Category 0 SIL2 SIL2 CL Safety category 3PL dWith UOC Category 1

Safety66 EIO0000001505 04/2014Standard Motion & Auxiliary FunctionsOverviewFor general descriptions, refer to Standard Motion (seepage131) and Auxiliary functions (seepage133).A relay assignment can be done for the Remote Device motion buttons with the eXLhoist Configuration Software. An UOC relay (see page 105) can be associated to a motion axis (and its motion relays) thanks to the eXLhoist Configuration Software.Auxiliary functions can be assigned to auxiliary buttons and relays thanks to the eXLhoist Configuration Software.The undesired event of standard motion & auxiliary functions is the unintended standard motion or auxiliary function activation.The safe state of the standard motion & auxiliary function is to open safety relays.In order to justify of the safety category 2, an automatic diagnostic is realized on buttons of the Remote Device when the Remote Device is switched ON and during a START of the machine. So during these 2 phases, the operator must not push any motion or auxiliary buttons.Standard motion & auxiliary functions are passive stop functions (functions activated when an input signal is detected).Function Installation IEC 60204-32 IEC 61508 IEC 62061 ISO 13849STOP categorySIL SIL CL Safety category PLStandard motion & auxiliary functionsNo UOC Category 1 SIL1 SIL1 CL Category 2 for electronic partsCategory 1 for electromechanical partsPL cWith UOC

SafetyEIO0000001505 04/2014 67SafeguardingOverviewFor general description, refer to Safeguarding function (see page 107).Safeguarding can be assigned to a motion direction thanks to the eXLhoist Configuration Software.The undesired event of Safeguarding function is the no disabling of motion buttons.Safeguarding limit switches contacts must be NC contacts.The safe state of the Safeguarding function is to open safety relays.Safeguarding input signal:In order to justify of the safety category 2, an automatic diagnostic is realized on the Safeguarding inputs thanks to the IN_COM output port. An external power supply of Safeguarding inputs cannot be used.Safeguarding is a passive stop function (function activated when an input signal is detected).Function Installation IEC 60204-32 IEC 61508 IEC 62061 ISO 13849STOP categorySIL SIL CL Safety category PLSafeguarding NC Category 2 on the motion directionSIL1 SIL1 CL Category 2 for electronic partsCategory 1 for electromechanical partsPL cInput signals limit switch Units ValueLogic 0 (Ulow) V < 1Logic 1 (Uhigh) V > 2Impedance kΩ1.5Debounce time ms 1Response time of safety function ms < 300

Safety68 EIO0000001505 04/2014Priority of Safety FunctionsOverviewPriority of safety functions Safety functions1E-STOP2STOP3 Safeguarding4 Standard motion & auxiliary functions

SafetyEIO0000001505 04/2014 69Safe State of the Wireless Remote Control SystemOverviewSafe states of the Base Station are:SAFE-STOP failure: if a failure is detected by the Base Station, the Base Station opens safety relays with a stop category 0 and stops the radio communication with the Remote Device.SAFE-STOP radio: if the Base Station looses the communication with the Remote Device, the Base Station opens the safety relays in stop category 0 or stop category 1 according to the commissioning.The Safe state position of the Remote Device is no communication with the base station: if a failure is detected in the Remote Device, the Remote Device stops the radio communication. So the Base Station goes to SAFE-STOP radio mode and opens the safety relays in stop category 0 or stop category 1 according to the commissioning.

Safety70 EIO0000001505 04/2014Response Time and Process Safety Time (PST)OverviewThe maximum Process Safety Time (PST) of STOP function is 550 ms according to IEC 60204-32 Ed.2 §9.2.7.3. This PST of 550 ms is taken into account for all safety functions. The PST allocation is:So 250 ms are allocated for contactors / drives of the hoisting system. The rest (300 ms) is allocated for Wireless Remote Control System. In consequences, the maximum response time of the Wireless Remote Control System is 300 ms for all safety functions in any configurations.

SafetyEIO0000001505 04/2014 71Legal RFU (Recommendation for Use)OverviewAccording to the machinery directive 2006/42/EC and the amendment - RECOMMENDATION FOR USE n°CNB/M/11.050 rev02, functional test (automatic or manual) shall be performed within the following test intervals:At least every month for PL e with category 3 or category 4 (according to EN ISO 13849-1) or SIL3 with HFT = 1 (according to EN 62061);At least every 12 months for PL d with category 3 (according to EN ISO 13849-1) or SIL2 with HFT = 1 (according to EN 62061).

Safety72 EIO0000001505 04/2014Summary of the Reliability StudySynthesis of Reliability Study in Configuration 1 Remote Device & 1 Base Station(1) IEC 62061 standard concerns integration. This standard distinguishes the overall safety function (classified SIL1, SIL2, or SIL3 according to diagrams in §1.4) from components which constitute the safety function (classified SIL1 CL, SIL2 CL or SIL3 for eXLhoist).NOTE: The table above is not sufficient to evaluate the PL of the hoisting system. The PL evaluation has to be done at the system level. The fitter of the integrator of the eXLhoist has to do the PL evaluation by including sensors and actuators data numbers from the table above. SISTEMA software can evaluate the PL of the system. NOTE: The radio communication of the Wireless Remote Control System is compliant with IEC 61784-3 Ed2 2010.Synthesis of Reliability Study in Configuration TANDEM 1 Remote Device & 2 Base StationTANDEM mode will be available on Q4 2014Standard Safety features E-STOP STOP Standard motion & auxiliary functionsLimit switchWith auxiliary contactWithout UOCUOC Without UOCUOC NC contactIEC 61508 Ed 2 SFF per channel 97.8 % 85 % 84.8 % 90.1 % 95 %PFH (10-9 h-1)7.32 7.54 7.57 52.3 51.8 17.9Type BHFT 1 0Diagnostic Coverage per channel91.4 % 41.7 % 41.8 % 73.8 % 90 %SIL capability 3 2 1IEC 62061 (1) SIL CL capability 3 2 1ISO 13849-1 2008 PL e d cSafety category 4 3 2MTTF in years 15584 15130 15070 2183 2202 6380Proof test interval (manual functional test) Once per monthOnce per yearMaximum response time 300 ms

SafetyEIO0000001505 04/2014 73Functional Safety Function Com missioningSection 3.3Functional Safety Function CommissioningWhat Is in This Section?This section contains the following topics:Topic PageSafety Parameters and Steps to Configure the Safety Functions 74Machine Signature 75

Safety74 EIO0000001505 04/2014Safety Parameters and Steps to Configure the Safety FunctionsCommissioning of Safety Functions The commissioning type of safety function is:Some passwords/codes can be configured on the eXLhoist Configuration Software:E-STOP code sequence on the Remote DeviceStart code sequence on the Remote DeviceTransfer password:For the read of the Configuration File in a Remote DeviceFor the transfer of the Configuration File between a Remote Device and a Base Station.Functions UOC delay time Relay assignment RemarksE-STOP - - No commissioningSTOP Yes - Safety relays cannot be commissionedMotion & auxiliary functions Yes Yes -Safeguarding - Yes -Passwords/codes Default valueE-STOP code sequence -Start code sequence 5, 6, 5, 6Transfer password 5, 6, 5, 6

SafetyEIO0000001505 04/2014 75Machine SignatureOverviewThe acceptance test for systems with safety integrated functions focuses on validating the functionality of safety integrated monitoring and stop functions configured in the Wireless Remote Control System.The purpose of the test is to verify proper configuration of the defined safety functions and test mechanisms and to examine the response of dedicated monitoring functions to explicit input of values outside the tolerance limits.The test must cover all Wireless Remote Control System-specific safety configured monitoring functions and global safety integrated functionality in eXLhoist.Condition Prior to Acceptance TestThe machine is wired up correctly.All safety devices such as limit switches, overload sensors, and emergency stop switches are connected and ready for operation.All commissioning parameters must be correctly set on the Wireless Remote Control System.Acceptance Test Process Step Action Comment1 Select the Base Station and the Remote Device With the eXLhoist Configuration Software2 Configure the relay assignments by functions.3 Configure the interlocking assignments (optional)4 Define passwords (optional):E-STOPSTOPConfigurationConfigure:TimeoutUOC delayMotion enable / limit switch5 Select the Microsoft® Excel acceptance test template file in www.schneider-electric.com. Complete the acceptance test template according to the system specificities.Mark down the configuration signature thanks to the eXLhoist Configuration Software.With Microsoft® ExcelThe acceptance test template is a generic acceptance test for generic application. The acceptance report must be updated according to the system application.The signature allows you to compare the checksum value with the one displayed in the identification menu on the graphic display.

Safety76 EIO0000001505 04/2014Acceptance ReporteXLhoist Configuration Software and Microsoft® Excel are required to create the acceptance report. The acceptance report is the safety signature of the Wireless Remote Control System. The acceptance report provides a final private report when the Wireless Remote Control System has been configured as Safe and declared Safe during operation. This report is deemed to be a machine signature and certifies that all the safety functions are operational.If the system configuration is modified, you must repeat the acceptance test.6 Test the system according to the acceptance testNotify the result of the test in the acceptance result.The acceptance test list becomes the acceptance result once it fulfills with test results.7 Print, save, and sign the acceptance report. -Step Action Comment

SafetyEIO0000001505 04/2014 77Functional Safety Requirements for Maintena nceSection 3.4Functional Safety Requirements for MaintenanceWhat Is in This Section?This section contains the following topics:Topic PageMaintenance 78Base Station or Remote Device Replacement 79Changing Machine Equipment 80

Safety78 EIO0000001505 04/2014MaintenanceE-STOPBy way of preventive maintenance and according to the Recommendation For Use (see page 71), the E-STOP and the STOP function must be activated at least once a month. The Remote Device and the Base Station must be turned off and then on again before carrying out this preventive maintenance.Others Safety FunctionsBy way of preventive maintenance and according to the Recommendation For Use (see page 71), the STOP, motion, auxiliary, limit switch functions must be activated at least once a year. The Remote Device and the Base Station must be turned off and then on again before carrying out this preventive maintenance.

SafetyEIO0000001505 04/2014 79Base Station or Remote Device ReplacementOverviewYou can replace the Base Station part and the Remote Device part.If you replace the Base Station or the Remote Device configured in Single, you will not lose your safety configuration thanks to the maintenance / device replacement procedure but you need to repeat the acceptance test to avoid incorrect wiring or incorrect behavior of the safety function.If you replace the Base Station or the Remote Device configured in Tandem, you will lose your safety configuration. You need to reinstall your configuration on the new Base Station or Remote Device and then repeat the acceptance test to avoid incorrect wiring or incorrect behavior of the safety function.NOTE: For more product information, see the Maintenance / Device Replacement (see page 201).

Safety80 EIO0000001505 04/2014Changing Machine EquipmentOverviewIf you need to change any part of the hoisting system (contactor, drive, …) you must repeat the acceptance test.NOTE: For more product information, see the installation part (see page 81).

EIO0000001505 04/2014 81Harmony eXLhoistInstallation and WiringEIO0000001505 04/2014Installation and WiringChapter 4Installation and WiringWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page4.1 Base Station Installation 824.2 Base Station Wiring 864.3 Functionalities Description 984.4 Remote Device Installation 112

Installation and Wiring82 EIO0000001505 04/2014Base Stat ion InstallationSection 4.1Base Station InstallationBase Station Installation PrecautionInstallation PrecautionExample of a recommended Base Station location: Base Station location:The Base Station must be installed vertical, with the cable at the bottom.

Installation and WiringEIO0000001505 04/2014 83Consider the wiring limitation and the radio communication limitation to choose the Base Station location.Do not create obstacle between the Base Station and the Remote Device to optimize the radio communication level.The Base Station must not be installed inside closed metal containers.To prevent communication perturbation:Do not place cables or metallic parts in front of the Base Station cover.Do not place obstacles between the Base Station and the Remote Device.According to IEC 61010-1, it is recommended to install the power switch of the Base Station close to the Base Station.To be compliant with IEC 61508, EN 62061 and EN ISO 13849, terminal ferrule must be used for the output wiring of the ZARB•W DANGERHEAVY LOAD MOVING HAZARDThe working range must be free of people when the hoisting system is operating. Failure to follow these instructions will result in death or serious injury.WARNINGUNINTENDED EQUIPMENT OPERATIONInstall and operate this equipment according to the environmental conditions described in the operating limits.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and Wiring84 EIO0000001505 04/2014Installation WARNINGUNINTENDED EQUIPMENT OPERATIONUse appropriate safety interlocks where personnel and/or equipment hazards exist.Use the sensor and actuator power supplies only for supplying power to the sensors or actuators connected to the device.Power line must be wired and protected with fuse or thermal magnetic switch (ex: Schneider-Electric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment.Do not disassemble, repair, or modify this equipment.Failure to follow these instructions can result in death, serious injury, or equipment damage.Step Action1 Unscrew the 4 screws at the bottom of the Base Station.2 Remove the cover.

Installation and WiringEIO0000001505 04/2014 85Use the ZARC09 silent blocs in case of applications with severe vibration constraints.3 Introduce the 4 screws in the dedicated holes (legend G):4 Screw the 4 mounting screws.5 Install the Base Station cover.6 Screw the 4 screws to fasten the Base Station cover.Step Action

Installation and Wiring86 EIO0000001505 04/2014Base Stat ion WiringSection 4.2Base Station WiringWhat Is in This Section?This section contains the following topics:Topic PageBase Station Wiring 87Wiring Best Practices 91Factory Setting Description 94

Installation and WiringEIO0000001505 04/2014 87Base Station WiringZARB•WWiring procedure: ZARB18 terminals:Insulation: The group of relays (Q1…Q3), (Q4…Q6), (Q7…Q9), (Q10…Q12) and (Q13…Q18), as well as the group of inputs (IN0…IN18) and the group of power supply (AC_Phase/+, AC_Neutral/-) respect a SELV insulation between each other.A single 240 V insulation shall be respected inside each of the following groups: (AC_Phase/+, AC_Neutral/-),(Q1…Q3), (Q4…Q6), (Q7…Q9), (Q10…Q12) and (Q13…Q18).A single 24 V insulation shall be respected inside the (IN0…IN18) group.Step Action1 Unscrew the 4 screws at the bottom of the Base Station.2 Remove the cover and insert a cable gland.3 Remove the caps.4 Introduce the cable through the Base Station dedicated hole.5 Connect the wires in the dedicated connectors.6 Screw the cable gland.7 Install the Base Station cover.8 Screw the 4 screws to fasten the Base Station cover.

Installation and Wiring88 EIO0000001505 04/2014ZARB•HThe input/output are wired to the connector (except the safeguarding inputs).To connect the Base Station, respect the connector description:If the ZARC03 external antenna is used, refer to the dedicated Instruction Sheet (seepage9). Safeguarding InputsSafeguarding inputs wiring procedure: Input/Output Possible UsesStep Action1 Unscrew the 4 screws at the bottom of the Base Station.2 Remove the cover and insert a cable gland.3 Remove the caps of cable gland.4 Introduce the cable through the Base Station dedicated hole.5 Connect the wires in the dedicated terminals.6 Screw the cable gland.7 Install the Base Station cover.8 Screw the 4 screws to fasten the Base Station cover.Input/Output Possible uses (Depending of the configuration)IN0 Safety loop input (see page 111)IN1…IN6 Detected Applicative Alarm (see page 103)IN7…IN18 Safeguarding (see page 107)S2_S3 Terminals for SIL2 / SIL3 E-STOP Configuration (see page 111)Q0A, Q0B Safety relay (see page 111)Q1…Q9 Motion relays (see page 99)

Installation and WiringEIO0000001505 04/2014 89Power SupplyProtective Earth GroundThe electrical isolation of the Base Station power supply from machine ground could cause static electricity damages. The limit switch could unintended operates in case of ground fault.The equipment could non-stop in case of ground fault detections on any control circuits.Factory SettingFor details on factory setting (wiring and configuration), refer to factory setting description (seepage94).Q10…Q16 (NO type)Q17, Q18 (NO+NC type)Auxiliary relays (see page 99)Selector (seepage102)UOC (see page 105)Specific relays (see page 109)Input/Output Possible uses (Depending of the configuration)NOTICEINOPERABLE EQUIPMENTThe ZARB•H Base Station must be powered with a voltage:From 24 Vac -15% to 48 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%.From 24 Vdc -15% to 48 Vdc +20%.The ZARB•W Base Station must be powered with a voltage:From 24 Vac -15% to 240 Vac +10% with frequency of 50 Hz -6%/+4% and frequency of 60 Hz -6%/+4%.From 24 Vdc -15% to 240 Vdc +20%.Failure to follow these instructions can result in equipment damage.WARNINGUNINTENDED EQUIPMENT OPERATIONConnect the Base Station protective earth ground connection to the machine ground.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and Wiring90 EIO0000001505 04/2014General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).

Installation and WiringEIO0000001505 04/2014 91Wiring Best PracticesOverviewThis section describes the wiring guidelines and associated best practices to be respected when using the system.1 For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest edition), "Safety Standards for Construction and Guide for Selection, Installation, and Operation of Adjustable-Speed Drive Systems" or their equivalent governing your particular location.DANGERHAZARD OF 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 except under the specific conditions specified in the appropriate hardware guide for this equipment.Always use a properly rated voltage sensing device to confirm that the power is off where and when indicated.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.WARNINGLOSS OF CONTROLThe designer of any control wiring diagram must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and overtravel stop, power outage and restart.Separate or redundant control paths must be provided for critical control functions.System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link.Observe all accident prevention regulations and local safety guidelines.1Each implementation of this equipment must be individually and thoroughly tested for proper operation before being placed into service.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and Wiring92 EIO0000001505 04/2014Protective Ground (PE) on the BackplaneThe protective ground (PE) is connected to the conductive backplane by a heavy-duty wire, usually a braided copper cable with the maximum allowable cable section.1Multipoint grounding is permissible if connections are made to an equipotential ground plane dimensioned to help avoid cable shield damage in the event of power system short-circuit currentsWiring GuidelinesThe following rules must be applied when wiring the system:I/O wiring must be kept separate from the power wiring. Route these 2 types of wiring in separate cable ducting.Verify that the operating conditions and environment are within the specification values.Use proper wire sizes to meet voltage and current requirements.Use copper conductors (highly recommended).Use twisted pair, shielded cables.WARNINGIMPROPER GROUNDING CAN CAUSE UNINTENDED EQUIPMENT OPERATIONUse cables with insulated shielded jackets for I/O signals.Ground shielded cables for I/O signals at a single point 1.Always comply with local wiring requirements regarding grounding of cable shields.Failure to follow these instructions can result in death, serious injury, or equipment damage.WARNINGUNINTENDED EQUIPMENT OPERATIONUse shielded cables wherever specified for inputs and outputs connections.Properly ground the cable shields as indicated in the related documentation.Route I/O cables separately from power cables.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and WiringEIO0000001505 04/2014 93Rules for Screw Terminal BlockThe following tables show the cable types and wire sizes for a 5.08 mm pitch screw terminal block:The use of copper conductors is required.The use of cable ends is required.WARNINGUNINTENDED EQUIPMENT OPERATIONPower line must be wired and protected with fuse or thermal magnetic switch (ex: Schneider-Electric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment.Failure to follow these instructions can result in death, serious injury, or equipment damage.DANGERFIRE HAZARDUse only the recommended wire sizes for I/O channels and power supplies.Failure to follow these instructions will result in death or serious injury.NOTICEINOPERABLE EQUIPMENTDo not tighten screw terminals beyond the specified maximum torque (Nm / lb-in.).Failure to follow these instructions can result in equipment damage.

Installation and Wiring94 EIO0000001505 04/2014Factory Setting DescriptionGeneral ParametersDetected Applicative AlarmsBase Station wiring:Safeguarding function (only for ZARB18•)Base Station wiring:General Label Factory setting valueParameter Start access sequence (see page 192)Enable: 5, 6, 5, 6E-STOP RESET sequence (see page 192)DisableStandby Time-out (see page 193)15 minutesPower saving Time-out (seepage193)15 minutesHorn duration (see page 193)2 secondsProtection Configuration File Transfer Password (see page 183)Enable: 5, 6, 5, 6Label Wiring description Factory setting descriptionIN1 Sensor input Overload pre-alarmIN2 Sensor input Overload alarmIN3 Sensor input Over wind pre-alarmIN4 Sensor input Over wind alarmIN5 Sensor input Over speed alarmIN6 Sensor input Generic alarmIN_COM Common output port (to be connected to the other side of the dry contact connected to the IN1…IN6 inputs)-Label Wiring description Factory setting descriptionIN7 Limit switch input (for button 1) When IN7 is activated, the relay 1 is OFFIN8 Limit switch input (for button 1H) When IN8 is activated, the relays 1 and 3 are OFFIN9 Limit switch input (for button 2) When IN9 is activated, the relay 2 is OFFIN10 Limit switch input (for button 2H) When IN10 is activated, the relays 2 and 3 are OFFIN11 Limit switch input (for button 3) When IN11 is activated, the relay 4 is OFFIN12 Limit switch input (for button 3H) When IN12 is activated, the relays 4 and 6 are OFFIN13 Limit switch input (for button 4) When IN13 is activated, the relay 5 is OFFIN14 Limit switch input (for button 4H) When IN14 is activated, the relays 5 and 6 are OFF

Installation and WiringEIO0000001505 04/2014 95Motion RelaysBase Station wiring:IN15 Limit switch input (for button 5) When IN15 is activated, the relay 7 is OFFIN16 Limit switch input (for button 5 +7) When IN16 is activated, the relays 7 and 9 are OFFIN17 Limit switch input (for button 6) When IN17 is ON, the relay 8 is OFFIN18 Limit switch input (for button 6 +7) When IN18 is ON, the relays 8 and 9 are OFFIN_COM Common output port (to be connected to the other side of the dry contact connected to the IN7…IN18 inputs)-Label Wiring description Factory setting descriptionLabel Wiring description Factory setting descriptionMotion relays (for motor axis X)CC_X Common for relays 1…3 -CT_1 Output of motion relay 1 Command for motion direction 1Relay is ON when button 1 or 1H is pressedCT_2 Output of motion relay 2 Command for motion direction 2Relay is ON when button 2 or 2H is pressedCT_3 Output of motion relay 3 Command for high speedRelay is ON when button 1H or 2H is pressedMotion relays (for motor axis Y)CC_Y Common for relays 4…6 -CT_4 Output of motion relay 4 Command for motion direction 1Relay is ON when button 3 or 3H is pressedCT_5 Output of motion relay 5 Command for motion direction 2Relay is ON when button 4 or 4H is pressedCT_6 Output of motion relay 6 Command for high speedRelay is ON when button 3H or 4H is pressedMotion relays (for motor axis Z)CC_Z Common for relays 7…9 -CT_7 Output of motion relay 7 Command for motion direction 1Relay is ON when button 5 or 5+7 is pressedCT_8 Output of motion relay 8 Command for motion direction 2Relay is ON when button 6 or 6+7 is pressedCT_9 Output of motion relay 9 Command for high speedRelay is ON when button 5+7 or 6+7 is pressed

Installation and Wiring96 EIO0000001505 04/2014Auxiliary RelaysBase Station wiring:The description of the relays 13 to 18 depends on the Base Station and Remote Device;Base Station:General Label Wiring description Factory setting descriptionAuxiliary relay 10 CC_10 Common SelectorRelay 10 is ON when the Selector (button 10) is in position 1 or 1+2Relay 11 is ON when the Selector (button 10) is in position 2 or 1+2CT_10 Output (NO type)Auxiliary relay 11 CC_11 CommonCT_11 Output (NO type)Auxiliary relay 12 CC_12 Common “Horn” relayRelay is ON during the start procedure, and for a configurable duration.In START mode, the relay is ON as long as the ON/START/Horn button is pressed.CT_12 Output (NO type)Auxiliary relay 13 CC_13 Common “Radio link” relayRelay 13 is ON as long as the radio communication is achieved between the Base Station and its Remote Device.CT_13 Output (NO type)Auxiliary relay 14 CC_14 Common Relay 14 is ON when button 11 is pressedCT_14 Output (NO type)Auxiliary relay 15 CC_15 Common Relay 15 is ON when button 12 is pressedCT_15 Output (NO type)Auxiliary relay 16 CC_16 Common Relay 16 is ON when button 13 is pressedCT_16 Output (NO type)Auxiliary relay 17 CC_17 Common Relay 17 is ON when button 14 is pressedCT_17 Output (NO type)CR_17 Output (NC type)Auxiliary relay 18 CC_18 Common Relay 18 is ON when button 15 is pressedCT_18 Output (NO type)CR_18 Output (NC type)References ZARB12• ZARB18•Motion & auxiliary standard relays12 (Q1…Q12) 18 (Q1…Q18)

Installation and WiringEIO0000001505 04/2014 97Remote Device:Power Supply and PEBase Station wiring:SafetyBase Station wiring:References ZART8L ZART8D ZARB12•Number of buttons 11 (8 configurable) 11 (8 configurable) 15 (12 configurable)Label Wiring description Factory setting descriptionPE Protected earth ground -AC_Neutral /- Base Station power supply -AC_Phase /+Label Wiring description Factory setting descriptionQ0A_1 Safety relay 1 -Q0A_2Q0B_1 Safety relay 2Q0B_2IN0 Safety loop -S2_S3

Installation and Wiring98 EIO0000001505 04/2014Functionalities Des criptionSection 4.3Functionalities DescriptionWhat Is in This Section?This section contains the following topics:Topic PageMotion/Auxiliary Relays 99Selector 102Detected Applicative Alarm 103Unintended Operating Control (UOC) Function 105Safeguarding Function 107Special Functions 109Safety Relay 111

Installation and WiringEIO0000001505 04/2014 99Motion/Auxiliary RelaysDescriptionThe motion/auxiliary relays are switched ON as long as the associated button is pressed.Only up to 6 motion/auxiliary relays activation occurs at the same time.If more than 6 motion/auxiliary relays switching are requested at the same time, then they are actuated in successive switching every 20 ms (except for UOC relays).You can configure the motion/auxiliary relays with the eXLhoist Configuration Software (seepage194).General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).WiringQ1…Q9 motion relay internal wiring (NO type):

Installation and Wiring100 EIO0000001505 04/2014Q10…Q16 motion/auxiliary relay wiring (NO type only) Q17, Q18 auxiliary relay wiring (NO+NC type)Motion WiringFor wiring examples, refer to the Architecture examples (seepage216).The motion/auxiliary relays output cable length should not exceed 20 m (65.6 ft).WARNINGUNINTENDED EQUIPMENT OPERATIONPower line must be wired and protected with fuse or thermal magnetic switch (ex: Schneider-Electric GV2) in compliance with local and national regulatory requirements for the rated current and voltage of the particular equipment.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and WiringEIO0000001505 04/2014 101Auxiliary WiringThe auxiliary buttons can be used, for example, to manage a:Vacuum/magnetic function (see page 221)Room lighting function (see page 224)Selector switch function (see page 102)Supplementary motionThe motion/auxiliary relays output cable length should not exceed 20 m (65.6 ft).Factory SettingFor details on factory setting (wiring and configuration), refer to factory setting description (seepage94).

Installation and Wiring102 EIO0000001505 04/2014SelectorDescriptionIn SINGLE configuration, the Selector button is associated to 2 relays.With an adapted wiring, these relays enable/disable the motions of the selected device (hook/trolleys).In TANDEM configuration, no relays are associated with the selector button. The button is used to select directly which Base Station are piloted.You can configure the selector with the eXLhoist Configuration Software (see page 194).General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).

Installation and WiringEIO0000001505 04/2014 103Detected Applicative AlarmOverviewThe ZARB18• Base Station implements 6 inputs: IN1…IN6.Different sensors can be connected to these inputs.These inputs are dedicated for applicative alarms.DescriptionThe detected applicative alarms are only displayed on the ZART•D Remote Device.Factory settings:You can configure the detected applicative alarm inputs with the eXLhoist Configuration Software (seepage199).General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).Input DescriptionIN1 Overload pre-alarmIN2 Overload alarmIN3 Over wind pre-alarmIN4 Over wind alarmIN5 Over speed alarmIN6 Generic alarm

Installation and Wiring104 EIO0000001505 04/2014WiringWiring diagram for the detected applicative alarm devices:1-6 Detected applicative alarm sensors

Installation and WiringEIO0000001505 04/2014 105Unintended Operating Control (UOC) FunctionOverviewThe Base Station can manage 3 UOC functions.These relays have temporization that shall correspond to the decelerating time ramp of the drive. After this time, the UOC relay will switch OFF to enable the Safe Torque Off (STO according to EN IEC 61500-5-2) input on the drive.The UOC function allows the Wireless Remote Control System to get a STOP category 1 according to EN60204.DescriptionA UOC relay is associated to one motion axis (4 motion buttons).Once a motion button is pressed, the associated UOC relay is switched ON.When all motion buttons are released, the UOC delay time starts.The UOC relay is switched OFF after the UOC pre-defined delay.UOC function diagram with a drive (the UOC relay is normally open (NO)):T1 Drive deceleration time.T2 UOC delay time.You can configure the UOC with the eXLhoist Configuration Software (seepage194).WARNINGUNINTENDED EQUIPMENT OPERATIONThe UOC delay time must be longer than the drive deceleration time.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Installation and Wiring106 EIO0000001505 04/2014General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).WiringDepending on the DRIVE functionality and its application schematic, the UOC relay can be directly connected to the DRIVE Safe Torque Off (STO according to EN/IEC 61500-5-2) input or in serial with a contactor coil.For wiring examples, refer to the Architecture examples (seepage216).

Installation and WiringEIO0000001505 04/2014 107Safeguarding FunctionOverviewThe ZARB18• Base Station implement 12 inputs IN7…IN18.These inputs are dedicated for limit switches to provide a protection to the hoist system.DescriptionThere are 4 limit switches per axis that allow to:Stop the motion at minimum mechanical position.Disable the high speed of the direction when the hoist system is near the minimum position.Stop the motion at maximum mechanical position.Disable the high speed of the direction when the hoist system is near the maximum position.These inputs are associated to motion buttons.Once a limit switch is opened, the associated motion relay(s) is(are) switched OFF. You can configure the limit switches with the eXLhoist Configuration Software (see page 194).Installation PrinciplePrinciple of safeguarding function installation for 1 axis:1 Mechanical target for limit switch triggering for stopping the motion direction2 Mechanical target for limit switch triggering for slowing the motion direction3 Mechanical target for limit switch triggering for slowing the motion direction4 Mechanical target for limit switch triggering for stopping the motion direction5 Stationary part6 Mobil part7 Motion (example: button 1 or 1H)8 Motion (example: button 2 or 2H)General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).

Installation and Wiring108 EIO0000001505 04/2014WiringWiring diagram for the detected safeguarding devices:1-6 Limit switchesFactory SettingFor details on factory setting (wiring and configuration), refer to factory setting description (seepage94).

Installation and WiringEIO0000001505 04/2014 109Special FunctionsDescriptionThe Wireless Remote Control System manages 4 specific relays:You can configure the specific relays with the eXLhoist Configuration Software (see page 194).Application ExampleA “Radio link” indication shall inform operator about the system communication status according to EN 15011 standard.It is recommended to use a Schneider Electric beacon:1 Light wired to the “Radio link” relay2 Light wired to the “Safety relay image” relay3 Buzzer wired to the “Horn” relay (an additional flash light can be wired to this relay)The beacon operating is described in the START mode description (see page 125).Relay DescriptionHorn This relay is switched ON during the start procedure, and for a configurable duration.This relay is also switched ON, in START mode, as long as the ON/START/Horn is pressed.Radio link This relay is switched ON as long as a RADIO communication is achieved between the Base Station and its Remote Device.Safety relay imageThis relay is switched ON as long as the 2 safety relays are ON.It occurs only in START mode and if all the safety conditions are fulfilled.It can indicate when the motions are enabled.Tandem 1+2 This relay is switched ON only in TANDEM configuration and only when the 2 Base stations are selected.This relay can be used in case of inhibition of anticollision in TANDEM configuration.

Installation and Wiring110 EIO0000001505 04/2014General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).Factory SettingFor details on factory setting (wiring and configuration), refer to factory setting description (seepage94).

Installation and WiringEIO0000001505 04/2014 111Safety RelayIN0 Safety Loop InputThe IN0 input is dedicated to check the correct actuator functionality with the auxiliary contact state.The E-STOP function can reach up to SIL 3 level only if all the relevant auxiliary contacts are connected between the IN0 input and the S2_S3 port terminal.The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).Q0A/Q0B Safety RelaysThe safety relays are switched ON when ON/START/Horn button is activated and all the safety conditions are fulfilled.The safety relay output cable length should not exceed 20 m (65.6 ft).General Wiring RulesThe I/O and power supply cables should be AWG 16 (cross-sectional conductor area = 1.3 mm2).The I/O and power supply cable lengths should not exceed 20 m (65.6 ft).For more details, refer to Wiring Best Practices (see page 91).WiringFor wiring examples, refer to the Architecture examples (seepage216).Safety DetailsFor more details about safety, refer to Safety chapter (seepage53).

Installation and Wiring112 EIO0000001505 04/2014Remote Devi ce Installatio nSection 4.4Remote Device InstallationWhat Is in This Section?This section contains the following topics:Topic PageCustomize The Remote Device 113First Commissioning 114

Installation and WiringEIO0000001505 04/2014 113Customize The Remote DeviceOverviewThe Wireless Remote Control System is delivered with a factory configuration. Use the label set to customize the remote buttons in accordance with the motion/auxiliary configuration.For details on factory setting (wiring and configuration), refer to factory setting description (seepage94).You can also stick an empty label above the top side of the Remote Device, and write on it the label of the hoisting system driven by it.

Installation and Wiring114 EIO0000001505 04/2014First CommissioningOverviewThe following procedures describe the first commissioning of a Wireless Remote Control System from a pack (Base Station + Remote Device).The installation must be in accordance to the factory setting (see page 94). In other case, refer to eXLhoist Configuration Software (see page 201) and the Discovery procedure description (seepage137).First Commissioning with 1 Base Station and the ZART8L Result: The Wireless Remote Control System is in STOP mode (see page 123).First Commissioning with 1 Base Station and the ZART•D Step Action1 Charge the Remote Device for more than 20 minutes.2 Install the Base Station.3 Power ON the Base Station.4 Place yourself to an appropriate distance from the Base Station (around 10 m (32.8 ft)).5 Press only the ON/START/Horn button more or equal than 1 s.6 Wait for the E-STOP LED to be permanently ON.Step Action1 Charge the Remote Device for more than 20 minutes.2 Install the Base Station.3 Power ON the Base Station.4 Place yourself to an appropriate distance from the Base Station (around 10 m (32.8 ft)).

Installation and WiringEIO0000001505 04/2014 1155 Press only the ON/START/Horn button more or equal than 1 s.Result: The Remote Device displays the ID list of detected Base Station:6 Selects the ID of the new Base Station with buttons 5 and 6.7 Press the button 7 (trigger) to validate.Result:8 Select the validation cell (check symbol) with buttons 1 and 2.Step Action

Installation and Wiring116 EIO0000001505 04/2014Result: The Wireless Remote Control System is in STOP mode (see page 123).9 Press the button 7 (trigger) to validate.Result: The Remote Device proposes to load the Configuration File from the Base Station to the Remote Device.10 Select the validation cell (check symbol) with buttons 1 and 2.11 Press the button 7 (trigger) to validate.Result: The Remote Device loads the Configuration File from the Base Station to the Remote Device.12 Wait for the end of the Configuration File load.Step Action

EIO0000001505 04/2014 117Harmony eXLhoistUsing The Wireless Remote Control SystemEIO0000001505 04/2014Using The Wireless Remote Control SystemChapter 5Using The Wireless Remote Control SystemWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page5.1 Basic Uses 1185.2 Functionalities 1305.3 Discovering 1375.4 How to Modify the Configuration 1405.5 Remote Device Charge 143

Using The Wireless Remote Control System118 EIO0000001505 04/2014Basic UsesSection 5.1Basic UsesWhat Is in This Section?This section contains the following topics:Topic PageMain Modes Diagram 119Power ON 120E-STOP 121STOP 123START 125Power OFF 128

Using The Wireless Remote Control SystemEIO0000001505 04/2014 119Main Modes DiagramMain Modes DiagramThe following diagram presents the main modes of the Wireless Remote Control System:

Using The Wireless Remote Control System120 EIO0000001505 04/2014Power ONOverviewThe aim is to describe how to power ON the Wireless Remote Control System.Triggering Procedure Result: The Remote Device is powered ON.The discovery procedure is automatically launched. If the Wireless Remote Control System has been installed correctly, the Wireless Remote Control System goes automatically in STOP mode (seepage123).In other case, refer to the discovery description (see page 137).ReleaseThe Remote Device is powered OFF:By the Power OFF procedure (see page 128).Automatically when the Remote Device battery level is too low.Automatically after the Power-saving time-out. You can configure the Power-saving time-out in the XAR Configuration software (see page 193).Step Action1 Check that the Remote Device is powered OFF.2 Power ON the Base Station.3 Press only the ON/START/Horn button more or equal than 1 s.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 121E-STOPOverviewThe E-STOP function leads to go to the safe position of the Wireless Remote Control System when the operator presses the E-STOP red mushroom button.In E-STOP mode, the motion/auxiliary relays and the safety relays are OFF.NOTE: The Remote Device cannot go to the E-STOP mode while the E-STOP function is not operational (E-STOP LED is OFF).Triggering Procedure Wireless Remote Control System In E-STOP ModeRemote Device:Base Station:Step Action1 Press the E-STOP button.Reference DescriptionZART8L The START LED is OFF.The E-STOP LED is blinking at a frequency of 1 Hz.ZART•D The STOP mode symbol is displayed.The E-STOP symbol is permanently displayed.The E-STOP LED is blinking at a frequency of 1 Hz.The Remote Device generate a vibration for 3 seconds and generate the same thing every 10 min until the E-STOP mode is released.Reference DescriptionRelays The safety relays are OFF.The motion/auxiliary relays are OFF.The “Safety relay image” relay is OFF.LEDs The STATUS LED is blinking. The POWER LED is ON.The COM LED is blinking.

Using The Wireless Remote Control System122 EIO0000001505 04/2014ReleaseRelease procedure:Result: The Wireless Remote Control System is in STOP mode (see page 123).Specifics InformationYou can configure the E-STOP restart code sequence in the eXLhoist Configuration Software (seepage191).Step Action1 Verify that there is no more risk conditions.2 Release the E-STOP button.3 If an E-STOP restart code sequence is configured:Type the E-STOP restart code sequence with the motion buttons 1…6.Press the button 7 (trigger).

Using The Wireless Remote Control SystemEIO0000001505 04/2014 123STOPOverviewIn STOP mode, the motion/auxiliary relays are disabled and the safety relays are OFF.Triggering ProcedureThe STOP mode is reached in the following cases:The OFF/STOP button is pressed (the Wireless Remote Control System was previously in START mode).No button pressed for more than the configured time-out (Standby time-out) configured in eXLhoist Configuration Software (see page 191).Wireless connection lost (out of range for example).Remote Device accelerometer triggering due to:A shock on the Remote DeviceThe Remote Device fallTriggering procedure when the Wireless Remote Control System is in START mode:Wireless Remote Control System In STOP ModeRemote Device:ZART•D display from START mode to STOP mode:Step Action1 Check that the Wireless Remote Control System is in START mode.2 Press the OFF/STOP button.Reference DescriptionZART8L The START LED is OFF.The E-STOP LED is ON.ZART•D The STOP mode symbol is displayed.The E-STOP LED is ON.

Using The Wireless Remote Control System124 EIO0000001505 04/2014The Base Station execute the following steps:1 The motion/auxiliary relays are OFF.2 If configured, the UOC relays are OFF after a pre-configured time delay.3 The safety relays are OFF.Base Station:ReleaseFrom this mode, you can:Charge the Remote Device battery (see page 143).Power OFF the Remote Device (see page 128).Go to START mode (seepage125).Specifics InformationYou can configure the Time-Out Auto-Standby duration in the eXLhoist Configuration Software (seepage191).Element DescriptionRelays The safety relays are OFF.The motion/auxiliary relays are OFF.The “Radio link” relay is ON.The “Safety relay image” relay is ON.LEDs The STATUS LED is blinking. The POWER LED is ON.The COM LED is blinking.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 125STARTOverviewThe START mode is the only mode in which:You can command the motions (see page 131).You can command the auxiliary function (see page 133).You can command the horn (see page 136).The safety relays are switched ON.Triggering ProcedureRequired conditions: The Wireless Remote Control System must be in STOP mode.Triggering procedure:START DetailsIt is recommended to use a Schneider Electric beacon:1 Light wired to the “Radio link” relay2 Light wired to the “Safety relay image” relay3 Buzzer wired to the “Horn” relay (an additional flash light can be wired to this relay)Step Action1 If a START code sequence is configured:Type the START code sequence with the motion buttons 1, 2, 3, 4, 5, 6.The default START code sequence is 5, 6, 5, 6.Press the button 7 (trigger) to validate.2 Press only the ON/START/Horn button more or equal than 1 s.3 Wait during the START warning time (ZART•D vibrations, “Horn” relay ON).

Using The Wireless Remote Control System126 EIO0000001505 04/2014Beacon description in the operating modes: (example with ZART•D)Step Hoisting system signalingZART•DBefore Power ON -STOP modeThe motions are not enabled yet.Between STOP mode and START mode:The ZART•D vibrate facility is activated.The Horn sounds for the configured time.The motions are not enabled yet.START modeThe motions are enabled.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 127Wireless Remote Control System In START ModeRemote Device:Base Station:ReleaseTo leave the START mode:You can go to STOP mode (seepage123).You can go to E-STOP mode (see page 121).The Wireless Remote Control System goes automatically to STOP mode when no button pressed for more than the configured time-out (standby time-out).Specifics InformationYou can configure the optional start sequence and the Horn duration during start in the eXLhoist Configuration Software (see page 191).Reference DescriptionZART8L The START LED is ON.The E-STOP LED is ON.ZART•D The START mode symbol is displayed.The E-STOP LED is ON.Element DescriptionRelays The safety relays are ON.The motion/auxiliary relays are enabled.The “Radio link” relay is ON.The “Safety relay image” relay is ON.LEDs The STATUS LED is blinking. The POWER LED is ON.The COM LED is blinking.

Using The Wireless Remote Control System128 EIO0000001505 04/2014Power OFFOverviewThis function switches OFF the Remote Device.Triggering ProcedureRequired conditions: The Wireless Remote Control System must be in STOP mode.The "Power OFF function" is triggered in the following cases:The OFF/STOP button is pressed.No button pressed for more than the configured time-out: Auto Standby + Auto-OFF duration time.The Remote Device battery level is low.Triggering procedure when the Wireless Remote Control System is in STOP mode: Wireless Remote Control System In Power OFF ModeRemote Device:ZART•D display from STOP mode to Power OFF:Step Action1 Check that the Wireless Remote Control System is in STOP mode2 Press only the OFF/STOP button more or equal than 2 sReference DescriptionZART8L All the LEDs are OFF.ZART•D The display is inactive.The E-STOP LED is OFF.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 129Base Station:ReleaseFrom this mode, you can:Power ON the Remote Device (seepage120).Charge the Remote Device battery (see page 143).Specifics InformationYou can configure the Power-saving time out in the eXLhoist Configuration Software (seepage191).Element DescriptionRelays The safety relays are OFF.The motion/auxiliary relays are OFF.The “Radio link” relay is OFF.The “Safety relay image” relay is OFF.LEDs The STATUS LED is OFF. The POWER LED is ON.The COM LED is OFF.

Using The Wireless Remote Control System130 EIO0000001505 04/2014FunctionalitiesSection 5.2FunctionalitiesWhat Is in This Section?This section contains the following topics:Topic PageStandard Motion 131Auxiliary Function 133Selector 134Horn 136

Using The Wireless Remote Control SystemEIO0000001505 04/2014 131Standard MotionOverviewIn START mode, the motion buttons activate the associated motion relays that command the hoisting system movements.Triggering ProcedureRequired conditions: The Wireless Remote Control System must be in START mode (seepage125).Triggering procedure: Result: The associated relays are switched ON as long as the motion button is pressed.The Remote Device has no specific result.ReleaseRelease procedure:Result: The associated relays are switched OFF.Restrictions for Motion/Auxiliary Use Step Action1 Check that the Wireless Remote Control System is in START mode.2 Press a motion button 1, 1H, 2, 2H, 3, 3H, 4, 4H, 5, 5+7, 6, 6+7 (see page 24).Step Action1 Release the motion button.Type DescriptionNumber of simultaneous motionsOnly up to 6 motion/auxiliary relays can be activated at the same time (excluding the UOC relays).If more than 6 motion/auxiliary relays are requested (excluding the UOC relays), then the last motion relay request is not take into account.Interlocking If 2 buttons dedicated to same motion axis are pressed in opposite sense (interlocking), then the motion is stopped in these both directions.Buttons 5 and 6 The button 7 must be released to activate the button 5 or 6.

Using The Wireless Remote Control System132 EIO0000001505 04/2014Specifics InformationIn the eXLhoist Configuration Software, you can configure:Motion/auxiliary buttons associated to relays (see page 194).Motion/auxiliary buttons interlocking (see page 198).

Using The Wireless Remote Control SystemEIO0000001505 04/2014 133Auxiliary FunctionOverviewIn START mode, the auxiliary buttons activate the associated relays to command auxiliary action (for example to command open and close grab).Triggering ProcedureRequired conditions: The Wireless Remote Control System must be in START mode (seepage125).Triggering procedure: Result: The associated relays are switched ON as long as the auxiliary button is pressed.The Remote Device has no specific result.ReleaseRelease procedure:Result: The associated relays are switched OFF.Specifics InformationIn the eXLhoist Configuration Software, you can configure:Motion/auxiliary buttons associated to relays (see page 194).Motion/auxiliary buttons interlocking (see page 198).Step Action1 Check that the Wireless Remote Control System is in START mode.2 Press an auxiliary button (10, 10+7, 11, 11+7, 12, 12+7, 13, 13+7, 14, 14+7, 15, 15+7) (see page 24).Step Action1 Release the auxiliary button.

Using The Wireless Remote Control System134 EIO0000001505 04/2014SelectorDescriptionThere are 3 different configurations to use the selector auxiliary button:Bridge selector (3 positions) in TANDEM configuration: to manage 2 bridges by using 2 Base stations.Trolley selector (2 or 3 positions): to manage 2 trolleys with one Base Station.Hook selector (2 positions): to manage 2 hooks with one Base Station.Triggering ProcedureRequired conditions: The Wireless Remote Control System must be in STOP mode (seepage123).Triggering procedure: Wireless Remote Control System ResultRemote Device:For the ZART8L: the Selector LEDs are activated depending on the selection done.For the ZART•D display: the Selector symbol indicates which bridge(s)/trolley(s)/hook(s) is(are) selected: Base Station relays:The associated relay(s) is(are) switched ON.In TANDEM configuration, when the Base stations 1 and 2 are selected, the motions asked with the Remote Device are realized simultaneously by the 2 Base stations.Step Action1 Check that the Wireless Remote Control System is in STOP mode.2 Press the Selector button more or equal than 1 s to loop between the several positions.Nb of position Description23

Using The Wireless Remote Control SystemEIO0000001505 04/2014 135In TANDEM configuration, the “Radio link” relay of the selected Base Station switches ON:Specifics InformationAt the first Power ON, the Selector position is 1. For further Power ON, the Selector position is the last known Selector position.You can configure the Selector in the eXLhoist Configuration Software (see page 194). Relay Selector position 1 Selector position 1+2 Selector position 2RADIO link Bridge 1 Bridge 2 Bridge 1 Bridge 2 Bridge 1 Bridge 2

Using The Wireless Remote Control System136 EIO0000001505 04/2014HornOverviewFrom STOP mode to START mode, the “Horn” relay is switched ON for a predefined duration time.In START mode, as long as you press the ON/START/Horn button, the “Horn” relay is switched ON.Triggering ProcedureTriggering procedure: Result: The “Horn” relay is switched ON as long as the ON/START/Horn button is pressed.The Remote Device has no specific result.ReleaseRelease procedure:Result: The “Horn” relay is switched OFF.Specifics InformationThe Horn duration during start can be configured in the eXLhoist Configuration Software (seepage193).Step Action1 Check that the Wireless Remote Control System is in START mode.2 Press the ON/START/Horn button.Step Action1 Release the ON/START/Horn button.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 137DiscoveringSection 5.3DiscoveringDiscoveringOverviewThe discovering function is developed to be as automatic as possible.This function manages 2 different tasks:The pairing of the system: association between a Remote Device and a Base StationThe Configuration File Upload/Download: this file contains the Wireless Remote Control System configuration information.This function is launched at each Remote Device Power ON. In normal use, this function is automatic. You have to realize intermediate operations during:A device replacement (seepage203)The first commissioning (see page 114)NOTE: This function is only applicable to ZAR•D Remote Device.

Using The Wireless Remote Control System138 EIO0000001505 04/2014Discovering DiagramThe following diagram presents the detailed Discovering function:PairingThe pairing is the action to associate a Base Station with a Remote Device.Each Base Station have a unique ID.The pairing test is launched at each Remote Device power ON.As long as the pairing test is OK, the validation procedure is not requested to the operator.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 139Configuration FileThe Configuration File is stored in the Remote Device and in the Base Station.The Configuration File can be created or modified in the eXLhoist Configuration Software (seepage161).It contains:The Remote Device referenceThe Base Station IDThe Base Station referenceThe button/relay associationsThe UOC relay assignment and time delay definedThe detected applicative alarm configurationThe safeguarding configurationThe standby time-out and power-saving time-out

Using The Wireless Remote Control System140 EIO0000001505 04/2014How to Modify the ConfigurationSection 5.4How to Modify the ConfigurationHow to Modify a ConfigurationConfiguration ModificationThe following procedure describes how to modify the system configuration:Result: The Remote Device goes to STOP mode (see page 123).It is recommended to redo an Acceptance Test (see page 75).Configuration File load With a ZART8LAfter the modification of the configuration with the eXLhoist Configuration Software:Result: The Remote Device goes to STOP mode (see page 123).It is recommended to redo an Acceptance Test (see page 75).Step Action1 Connect the Remote Device to a PC (see page 165).2 Start the eXLhoist Configuration Software (see page 178).3 Create a project (see page 179).4 Modify the configuration of the project (see page 188)5 Select Communication → Store to Device.6 Wait for the end of the Configuration File load in the Remote Device.7 Disconnect the Remote Device to the PC.8 Power ON the Base Station.9 The Configuration File must be loaded from the Remote Device to the Base Station.Refer to:Configuration File load With a ZART8L (see page 140).Configuration File load With a ZART•D (see page 141).Step Action1 Power ON the Remote Device.2 The Configuration File is automatically loaded from the Remote Device to the Base Station.During the load, the START LED and “2” LED are flashing (see page 157) .Wait for the end of the Configuration File load.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 141Configuration File load With a ZART•DAfter the modification of the configuration with the eXLhoist Configuration Software:Step Action1 Power ON the Remote Device.Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device.2 Select the cancel cell (X) with buttons 1 and 2.3 Press the button 7 (trigger) to validate.4 The Remote Device propose to load the Configuration File from the Remote Device to the Base Station.Select the validation cell (check symbol) with buttons 1 and 2.

Using The Wireless Remote Control System142 EIO0000001505 04/2014Result: The Remote Device goes to STOP mode (see page 123).It is recommended to redo an Acceptance Test (see page 75).5 If the Configuration File has a transfer password, a padlock is displayed:Enter the Configuration File transfer code with the buttons 1 to 6.The default transfer password is 5, 6, 5, 6.6 Press the button 7 (trigger) to validate.Result: The Remote Device loads the Configuration File from the Remote Device to the Base Station.7 Wait for the end of the Configuration File load.Step Action

Using The Wireless Remote Control SystemEIO0000001505 04/2014 143Remote Device ChargeSection 5.5Remote Device ChargeRemote Device ChargeRequired ConditionsThe Remote Device must only be charged indoor with the ZARC01 charger.The Remote Device must be in STOP mode or Power OFF.The Remote Device temperature range must be 10…60 °C (50…140 °F) in case of battery charge.NOTE: At the first commissioning, you must charge the Remote Device for 30 minutes.NOTE: The Remote Device charge time is 15 minutes long at the maximum if the temperature range is 10…35 °C (50…95 °F), and is longer if the temperature is higher than 35 °C (95 °F).WARNINGBATTERY LIFESPAN, RISK OF EXPLOSION AND FIREDo not dispose of electric tools together with household waste material.In observance of european directive 2002/96/EC on wasted electrical and electronic equipment and its implementation in accordance with national law, electric tools that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.Failure to follow these instructions can result in death, serious injury, or equipment damage.

Using The Wireless Remote Control System144 EIO0000001505 04/2014Procedure Step Action1 Power OFF the Remote Device.2 On the bottom of the Remote Device, remove the protective cap.1 Remote Device battery charge connector2 Protective cap3 Connect the charger to the Remote Device battery charge connector.4 Plug the charger to the dedicated power source.

Using The Wireless Remote Control SystemEIO0000001505 04/2014 145NOTE: If the system is in START mode, it goes automatically in STOP mode at the connection of the charger.5 Wait for around 15 minutes.During the charge:ZART8L: the battery LED is flashing.ZART•D: the blinking battery symbol indicates the battery level:The battery is fully charged when:ZART8L: the battery LED is permanently ON.ZART•D: the battery symbol is permanently displayed.For more details, refer to Diagnostic (see page 153).NOTE: The time duration for charge or the Remote Device depends on the ambient temperature.6 Unplug the charger to the dedicated power source.7 Unconnect the charger to the Remote Device battery recharge connector.8 On the bottom of the Remote Device, place back the protective cap.Step Action

Using The Wireless Remote Control System146 EIO0000001505 04/2014

EIO0000001505 04/2014 147Harmony eXLhoistDiagnost icEIO0000001505 04/2014Diagnost icChapter 6DiagnosticWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page6.1 Base Station Diagnostic 1486.2 ZART•D Diagnostic 1496.3 ZART8L Diagnostic 157

Diagnostic148 EIO0000001505 04/2014Base Stat ion DiagnosticSection 6.1Base Station DiagnosticDiagnosticDescriptionThe Base Station have 3 LED indicators: LED Color State DescriptionSTATUS Green Blinking The Wireless Remote Control System is working properly.OFF Base Station Power OFF or internal fault detected.COM Yellow OFF No communication between the Base Station and the Remote Device.Blinking The communication is established between the Base Station and the Remote Device.POWER White OFF Base Station powered OFF.ON Base Station powered ON.

DiagnosticEIO0000001505 04/2014 149ZART•D DiagnosticSection 6.2ZART•D DiagnosticWhat Is in This Section?This section contains the following topics:Topic PageDiagnostic Mode 150Radio Communication Indicator 152Battery Level of the Remote Device 153E-STOP LED 154Applicative Alarms Signals 155Detected Failure Displays 156

Diagnostic150 EIO0000001505 04/2014Diagnostic ModeOverviewTo test the Wireless Remote Control System configuration, the ZART•D has a specific diagnostic mode display.Procedure to Activate the Diagnostic ModeThe diagnostic mode on the ZART•D indicates the inputs and relays states of the Base Station. Diagnostic Display DescriptionIn STOP mode, use the buttons 5 and 6 to alternate between the 3 screens:Base Station information:IDHardware versionFirmware versionRemote Device information:IDHardware versionFirmware versionRemote Device battery information (only for Schneider-Electric use).In START mode, the Remote Device displays dynamically the I/O status:1 IN1...IN18 states: up for input = 1, down for input = 02 Relays 1...18 states: up for output = 1, down for output = 0Step Action1 Go to STOP mode (see page 123).2 Simultaneously press the buttons 1 and 2, and release immediately.3 Less than 5 seconds later, simultaneously press the buttons 3 and 4.4 Release the buttons 3 and 4.

DiagnosticEIO0000001505 04/2014 151Procedure to Leave the Diagnostic Mode Step Action1 Power OFF the Remote Device

Diagnostic152 EIO0000001505 04/2014Radio Communication IndicatorZART•DDisplay ZART•D radio communication level with the Base StationHighMediumLowNo radio communication

DiagnosticEIO0000001505 04/2014 153Battery Level of the Remote DeviceZART•DDisplay DescriptionBattery charge level is highBattery charge level is mediumBattery charge level is lowThis display occurs at least 10 minutes before the Remote Device cannot properly work.In addition, the Remote Device vibrate facility is activated for 1 second.

Diagnostic154 EIO0000001505 04/2014E-STOP LEDDescriptionE-STOP LED DescriptionPermanently ON E-STOP is operational and not triggered.Blinking at a frequency of 1 Hz. E-STOP is operational and triggered.Permanently OFF E-STOP is not operational.

DiagnosticEIO0000001505 04/2014 155Applicative Alarms SignalsOverviewSome devices can be connected to the ZARB18• Base Station to provide detected applicative alarms signals that can be displayed in the ZART•D.ZART•DWhen applicative alarms signals come from ZARB18• Base Station, the ZART•D Remote Device involves a symbol display and 3 seconds of vibration every 10 minutes as long as the alarm signal is active.The Remote Device displays the following symbols: NOTE: The applicative alarms are only information, the Wireless Remote Control System does not change its functional mode.Display Status DescriptionPermanently ON Overload pre-alarmBlinking at a frequency of 1 Hz Overload alarmPermanently ON Over wind pre-alarmBlinking at a frequency of 1 Hz Over wind alarmBlinking at a frequency of 1 Hz Over speed alarmBlinking at a frequency of 1 Hz Generic alarm

Diagnostic156 EIO0000001505 04/2014Detected Failure DisplaysZART•DThe ZART•D Remote Device can display the following symbols: Display Status DescriptionBlinking Configuration File download failure detectedBlinking Configuration File upload failure detectedBlinking Remote Device failure detectedBlinking Remote Device battery charge failure detected

DiagnosticEIO0000001505 04/2014 157ZART8L DiagnosticSection 6.3ZART8L DiagnosticZART8L LED DiagnosticOverviewThis section describes the ZART8L Display LEDs (see page 28).LED Status Chronogram The following diagram presents the different status of the ZART8L LEDs:

Diagnostic158 EIO0000001505 04/2014Start LEDBattery LEDCharger ZARC01 not connectedLabel StatusAOFFBONC Normal blinkDFast blinkE Flash step 1F Flash step 2G Reverse flash step 1Label Status DescriptionB ON The system is in START mode with radio operationalC Normal blink Radio not established or START mode not yet confirmedF Reverse flash step 1 A password has not yet been provided & validated (either for before START, or after unlocking the E-Stop before START)D Fast blink Wrong Configuration File E Flash step 1 The Remote Device is connected to a PC.A OFF To represent other states than the previous onesLabel Status DescriptionB ON Battery charge level is highBattery charge level is mediumC Normal blink Battery charge level is lowD Fast blink Battery charge level is very lowThe battery capacity just allows 10 minutes of normal operation.A OFF The battery is fully discharged or the Remote Device is Power OFF.

DiagnosticEIO0000001505 04/2014 159Charger ZARC01 connectedOnce the Remote Device is connected to the battery charger, the battery LED flashes 3 times (E label = FLASH_STEP_1). After the 3 flash, the battery LED status changes to the following ones:Selector LEDsThe “1” LED:The “2” LED:Set of LEDsPower ON - Check LEDs:At Remote Device Power ON, the 4 LEDs (START, Battery, 1, and 2) flash one time (status E = Flash step 1).Remote failure detected:If a remote internal failure is detected, the 4 LEDs go in the following status:The START LED is in status E = Flash step 1The BATTERY LED is in status E = Flash step 1The “1” LED is in status E = Flash step 1The “2” LED is in status E = Flash step 1Label Status DescriptionB ON Battery charge level is full (No need to charge or end of charge)E Flash step 1 Battery charge in progressC Normal blink Impossible to charge (charger failure detected) or temperature out of the allowed boundariesA OFF Impossible to charge (battery too low to be charged)Label Status DescriptionB ON The “1” or the “1+2” selector position is selected and confirmedC Normal blink The “1” or the “1+2” selector position is required but not yet confirmedA OFF The selector position “1” is NOT selectedLabel Status DescriptionB ON The “1+2” or the “2” selector position is selected and confirmedC Normal blink The “1+2” or the “2” selector position is required but not yet confirmedA OFF The selector position “2” is NOT selected

Diagnostic160 EIO0000001505 04/2014Configuration file download:During the transfer of a Configuration File (from the Remote Device to the Base Station):The START LED is in status E = Flash step 1The “2” LED is in status F = Flash step 2Remote device reset:When you press the reset button : until the “1” and “2” LED comes in the following status:The “1” LED is in status E = Flash step 1The “2” LED is in status A = OFFE-STOP LEDLabel Status DescriptionB ON E-STOP is operational and not triggered.C Normal blink E-STOP is operational and triggered.A OFF E-STOP is not operational.

EIO0000001505 04/2014 161Harmony eXLhoisteXLhoist Configurat ion SoftwareEIO0000001505 04/2014eXLhoist Configurat ion SoftwareChapter 7eXLhoist Configuration SoftwareWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page7.1 Introduction to eXLhoist Configuration Software 1627.2 User Interface 1687.3 Project Management 1757.4 Configuration 188

eXLhoist Configuration Software162 EIO0000001505 04/2014Introduction to eXLhoist Configuration SoftwareSection 7.1Introduction to eXLhoist Configuration SoftwareWhat Is in This Section?This section contains the following topics:Topic PageWhat is eXLhoist Configuration Software? 163Connect a Remote Device to the PC 165Installation 167

eXLhoist Configuration SoftwareEIO0000001505 04/2014 163What is eXLhoist Configuration Software?IntroductioneXLhoist Configuration Software is a graphic user interface allowing you to manage the configuration of the Wireless Remote Control System.Software FeaturesMain software features of eXLhoist Configuration Software:Standard Windows® interfaceApplication browser and multiple window viewsProgramming and configuration supportCommunication with controllerStandard Windows® InterfaceKey standard Windows® features:Easy use of keyboard or mouseDockable windowsStandard menu organizationTooltips, status bar, and shortcut menusOnline help including context-sensitive helpController Communication and ControlMain eXLhoist Configuration Software features for remote support:Connecting and disconnecting a remoteDownloading and uploading remote configuration filesAdditional InformationRefer to the following for additional information:For information on standard Windows® interface features, refer to Microsoft Windows® documentation and help files.For context-sensitive help, first click in the main window and then press F1 or click the help buttons in dialog boxes.

eXLhoist Configuration Software164 EIO0000001505 04/2014ConventionsThe following typographic conventions are used in this operation guide.Format RepresentsBold For user input, enter words or phrases shown in bold as they appear. Menu names and options, commands and toolbar names, and dialog box names and options are also shown in bold type.UPPER CASE Keyboard names, combinations, and sequences are shown in all uppercase letters. For example, the keyboard shortcut for creating a new application is CTRL+N. To perform this shortcut, press and hold the CTRL key and then press the N key.File → Open The arrow indicates a menu selection. In this instance, go to the File menu to select the Open command.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 165Connect a Remote Device to the PCIntroductionThe connection is made using the RJ45 to USB converter cable.It is recommended to Power OFF the Remote Device before connecting it to the PC DescriptionThe figure illustrates the connection to a personal computer:1 Personal computer2 USB to RJ45 converter cable: TCSMCNAM3M002P3 Remote DeviceThe PC does not supply the Remote Device. As long as the Remote Device is connected to the PC, it is recommended to charge the remote (see page 143).NOTICEINOPERABLE EQUIPMENTAlways connect the communication cable to the PC before connecting it to the device.Only use the Schneider Electric cable TCSMCNAM3M002P.Failure to follow these instructions can result in equipment damage.

eXLhoist Configuration Software166 EIO0000001505 04/2014As long as the Remote Device is connected to the PC: ZART•D: a dedicated screen is displayed ZAR8L: The Start LED is flashing.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 167InstallationIntroductionThe software can be downloaded from www.schneider-electric.com.It must be installed via an administrator account.PrerequisiteseXLhoist Configuration Software requires the following minimal configuration:Dual core processorRAM: 2 GBRequired disk space: 2 GBWindows® XP SP3 32 bits / 7 Pro 32 bitsInstallation ProcessTo install eXLhoist Configuration Software, follow the steps below:Step Action1 Double-click the program file (setup.exe).2 If the .NET® framework 3.5 SP1 is not already installed, the installer automatically installs it.3 Follow all the steps.

eXLhoist Configuration Software168 EIO0000001505 04/2014User InterfaceSection 7.2User InterfaceWhat Is in This Section?This section contains the following topics:Topic PageStarting Screen 169Main Window 170Status Bar 171Toolbar 172Menu Bar 173Workspace 174

eXLhoist Configuration SoftwareEIO0000001505 04/2014 169Starting ScreenIntroductionThe eXLhoist Configuration Software starting window is displayed at software launching. It provides easy access to the main functions: Create a new project.Open an existing project.Connect a Remote Device.DescriptionThe illustration shows the eXLhoist Configuration Software starting screen: For more details, refer to Create a project (seepage179).Button DescriptionCreate a Project Allows you to create a new project with default values.Open a Project Allows you to open an existing project. Project files have the “xpf” extension.Connect Allows you to create a project with the data stored in a Remote Device. The data are uploaded from the Remote Device to the PC.

eXLhoist Configuration Software170 EIO0000001505 04/2014Main WindowIntroductionThe eXLhoist Configuration Software main window provides access to menus and commands, windows and toolbars, and views of an application.DescriptionThe illustration shows the eXLhoist Configuration Software main window:

eXLhoist Configuration SoftwareEIO0000001505 04/2014 171Status BarIntroductionThe status bar is a panel at the bottom of the main window that displays information about the application and the connected device. The status bar can be turned on or off by selecting View → Status Bar from the menu bar.DescriptionThe status bar displays:Status messages and promptsProject status

eXLhoist Configuration Software172 EIO0000001505 04/2014ToolbarIntroductionThe toolbar is a panel at the top of the main window which provides access to the main commands using icons.The toolbar can be turned on or off by selecting View → Toolbar from the menu bar.DescriptionThe illustration shows the eXLhoist Configuration Software toolbar:Element Description1Go to Start Page: Displays the start page, any opened project must be closed. If the project is not saved, a dialog box asks to save the project.2New Project: Creates new project, any opened project must be closed. If the project is not saved, a dialog box asks to save the project.3Open Project: Opens a project saved on your computer.4Save: Saves modifications to an existing project.5Save As: Saves an open project under a name and/or in a new location.6Page Setup: Ables to configure the printing page setup.7Print Preview: Displays the print preview.8Print: Prints the project.9Identify Device (see page 189)10 Edit Connection (see page 182).11 Connect to Device: Establishes the connection between the remote and the software.12 Disconnect from Device: Disconnects the connection between the remote and the software.13 Load From Device: Loads the parameters from the connected remote to the project file.If no project is opened, this command loads the remote information to the project file.If a project is opened, this command loads the remote configuration to the project. Project data are overwritten.14 Store to Device: Transfer configuration from project to the remote.If no project is opened, this command downloads the existing project file information to the remote.If a project is opened, this command transfers the project information to the remote.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 173Menu BarIntroductionThe menu bar is a panel at the top of the main window which provides access to the command menus.DescriptionThe illustration shows the eXLhoist Configuration Software menu bar:Menu DescriptionFile Available to launch file related operations (New, Open, Export, Print, Save, Close, and so on).View Available to toggle the toolbar and status bar visibility. Communication Available to manage the communication-related operation.Device Available to manage the Transfer Configuration File Password (see page 183).Tools Available to switch the language of the eXLhoist Configuration Software.Help Available to manage the Help and About of the eXLhoist Configuration Software.

eXLhoist Configuration Software174 EIO0000001505 04/2014WorkspaceIntroductionThe eXLhoist Configuration Software workspace provides access to the connected remote parameters.DescriptionThe illustration shows the eXLhoist Configuration Software workspace:The following tabs are available from the workspace:Parameters (see page 191)Relays Assignment (see page 194)Interlocking (see page 198)Alarm Assignment (seepage199)Device Identity (seepage189)

eXLhoist Configuration SoftwareEIO0000001505 04/2014 175Project ManagementSection 7.3Project ManagementWhat Is in This Section?This section contains the following topics:Topic PageDiagram 176Starting and Exiting eXLhoist Configuration Software 178Creating a Project 179Edit a Connection 182Project Passwords Management 183Load the Configuration into the Remote Device 185Save a Project 186Export to PDF 187

eXLhoist Configuration Software176 EIO0000001505 04/2014DiagramUses CasesThe main use cases of the eXLhoist Configuration Software are:Create a project.Open an existing project.Open a new project using data from remote connected.Save project.Close project.Generate the configuration documentation to export in “.pdf” file.Transfer configuration from PC to Remote Device.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 177The diagram illustrates the use cases:

eXLhoist Configuration Software178 EIO0000001505 04/2014Starting and Exiting eXLhoist Configuration SoftwareStarting eXLhoist Configuration SoftwareThe installation procedure for eXLhoist Configuration Software creates one or more of the following options for starting the software, depending on selections made during installation.Select one of the following options to start eXLhoist Configuration Software:Double-click the eXLhoist Configuration Software icon on the Windows® desktop.Select the eXLhoist Configuration Software entry from the Windows® programs menu.Select Run from the Windows® start menu and browse for the eXLhoist Configuration Software program.eXLhoist Configuration Software starts and the starting screen is displayed.Exiting eXLhoist Configuration SoftwareTo exit eXLhoist Configuration Software:Step Action1 Select File → Exit from the main menu.If there is no change, the application closes and eXLhoist Configuration Software exits to the Windows® desktop.If there are changes, an exit dialog box is displayed prompting you to save changes.2 Select Yes to save changes and exit eXLhoist Configuration Software.Select No to discard changes and exit.Select Cancel to return to eXLhoist Configuration Software with changes intact.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 179Creating a ProjectOverviewAs shown in the eXLhoist Configuration Software diagram, there are 3 ways to start a project:Create a new project with default values (see page 179).Open an existing project (seepage180).Create a new project with the configuration stored in a connected Remote Device (seepage180).These 3 ways can be realized form the starting screen but also from the main menu.Create a New Project with Default ValuesFollow the procedure to create a new project with default values.Step Action1 From the starting screen, click Create a project button.Note: From the main menu, select File → New.2 A device selection window is displayed:Select the appropriate device.3 Click Create button.Result: The project window is activated.

eXLhoist Configuration Software180 EIO0000001505 04/2014Open an Existing ProjectFollow the procedure to open an existing project from your PC:Note: If you do not enter the correct project password, the project is nevertheless opened but in “Locked” mode. In this mode, only the Device Identity tab content is displayed.Create a New Project with the Configuration Stored in a Remote DeviceFollow the procedure to create a new project with the configuration stored in a connected Remote Device:Step Action1 From the starting screen, click Open a project button.Note: From the main menu, select File → Open.2 A browser window is displayed.Select the project file (“.xpf”).3 Click Open.4 If the project file is locked, a window is displayed.Enter the project password (see page 184).Click Enter.The project window is activated.Step Action1 Connect a Remote Device to the PC (see page 165). 2 From the starting screen, click Connect button.3 If the communication between the PC and the Remote Device is not established, a window is displayed:Click Configure to display the Edit Connection windows (see page 182).Click Connect to retry the connection.Click Cancel to cancel the connect procedure.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 181NOTE: If you do not enter the correct project password, the project is nevertheless opened in “Locked” mode. In this mode, only the Device Identity tab content is displayed.4 If the configuration in the Remote Device has a transfer Configuration File password, a window is displayed.Enter the Transfer Password (see page 183) with the keyboard of the PC.Click Enter.5 Wait during the transfer.Note: A progress bar is displayed during the transfer.6 If the project file is locked, a window is displayed.Enter the project password (see page 184).Click Enter.The project window is activated.Step Action

eXLhoist Configuration Software182 EIO0000001505 04/2014Edit a ConnectionOverviewFollow the procedure to modify the communication settings for the connected device:Step Action1 Connect a Remote Device to the PC (see page 165). 2 From the main menu, select Communication → Edit Connection.3 A window is displayed:Select the COM Port.4 Click Test.5 If the communication is not established with the Remote Device, click Cancel and modify the Modbus protocol settings.Modbus Driver setting available: Baud rate: 19200 baudsMode (Data Bits): RTU (8 bits)Even ParityOne Stop bit6 Click OK to validate and close the window.Click Cancel to close the window.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 183Project Passwords ManagementOverviewYou can configure 2 passwords to the project:The transfer password of the Configuration FileThe project passwordTransfer PasswordThe transfer password is asked before each Configuration File transfer.After a modification of the system configuration (see page 140)During a remote replacement (see page 207)Follow the procedure to create or modified the transfer password:The transfer password is stored in the project and in the Configuration File.During configuration, use the keyboard of the PC to enter the transfer password.In normal use (not connected to a PC), use the motion buttons 1...6 of the Remote Device to enter the transfer password.Step Action1 From the main menu, select Device → Transfer Password → Create Password.Result: A window is displayed.The default transfer password is: 5, 6, 5, 62 To modify an existing password, enter the previous password in the Old Password fields.3 Enter the new transfer Configuration File password in the New Password and in the Confirm Password fields.NOTE: Password must be 2 digits up to 6 digits.Digits allowed are 1, 2, 3, 4, 5 and 6.4 Click OK.

eXLhoist Configuration Software184 EIO0000001505 04/2014Project PasswordThe project password is asked before opening a locked project.Follow the procedure to create or modified the project password:If the project password is not entered at the opening project, select File → Password → Unlock Project.Step Action1 From the main menu, select File → Password → Project Password.Result: A window is displayed.2 To modify an existing password, enter the previous password in the Old Password fields.3 Enter the new project password in the New Password and in the Confirm Password fields.NOTE: Password can contain from 1 to 20 characters.Characters allowed are a…z, A…Z, and 0…9.All other characters are non-allowed ( + ° _ - % ’ .).4 Click OK.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 185Load the Configuration into the Remote DeviceHow To ...Follow the procedure to load the configuration from the PC to the Remote Device:Step Action1 Connect a Remote Device to the PC (see page 165). 2 Create or open a project. 3 From the main menu, select Communication → Store to device.4 If asked, enter the transfer password.5 Wait during the transfer.

eXLhoist Configuration Software186 EIO0000001505 04/2014Save a ProjectHow To ...Follow the procedure to save the project file on the PC:It is possible to change the name of the project file by selecting File → Save as.Step Action1 From the main menu, select File → Save.Result: A browser window is displayed.2 Choose the directory.3 Click Save.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 187Export to PDFHow To ...Follow the procedure to export the configuration to a PDF file:Step Action1 From the main menu, select File → Export → Export to PDF.Result: A browser window is displayed.2 Choose the directory and the name of the export file.3 Click Export.Result: The export file is created.4 A question window asks you to open or not the export file.Click Yes to open the export file.Click No to go back to the project workspace.

eXLhoist Configuration Software188 EIO0000001505 04/2014ConfigurationSection 7.4ConfigurationWhat Is in This Section?This section contains the following topics:Topic PageDevice Identity 189Parameters 191Relay Assignment 194Interlocking 198Detected Applicative Alarms 199

eXLhoist Configuration SoftwareEIO0000001505 04/2014 189Device IdentityOverviewFrom this tab, you can read generic information from the Remote Device:

eXLhoist Configuration Software190 EIO0000001505 04/2014DescriptionAt the activation, the fields are clear.Click the Read button to display generic information coming from the connected Remote Device. If there is no Remote Device connected, you are informed by a popup and all fields are cleared.These information are updated and stored in the Remote Device after a download Configuration File from PC.Field DescriptionReference Remote Device reference.Firmware Version Firmware version of the Remote Device.Format xxx.yyy (where xxx is major version and yyy is minor version).ID ID of the Remote DeviceFamily eXLhoistCode EAN13 Code EAN13 of the Remote Device.ZART8L: 3606480610356ZART8D: 3606480610363ZART12D: 3606480610370Last Download Date of the last load of a Configuration File in the Remote Device.Application name Name of the project file (Last 30 characters).Manufacturer www.schneider-electric.comDTM Version Version of the DTM.Configuration InformationCreation VersionVersion of the eXLhoist Configuration Software used at the project creation time (Never change after).Configuration InformationLast Modification VersionVersion of the eXLhoist Configuration Software used at the last project modification time.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 191ParametersOverviewIn this tab, you can configure the Wireless Remote Control System parameters.

eXLhoist Configuration Software192 EIO0000001505 04/2014Identification SettingYou can select the Wireless Remote Control System configuration between:SINGLETANDEMYou must enter the Base Station ID: Format: 00 80 F4 0X XX XX (0X XX XX is an hexadecimal value from 0 00 00 to 3 FF FF).This ID can be read on the Base Station.Click Label checkbox to enable the label management. Select in the listbox a label number (0…999). This label number is displayed on the ZART•D to identify the selected Base Station/Bridge.Start Access SequenceThe START access sequence is optional.When START access sequence is enabled, the operator MUST enter this sequence to go in START mode.The START access sequence is enabled by default.The default START access sequence is: 5, 6, 5, 6.Click Enable checkbox to enable/disable it.The allowed buttons for this sequence are 1, 2, 3, 4, 5, 6.The sequence can have 1 to 6 steps. Access sequence can use same button several times. For example: step 1 = 3 and step 4 = 3.E-STOP RESET SequenceThe E-STOP RESET sequence is optional.E-STOP RESET sequence is asked to the operator to reset the Remote Device after an E-STOP. If reset sequence is empty or disable, the operator has to press the button 7 (trigger).Click Enable checkbox to enable/disable it.The allowed buttons for this sequence are 1, 2, 3, 4, 5, 6.The sequence can have 1 to 6 steps.E-STOP RESET sequence can use same button several times. For example: step 1 = 3 and step 4 = 3.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 193Standby Time-outThe Remote Device goes automatically from START mode to STOP mode if no buttons are pressed during the Standby Time-out delay.You can modify the duration: 1…60 minutes.The factory setting value is 15 minutes. Power saving Time-outWhen the Wireless Remote Control System is in STOP mode due to Standby Time-out, if no button is pressed during this Power saving Time-out, the Remote Device automatically power OFF.You can modify the duration: 1…300 minutes.The factory setting value is 15 minutes. Horn durationThis value is the Horn duration activation during the Start procedure.You can modify the duration: 1…60 seconds.The factory setting value is 2 seconds.

eXLhoist Configuration Software194 EIO0000001505 04/2014Relay AssignmentOverviewIn this tab, you can:Configure the motion buttons.Configure a selector.Configure the auxiliary buttons.Configure UOC function.Configure the limit switches.Configure the special functions.

eXLhoist Configuration SoftwareEIO0000001505 04/2014 195Restriction Due To Remote DeviceThis tab is automatically modified according to the selected/connected Remote Device:Generic DescriptionThe main use of this tab is to configure the association between the buttons and the relays.To associate a button to a relay:As long as the button is pressed, the associated relay(s) is(are) activated.The cells in gray cannot be assigned.4 relays maximum can be associated with the motion buttons (1…6+7).Selector ConfigurationThe Selector configuration consists in:In SINGLE configuration:The selector is used to manage relays that are able to switch for example between 2 hooks or 2 trolleysReference Disable relay column Disable limit switches groupDisable buttons rowsZART8L 13...18 Yes 12…15+7ZART8D - - 12…15+7ZART12D - - -Step Action1 Click a cell to associate a button to a relay.Result: The empty cell has now an associated symbol 2 To be more explicit, you can click in the Name text zone of a button to modify it (24 characters maximum).Step Action1 Check the Selector Enable checkbox.2 Select in the N° Button listbox the button to be used as selector.For ZART8: it is possible to assign button 10...11 to the selector.For ZART12: it is possible to assign button 10...15 to the selector.3 Select 2 or 3 in the Nb Position combobox.4 Click a cell to associate a relay to a selector position.

eXLhoist Configuration Software196 EIO0000001505 04/2014In TANDEM configuration:In this configuration, no any relays are used.The selector is used to select Base Station to be piloted. The Use a Selector checkbox is checked and not modifiable.The Number of position field is set to 3 and is not modifiable.The relay assignment is the same for the 2 Base stations.UOC ConfigurationThe UOC configuration consists in associate a motion axis to a relay.This relay can be wired to the DRIVE Safe Torque Off (STO) or in serial with a contactor coil.For example: The relay 14 is ON when one or more of relays 1, 2, 3 is ON.When relays 1, 2 and 3 are OFF, the UOC delay starts.The relay 14 goes OFF when the UOC delay is expired.For more details, refer to UOC description (seepage105).NOTE: This functionality is available in the complete version of the eXLhoist Configuration Software.Step Action1 Select, in the N° Button combobox, the button to be used as selector.Step Action1 Click the UOC Enable checkbox.Note: There is an UOC function for the 3 axis.2 Select the associated relay in the Relay combobox.Result: Corresponding cells are automatically filled by a (U) symbol.3 Enter the UOC delay (0…99.9 seconds).

eXLhoist Configuration SoftwareEIO0000001505 04/2014 197Safeguarding Function ConfigurationThe Safeguarding function configuration consists in enable/disable the limit switches.The association between motion buttons and limit switch inputs are unmodifiable:When the limit switch is activated, the associated motion button is considered as unpressed and the associated relays are switched OFF.For more details, refer to limit switches description (see page 107).NOTE: This functionality is available in the complete version of the eXLhoist Configuration Software.Special Functions ConfigurationThe special functions configuration consists in associate a special function to a relay. The 4 special functions are:HornRadio linkTANDEM 1+2Safety relay imageFor more information, refer to special functions description (see page 109).Motion button11H22H33H44H55+766+7Limit switch inputIN7 IN8 IN9 IN10 IN11 IN12 IN13 IN14 IN15 IN16 IN17 IN18Step Action1 Check the Enable checkbox of an input N° (Input 7...input 18).Step Action1 For each of the 4 special functions, click a cell to associate a relay.

eXLhoist Configuration Software198 EIO0000001505 04/2014InterlockingOverviewIn this tab, you can configure the buttons combinations that cannot operate simultaneously.Example of the factory setting: The button 1 and 2 are associated to the same axis, for the opposites directions.The button 1 must not operate while the button 2 is pressed.The button 2 must not operate while the button 1 is pressed.If the buttons are pressed simultaneously, the movement is stopped.Step Action1 Click a cell to interlock (or not) 2 buttons (or buttons combinations).Result: When the buttons are interlocked, the empty cell has now an associated symbol .

eXLhoist Configuration SoftwareEIO0000001505 04/2014 199Detected Applicative AlarmsOverviewIn this tab, you can configure the Applicative Alarm states.The Base Station can provide detected alarms information to the ZART•D.Voltage free sensors can be connected to Base Station.For more information, refer to Special functions description (see page 103).Step Action1 Click High or Low to select the active state of each alarm.With a NO type switch, select High.

eXLhoist Configuration Software200 EIO0000001505 04/2014

EIO0000001505 04/2014 201Harmony eXLhoistMaintenance / Device ReplacementEIO0000001505 04/2014Maintenance / Device ReplacementChapter 8Maintenance / Device ReplacementWhat Is in This Chapter?This chapter contains the following sections:Section Topic Page8.1 Maintenance 2028.2 Device Replacement 2038.3 Remote Device Resets 211

Maintenance / Device Replacement202 EIO0000001505 04/2014MaintenanceSection 8.1MaintenanceRegular CleaningRemote Device CleaningWhen the surface or the frame of the display gets dirty, soak a soft cloth in water with a neutral detergent, wring the cloth tightly, and wipe the display.Periodic Check PointsAnnual check point for the ZARB•W Base Station: check the good terminal block tightening.For more information, refer to the Safety chapter (seepage53).NOTICEEQUIPMENT DAMAGEDo not use paint thinner, organic solvents, or a strong acid compound to clean the equipment.Failure to follow these instructions can result in equipment damage.

Maintenance / Device ReplacementEIO0000001505 04/2014 203Device Replaceme ntSection 8.2Device ReplacementOverviewThe Configuration File management allows some device replacement, without tool.What Is in This Section?This section contains the following topics:Topic PageBase Station Replacement 204ZART•D Replacement 207ZART8L Device Replacement 210

Maintenance / Device Replacement204 EIO0000001505 04/2014Base Station ReplacementNew Base Station ReplacementFollow the procedure to replace a Base Station by a new one:Step Action1 Execute a Remote Pairing Reset (see page 211).2 Install the new Base Station.3 Power ON the new Base Station.4 Place yourself with the Remote Device to an appropriate distance from the Base Station (around 10 m (32.8 ft)).5 Press only the ON/START/Horn button on the Remote Device more or equal than 1 s.Result: The Remote Device displays the ID list of detected Base Station:6 Selects the ID of the new Base Station with buttons 5 and 6.7 Press the button 7 (trigger) to validate.Result:8 Select the validation cell (check symbol) with buttons 1 and 2.

Maintenance / Device ReplacementEIO0000001505 04/2014 2059 Press the button 7 (trigger) to validate.Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device.10 Select the cancel cell (X) with buttons 1 and 2.11 Press the button 7 (trigger) to validate.12 The Remote Device propose to load the Configuration File from the Remote Device to the Base Station.Select the validation cell (check symbol) with buttons 1 and 2.Step Action

Maintenance / Device Replacement206 EIO0000001505 04/2014Result: The Wireless Remote Control System is in STOP mode (see page 123).It is recommended to do again an Acceptance Test (see page 75).13 If the Configuration File has a transfer password, a padlock is displayed:Enter the Configuration File transfer code with the buttons 1 to 6.The default transfer password is 5, 6, 5, 6.14 Press the button 7 (trigger) to validate.Result: The Remote Device loads the Configuration File from the Remote Device to the Base Station.15 Wait for the end of the Configuration File load.Step Action

Maintenance / Device ReplacementEIO0000001505 04/2014 207ZART•D ReplacementReplacement of a ZART•D by an out-of-the-box OneProcedure to replace an out of work ZART•D by an out-of-the-box one:Step Action1 Power ON the Base Station.2 Place yourself with the Remote Device to an appropriate distance from the Base Station (around 10 m (32.8 ft)).3 Press only the ON/START/Horn button on the Remote Device more or equal than 1 s.Result: The Remote Device displays the ID list of detected Base Station:4 Selects the ID of the appropriate Base Station with buttons 5 and 6.5 Press the button 7 (trigger) to validate.Result:6 Select the validation cell (check symbol) with buttons 1 and 2.

Maintenance / Device Replacement208 EIO0000001505 04/2014Result: The Wireless Remote Control System is in Stop mode (see page 123).It is recommended to do again an Acceptance Test (see page 75).7 Press the button 7 (trigger) to validate.Result: The Remote Device propose to load the Configuration File from the Base Station to the Remote Device.8 Select the validation cell (check symbol) with buttons 1 and 2.9 Press the button 7 (trigger) to validate.Result: The Remote Device loads the Configuration File from the Base Station to the Remote Device.10 Wait for the end of the Configuration File load.Step Action

Maintenance / Device ReplacementEIO0000001505 04/2014 209Replacement of a ZART•D by an Already Configured OneReplacement of an out of work ZART•D by an already configured one:Step Action1 Do a Remote Factory Reset (see page 211).2 Execute the procedure Replacement of an out of Work ZART•D by a New One (see page 207).

Maintenance / Device Replacement210 EIO0000001505 04/2014ZART8L Device ReplacementReplacement of an ZART8LProcedure to replace an out of work ZART8L:Result: The Remote Device goes to STOP mode (see page 123).It is recommended to redo an Acceptance Test (see page 75).Step Action1 Connect the Remote Device to a PC (see page 165).2 Start the eXLhoist Configuration Software (see page 178).3 Open an existing project (see page 180).4 Select Communication → Store to Device.5 Wait for the end of the Configuration File load in the Remote Device.6 Disconnect the Remote Device to the PC.7 Power ON the Base Station.8 Power ON the Remote Device.9 The Configuration File is automatically loaded from the Remote Device to the Base Station.During the load, the START LED and “2” LED are flashing.Wait for the end of the Configuration File load.

Maintenance / Device ReplacementEIO0000001505 04/2014 211Remote Device ResetsSection 8.3Remote Device ResetsRemote Device ResetsProcedure Step Action1 Power ON the Remote Device.2 On the rear of the Remote Device, unscrew the 2 screws.3 Remove the cover.4 Press and maintain the reset button for the appropriate duration (see page 212).For the ZAR•D:When the first delay is reached (for Pairing reset), the remote displays:When the second delay is reached (for Factory reset), the remote displays:5 Release the reset button.5 Place back the cover.6 Screw the 2 screws to mount the cover.

Maintenance / Device Replacement212 EIO0000001505 04/2014Remote Device rear view:1 Cover2 RJ45 connector3 Reset buttonReset Information Title t = Reset button duration pressRemote Device reactionSimple reset t < 5 s Remote Device reboot.Pairing reset 5 s ≤ t < 20 s Remote Device reboot.Erase in the remote memory the stored Base Station ID. The remote is no more paired with Base Station.Factory reset t > 20 s Remote Device reboot.Erase in the remote memory the stored Base Station ID. The remote is no more paired with Base Station.Delete the Configuration File. The Remote Device goes back to factory settings.

EIO0000001505 04/2014 213Harmony eXLhoistEIO0000001505 04/2014Appendices

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EIO0000001505 04/2014 215Harmony eXLhoistArchitecture ExamplesEIO0000001505 04/2014Architecture ExamplesAppendix AArchitecture ExamplesWhat Is in This Chapter?This chapter contains the following topics:Topic PageTested Architectures 216Vacuum/Magnetic Application Example 221Room Lighting Application Example 224

Architecture Examples216 EIO0000001505 04/2014Tested ArchitecturesOverviewSchneider Electric provides the basis of tested architecture. You can adapt these architectures to your individual requirements. NOTE: the architectures specified have been tested under actual service conditions. Your specific application requirements may be different from those assumed for these projects. In that case, you have to adapt the architecture to your particular needs. To do so, you need to consult the specific product documentation that you may find necessary to modify or adapt. Pay particular attention and conform to any safety information, different electrical requirements, and normative standards that would apply to your modifications and/or adaptations. Some or all of the architectures may contain recommendations of products that are not available in your country or locality, or may imply or recommend wiring, products, procedures, or controller logic and/or functions that are in conflict with your local, regional, or national electrical or safety codes and/or normative standards. The use and application of the architectures require expertise in the design of control systems. Only you, the designer or integrator, can be aware of all the conditions and factors present during installation and setup, operation, and maintenance of the machine or process, and can therefore determine the associated equipment, the functions, the related safety provisions and interlocks which can be effectively and properly used. When selecting control equipment, and any other related equipment or software for a particular application, you must also consider any applicable local, regional, or national standards and/or regulations. WARNINGREGULATORY INCOMPATIBILITYBe sure that all equipment applied and systems designed comply with and conform to all applicable local, regional, and national regulations and standards. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Architecture ExamplesEIO0000001505 04/2014 217DescriptionSchneider Electric has tested some possible architectures:Stop category depends on the UOC function/wiring (see page 105).E-Stop and Stop SIL level depends on the IN0 and S2_S3 wiring (see page 111).Safety Case 1S1 is a wired E-STOP SIL2;The E-STOP of the Remote Device is SIL2. No. Hoisting Trolley Translation E-STOPSTOP Motion Stop categoryAccording ToEN 61508EN 13849EN 61508EN 13849EN602041Contactor Contactor Contactor SIL2/Cat 3SIL1/Cat 2Cat 02ATV32 ATV32SIL3/Cat 43ATV71 SIL3/Cat 4 Cat 14 SIL3/Cat 4

Architecture Examples218 EIO0000001505 04/2014Safety Case 2S1 is a wired E-STOP SIL2;The E-STOP of the Remote Device is SIL3.Drive1 and Drive2 are motor drives

Architecture ExamplesEIO0000001505 04/2014 219Safety Case 3S1 is a wired E-STOP SIL2;The E-STOP of the Remote Device is SIL3.Drive1, Drive2, and Drive3 are motor drives

Architecture Examples220 EIO0000001505 04/2014Safety Case 4S1 is a wired E-STOP SIL2;The E-STOP of the Remote Device is SIL3.Drive1, Drive2, and Drive3 are motor drives

Architecture ExamplesEIO0000001505 04/2014 221Vacuum/Magnetic Application Example DescriptionA possible use of auxiliary buttons is a Vacuum/Magnetic function.ConfigurationExample of system configurationAs already done in the factory setting, it is recommanded to use buttons at different sides of Remote Device for load release function (operator uses both hands).Vacuum/Magnetic DescriptionTriggering “Vacuum/Magnetic ON“ button is assigned to 1 relay.When the operator presses the “Vacuum/Magnetic ON” button, the magnetic is activated through the associated relay.Releasing To release the load, simultaneously press ”Vacuum/Magnetic OFF 1” and “Vacuum/Magnetic OFF 2” buttons.“Vacuum/Magnetic OFF 1” button should be assigned to 1 NO+NC relay.“Vacuum/Magnetic OFF 2” button should be assigned to 1 different NO+NC relay. Topic Configured button Associated relayVacuum/Magnetic ON 13 Q16Vacuum/Magnetic OFF 1 14 Q17Vacuum/Magnetic OFF 1 15 Q18

Architecture Examples222 EIO0000001505 04/2014Wiring Example V_M_H1 V hold command magnetic 48…230 VacV_M_H2 V hold power magnetic 48…230 Vac

Architecture ExamplesEIO0000001505 04/2014 223NOTE: The Magnetic OFF flash is ON only in the 2 following cases:When the operator presses at least one of the Magnetic OFF buttons.If one the Magnetic OFF relay is welded. In this case, a maintenance action shall be done (Otherwise it is enough to press the other Magnetic OFF button for releasing the load).The power supply choice is the OEM responsibility. It depends on the risk analysis.

Architecture Examples224 EIO0000001505 04/2014Room Lighting Application ExampleDescriptionIt is possible to manage room lighting applications. An auxiliary button commands an impulse relay on the room lighting circuit.ConfigurationThere is no specific configuration needed. You have to associate an auxiliary button to a relay.Wiring ExampleNOTE: Schneider Electric offers modular impulse relays which are bistable switches designed to control load power mainly for lighting applications.

EIO0000001505 04/2014 225Harmony eXLhoistGlossaryEIO0000001505 04/2014GlossaryAAWG(American wire gauge) The standard that specifies wire section sizes in North America CCCF(Common Cause of Failure)CSA(Canadian standards association) The Canadian standard for industrial electronic equipment in hazardous environments.DDTM(Device Type Manager) Classified into 2 categories:Device DTMs connect to the field device configuration components.CommDTMs connect to the software communication components.The DTM provides a unified structure for accessing device parameters and configuring, operating, and diagnosing the devices. DTMs can range from a simple graphical user interface for setting device parameters to a highly sophisticated application capable of performing complex real-time calculations for diagnosis and maintenance purposes.EE-STOPEmergency stop (according to EN ISO13850:2008) function that is intended to:avert arising, or reduce existing, hazards to persons, damage to machinery or to work in progress,be initiated by a single human action.EMCElectroMagnetic Compatibility ENEN identifies 1 of many European standards maintained by CEN (European Committee for Standardization), CENELEC (European Committee for Electrotechnical Standardization), or ETSI (European Telecommunications Standards Institute).

Glossary226 EIO0000001505 04/2014FFE(Functional Earth) A common grounding connection to enhance or otherwise allow normal operation of electrically sensitive equipment (also referred to as functional ground in North America).In contrast to a protective Earth (protective ground), a functional earth connection serves a purpose other than shock protection, and may normally carry current. Examples of devices that use functional earth connections include surge suppressors and electromagnetic interference filters, certain antennas, and measurement instruments.FirmwareThe operating system (OS) of a device Hhex(hexadecimal)HFT(Hardware Fault Tolerance)IIEC(International Electrotechnical Commission) A non-profit and non-governmental international standards organization that prepares and publishes international standards for electrical, electronic, and related technologies.IP(Ingress Protection) The protection classification according to IEC 60529.LLED(Light Emitting Diode) An indicator that illuminates under a low-level electrical charge.

GlossaryEIO0000001505 04/2014 227MMAC address(Media Access Control address) A unique 48-bit number associated with a specific piece of hardware. The MAC address is programmed into each network card or device when it is manufactured.MTTF(Mean TIme To Failure)NNC(Normally Closed) A contact pair that closes when the actuator is de-energized (no power is applied) and opens when the actuator is energized (power is applied).NEMA(National Electrical Manufacturers Association) The standard for the performance of various classes of electrical enclosures. The NEMA standards cover corrosion resistance, ability to help protect from rain, submersion, and so on. For IEC member countries, the IEC 60529 standard classifies the ingress protection rating for enclosures.NO(Normally Open) A contact pair that opens when the actuator is de-energized (no power is applied) and closes when the actuator is energized (power is applied).PPC(Personal Computer)PELV(Protective Extra Low Voltage)PFD(Probability of Failure on Demand)PL(Performance Level)PST(Process Safety Time)

Glossary228 EIO0000001505 04/2014RRJ45A standard type of 8-pin connector for network cables.SSELV(Safety Extra Low Voltage) A system that follows IEC 61140 guidelines for power supplies is protected in such a way that voltage between any 2 accessible parts (or between 1 accessible part and the PE terminal for class 1 equipment) does not exceed a specified value under normal conditions or under inoperable conditions.SFF(Safe Failure Fraction)SIL(Safety Integrity Level) (according to IEC 61508) START warning timeTime between the STOP mode and START mode. During this time, the Horn is activated, the motion and auxiliary function are not enabled.STO(Safe Torque Off).UUL(Underwriters Laboratories) A US organization for product testing and safety certification.UOC(Unintended Operating Control) The UOC function allows control of a drive STO input.

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