Mercedes - W201 190 - Wiring Diagram - 2020 - 2020

Mercedes-Benz MBN 9666-3 Company standard Date published: 2020-07 Transition period: 0 months Total no. of pages (including annexes): 60 Person in charge: Oliver Zeller E-mail: [email protected] Plant: 010; Dept.: PT/TSD Phone: +49 160 8605757 Date of translation: 2020-08 Construction of and Specifications for Production Equipment, Components, Machines, Systems, Facilities, and Devices Part 3: Electrotechnical equipment, supplement to DIN EN 60204-1 (2019) Foreword The basis of MBN9666-3 is formed by DIN EN 60204-1 (2019). The chapter reference is therefore 1:1. The chapter headings from DIN EN 60204-1 are underlined. Headings that are not underlined are supplements to MBN9666-3. If no content is available, the content of DIN EN 60204-1(2019) shall apply. All requirements described therein ─ including passages of a recommendatory nature and proposals ─ shall be implemented. If content is available in MBN 9666-3, it is supplementary, represents a selection made from the possibilities offered by DIN EN 60204-1 or prohibits a specific design version. The specifications for implementation and components are supplemented by the other MBN9666 regulations. Refer to DIN 820-2 for verb forms and equivalent expressions. This edition supersedes the former edition of this Standard. A list of all document parts of the MBN 9666 series can be found in DocMaster. Application note: MBN 9666 can be referenced in its entirety by indicating the standard number "MBN 9666 (all parts)" without mentioning the part document, or a part document can be referenced individually, e.g. as "MBN 9666-1". Changes In comparison with edition 2015-04, the following changes have been made: Align the chapter structure with that of DIN EN 60204-1. Update to specifications due to technical developments. Corrections to assignment of specifications in chapter assignment. Inclusion of chapter texts from the previous BQF for DBL 9666-3. A before-and-after comparison is therefore not possible. NOTE: This translation is for information purposes only. The German version shall prevail above all others. Copyright Daimler AG MBN Vorlage EN 2016-12 MBN 9666-3 2020-07, page 2 Contents 1 2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.3 6.4 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 8 8.1 8.2 8.3 8.4 9 9.1 9.2 9.3 9.4 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 11 11.1 Scope of application ..........................................................................................................................5 Normative references ........................................................................................................................5 Terms and abbreviations ...................................................................................................................7 Terms and definitions ........................................................................................................................7 Abbreviations .....................................................................................................................................9 General requirements ..................................................................................................................... 10 General information ........................................................................................................................ 10 Selection of equipment ................................................................................................................... 11 Power supply .................................................................................................................................. 13 Physical environment and operating conditions ............................................................................. 14 Transport and storage .................................................................................................................... 15 Provisions for handling ................................................................................................................... 15 Power supply and devices to disconnect and switch off ................................................................ 15 Power supply .................................................................................................................................. 15 Terminal for connecting external protective conductor .................................................................. 15 Supply disconnecting device .......................................................................................................... 16 Devices for interrupting the energy flow to prevent unexpected start-up ....................................... 17 Devices for disconnecting electrical equipment ............................................................................. 17 Protection against unauthorized, inadvertent and/or mistaken connection.................................... 17 Protection against electric shock .................................................................................................... 17 General information ........................................................................................................................ 17 Basic protection .............................................................................................................................. 17 Fault protection ............................................................................................................................... 18 Protection by PELV ........................................................................................................................ 18 Protection of equipment.................................................................................................................. 18 General information ........................................................................................................................ 18 Overcurrent protection .................................................................................................................... 18 Protection of motors against overheating ....................................................................................... 19 Abnormal temperature protection ................................................................................................... 20 Protection against supply interruption or voltage reduction and subsequent restoration .............. 20 Motor overspeed protection ............................................................................................................ 20 Additional ground fault/residual current protection ......................................................................... 20 Phase sequence protection ............................................................................................................ 20 Protection against overvoltages due to lightning and switching surges ......................................... 20 Rated short-circuit current .............................................................................................................. 20 Equipotential bonding ..................................................................................................................... 20 General information ........................................................................................................................ 20 Protective earth conductor system ................................................................................................. 20 Measures for reducing high leakage current .................................................................................. 21 Functional equipotential bonding .................................................................................................... 22 Control circuits and control functions ............................................................................................. 22 Control circuits ................................................................................................................................ 22 Control functions ............................................................................................................................. 22 Protective interlocks ....................................................................................................................... 26 Control functions in the event of failure .......................................................................................... 27 Operator interface and machine-mounted control units ................................................................. 28 General information ........................................................................................................................ 28 Operating units ............................................................................................................................... 29 Indicator lights and displays ........................................................................................................... 30 Illuminated pushbuttons.................................................................................................................. 31 Rotary control devices .................................................................................................................... 31 Start devices ................................................................................................................................... 31 EMERGENCY STOP devices ........................................................................................................ 32 EMERGENCY OFF devices ........................................................................................................... 32 Enabling controls ............................................................................................................................ 32 Lamp test ........................................................................................................................................ 32 Filament lamps ............................................................................................................................... 32 Switchgears: location, mounting, structure and housings .............................................................. 32 General requirements ..................................................................................................................... 32 Copyright Daimler AG MBN 9666-3 2020-07, page 3 11.2 11.3 11.4 11.5 12 12.1 12.2 12.3 12.4 12.5 12.6 12.7 13 13.1 13.2 13.3 13.4 13.5 14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 15 15.1 15.2 16 16.1 16.2 16.3 16.4 16.5 17 17.1 17.2 17.3 18 18.1 18.2 18.3 18.4 18.5 18.6 18.7 19 19.1 19.2 19.3 20 20.1 20.2 21 21.1 21.2 22 22.1 22.2 23 24 Location and attachment ................................................................................................................ 34 Protection type ................................................................................................................................ 36 Housings, doors and openings ....................................................................................................... 36 Access to electrical equipment ....................................................................................................... 37 Conductors, cables, and lines ........................................................................................................ 37 General requirements ..................................................................................................................... 37 Conductor ....................................................................................................................................... 37 Insulation ........................................................................................................................................ 37 Current-carrying capacity in normal service ................................................................................... 37 Voltage drop for conductors and lines ............................................................................................ 37 Flexible cables ................................................................................................................................ 37 Conductor wires, conductor bars and slip-ring assemblies ............................................................ 37 Wiring practices .............................................................................................................................. 38 Connections and line routing .......................................................................................................... 38 Identification of conductors ............................................................................................................. 40 Wiring within housings .................................................................................................................... 40 Wiring outside housings ................................................................................................................. 40 Cable ducts, terminal boxes and other housings ........................................................................... 44 Electric motors and associated equipment..................................................................................... 45 General requirements ..................................................................................................................... 45 Motor housing ................................................................................................................................. 45 Motor dimensions ........................................................................................................................... 45 Motor mounting and compartments................................................................................................ 45 Motor selection criteria ................................................................................................................... 46 Protective devices for mechanical brakes ...................................................................................... 51 Motor name plates .......................................................................................................................... 51 Sockets and lighting ....................................................................................................................... 51 Sockets for accessories.................................................................................................................. 51 Workstation lighting on machines and accessories ....................................................................... 52 Marking, warning signs and reference designations ...................................................................... 52 General information ........................................................................................................................ 52 Warning signs ................................................................................................................................. 52 Functional identification .................................................................................................................. 52 Marking of housings for electrical equipment ................................................................................. 52 Reference designations (designations of operating equipment (BMK)) ......................................... 52 Technical documentation ............................................................................................................... 53 General information ........................................................................................................................ 53 Information pertaining to electrical equipment ............................................................................... 54 Software and data backups ............................................................................................................ 54 Tests 54 General information ........................................................................................................................ 54 Verification of conditions for protection by automatic disconnection of supply .............................. 55 Insulation resistance tests .............................................................................................................. 55 Voltage tests ................................................................................................................................... 55 Protection against residual voltages ............................................................................................... 55 Function tests ................................................................................................................................. 55 Retesting ........................................................................................................................................ 55 Commissioning, technical acceptance, training ............................................................................. 56 Commissioning ............................................................................................................................... 56 Technical acceptance ..................................................................................................................... 56 Instruction ....................................................................................................................................... 57 Electronic equipment ...................................................................................................................... 57 General information ........................................................................................................................ 57 Basic requirements ......................................................................................................................... 58 Programmable equipment .............................................................................................................. 59 Programmable controls .................................................................................................................. 59 Password protection ....................................................................................................................... 59 Energy efficiency measures ........................................................................................................... 59 Sleep mode .................................................................................................................................... 59 Heat/cooling supply ........................................................................................................................ 60 Engineered safeguards .................................................................................................................. 60 Component approval list ................................................................................................................. 60 Copyright Daimler AG MBN 9666-3 2020-07, page 4 Copyright Daimler AG MBN 9666-3 2020-07, page 5 Table 1: Normative references .......................................................................................................................5 Table 2: Distance for machine connection .................................................................................................. 14 Table 3: Basic data for switch cabinets ....................................................................................................... 33 Table 4: M12x1 connectors assigned to application ................................................................................... 41 Table 5: Cable sheath colors for coding lines ............................................................................................. 41 Table 6: PIN assignment, M12x1 and M8x1 connectors............................................................................. 43 Table 7: Excerpt from drawing frame .......................................................................................................... 53 Figure 1: Socket wrench profile ................................................................................................................... 34 Figure 2: Switch cabinet lock insert ............................................................................................................. 34 Figure 3: Vertical cable trays ....................................................................................................................... 39 Figure 4: Separating ribs in the trays .......................................................................................................... 39 Figure 5: One speed up to 7,5 kW (module max. 16 A) .............................................................................. 46 Figure 6: Two speeds with separate windings up to 7,5 kW (module max. 16 A) ...................................... 47 Figure 7: One speed up to 7,5 kW (module max. 40 A) .............................................................................. 47 Figure 8: Two speeds with separate windings up to 7,5 kW (module max. 40 A) ...................................... 48 Figure 9: Connection for 3-phase motors without brake and sensor up to 7,5 kW ..................................... 48 Figure 10: Motor connection for standard motors and geared motors up to 1,1 kW................................... 49 Figure 11: Motor connection up to 7,5 kW (max. 16 A) ............................................................................... 49 Figure 12: Motor connection up to 7,5 kW (max. 16 A) ............................................................................... 50 Figure 13: Motor connection over 7,5 kW ................................................................................................... 50 Figure 14: Motor connection over 7,5 kW ................................................................................................... 51 1 Scope of application This MBN defines the product equipment specifications for all production sites of the Daimler Group (hereafter referred to as Daimler) for the procurement of new equipment and machines as well as conversions of existing equipment by Daimler. If an offeror feels that deviations from individual points are necessary for technical or technological reasons, these deviations shall be indicated in the offer in an annex and approved in advance in writing by the respective Daimler specialist department or project management. This document shall be applied for all production and operating equipment, machines, systems, facilities, and devices, as well as replacement and wear parts that are directly or indirectly procured for the manufacture of products within the Daimler Group. 2 Normative references The following referenced documents in Table 1 are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. Table 1: Normative references Document number Title DIN 820-2 Standardization – Part 2: Presentation of Documents DIN 18252 Profile cylinders for door locks - Terminology, dimensions, requirements, test methods and marking Electrical engineering; low-voltage switchgear dimensions series for cubicles Key for the doors of electrical switchgear cubicles and cabinets; double-bit key DIN 41488-2 DIN 43668 Copyright Daimler AG MBN 9666-3 2020-07, page 6 DIN 51130 DIN 66217 DIN EN 1303 DIN EN 1837 DIN EN ISO 13850 DIN EN 60034-1 DIN EN 60079-0 DIN EN 60085 DIN EN 60204-1 (2019) DIN EN 60529 DIN EN 60715 DIN EN 60825-1 DIN EN 61076-2 DIN EN 61439-1 DIN EN 175301-803 DIN EN ISO 50001 IEC 60309-1 IEC 60364-5-53 IEC/TR 60890 DIN VDE 0100-410 DIN VDE 0100-729 RAL colors Testing of floor coverings - Determination of the anti-slip property Workrooms and fields of activities with slip danger - Walking method - Ramp test Axis and Motion Nomenclature for Numerically Controlled Machines Building hardware - Cylinders for locks - Requirements and test methods Safety of Machinery - Integral Lighting of Machines Safety of Machinery - Emergency Stop Function - Principles for Design Rotating Electrical Machines - Part 1: Rating and Performance Explosive Atmospheres - Part 0: Equipment – General Requirements Electrical Insulation - Thermal Evaluation and Designation Safety of Machinery - Electrical Equipment of Machines - Part 1: General Requirements Degrees of Protection Provided by Enclosures (IP Code) Dimensions of Low-Voltage Switchgear and Controlgear Standardized Mounting on Rails for Mechanical Support of Electrical Devices in Switchgear and Controlgear Installations Safety of laser products - Part 1: Equipment classification and requirements Connectors for electronic equipment - Product requirements - Part 2: Sectional specification for circular connectors Low-Voltage Switchgear and Controlgear Assemblies Part 1: General Rules Rectangular Connectors - Flat Contacts, 0,8 mm Thickness, Locking Screw Not Detachable Energy Management Systems - Requirements with Guidance for Use Plugs, socket-outlets and couplers for industrial purposes - Part 1: General requirements Low-voltage electrical installations - Part 5-53: Selection and erection of electrical equipment - Devices for protection for safety, isolation, switching, control and monitoring Method of temperature-rise verification of low-voltage switchgear and controlgear assemblies by calculation Low-Voltage Electrical Installations - Part 4-41: Protection for Safety - Protection Against Electric Shock Low-Voltage Electrical Installations - Part 7-729: Requirements for Special Installations or Locations Operating or Maintenance Gangways RAL Deutsches Institut für Gütesicherung und Kennzeichnung e. V. (German Institute for Quality Assurance and Labeling, Abbreviation for "Reichs-Ausschuss für Lieferbedingungen", State Commission for Delivery Terms and Quality Assurance) Copyright Daimler AG MBN 9666-3 2020-07, page 7 3 Terms and abbreviations 3.1 Terms and definitions 3.1.1 Operating unit 3.1.2 Ambient temperature 3.1.3 Cover 3.1.4 Basic protection 3.1.5 Cable trough 3.1.6 Cable trunking systems 3.1.7 to be opened simultaneously 3.1.8 Conductor wire 3.1.9 Electrical installation conduit 3.1.10 Control circuit (of a machine) 3.1.11 Control unit 3.1.12 Control point 3.1.13 Switchgear 3.1.14 Controlled shutdown 3.1.15 Direct contact 3.1.16 Forced opening 3.1.17 Cable duct 3.1.18 Ground 3.1.19 Electrical operating facility 3.1.20 Electronic equipment 3.1.21 EMERGENCY STOP device 3.1.22 EMERGENCY OFF device 3.1.23 Enclosed electrical operating facility 3.1.24 Housing 3.1.25 Electrical equipment 3.1.26 Equipotential bonding 3.1.27 Body 3.1.28 Foreign conductive part 3.1.29 Failure Copyright Daimler AG MBN 9666-3 2020-07, page 8 3.1.30 Defect 3.1.31 Fault protection 3.1.32 Functional equipotential bonding 3.1.33 Hazard 3.1.34 Indirect contact 3.1.35 Inductive power supply system 3.1.36 Instructed person 3.1.37 Lock 3.1.38 Active part 3.1.39 Machine drive element 3.1.40 System/machine 3.1.41 Identification 3.1.42 Neutral conductor 3.1.43 Obstacle 3.1.44 Overcurrent 3.1.45 Circuit overload 3.1.46 Plug/socket combinations 3.1.47 Main power circuit 3.1.48 Unimpacted short-circuit current 3.1.49 Protective equipotential bonding 3.1.50 Protective earth conductor system 3.1.51 Protective conductor 3.1.52 Redundancy 3.1.53 Reference designations (designations of operating equipment) 3.1.54 Risk of 3.1.55 Protective equipment 3.1.56 Technical protective measures 3.1.57 Safety function 3.1.58 Access level 3.1.59 Short-circuit current 3.1.60 Limited rated short-circuit current Copyright Daimler AG MBN 9666-3 2020-07, page 9 3.1.61 Specialist electrician 3.1.62 Supplier 3.1.63 Switching device 3.1.64 Uncontrolled shutdown 3.1.65 Operator 3.1.66 Supplementary terms and definitions of MBN9666-3 Setup Assembly of all units and individual parts at the installation location as well as alignment and attachment Rated voltage A value applicable for the specified operating conditions which is generally specified by manufacturers for an element, assembly or equipment. The rated voltage is greater than or equal to the nominal voltage and specifies the maximum value of the electrical voltage in normal operation Section switch Section switches are intended to switch off the load voltage of machine parts. They shall allow any interventions without having to switch off the entire machine Release list or material release list (MFL) Index for orderer listing components approved for usage Main switch The main switch is a supply disconnecting device as per DIN EN 60204-1 (VDE 0113 Part 1) Sections 5.3.2 a) to c) RF system Radio frequency system Nominal voltage A fixed value for normal operation at which the component shall function. Project manager Contact person at Daimler AG responsible for the order. Repair switch Directly stops and secures a motor (may be configured for reversing operation). Project documentation 3.2 Project-specific requirement specifications for procurement, including annexes... Abbreviations NC Numerical control SPS Programmable logic controller HMI Human Machine Interface Copyright Daimler AG MBN 9666-3 2020-07, page 10 4 General requirements To guarantee product safety and product quality, and to meet homologation requirements, all relevant statutory regulations and laws shall be complied with. In addition, the relevant requirements of the Daimler Group apply. All materials, process technologies, component parts, and systems shall conform to the current statutory requirements regarding regulated substances and recyclability. 4.1 General information DIN EN 60204-1 shall be referred to for EU conformity testing (CE certificate). Machines in interlinked groups which can be used individually shall be designed as autonomous units. Each autonomous machine shall be equipped with controls, control panel and similar and shall additionally feature a supply disconnecting device. The entire equipment (housing, cable ducts, etc.) shall be cleaned, in particular drilling chips or similar sharp objects. The sample plans, sample programs, operating structures for visualization, standard function modules, etc. from Daimler shall be used. Scopes not included in the samples shall be derived from the samples or defined according to existing specifications. System interfaces: • • • • The connection lines between the interfaces shall be connected by the system supplier. Signal exchange shall be clarified. The pull principle shall apply with regard to the processing of the required signals. Coupling at I/O level shall be designed potential-free. In point-to-point connections, power to interfaces shall be supplied from the corresponding subsystem while the signal receiver shall supply the signal transmitter with the operating voltage necessary. If no milestone plans or an acceptance schedule exists for the order, the following shall apply: • Before commencement of any design work, the machines/systems (including definition of the control, emergency-off and setup areas, grounding concept and Q-alarm) shall be submitted in detail. The designation of function groups in the layout and in the functional description represents provisional information and shall be specified following order allocation. • The circuit documentation and wiring diagrams shall be submitted for approval no later than 4 weeks before the start of production of the switch cabinets. • For further procedure, see chapter 19.2. Copyright Daimler AG MBN 9666-3 2020-07, page 11 4.2 4.2.1 Selection of equipment General information All devices shall comply with the directives and standards that apply at the time of commissioning. All electrical operating equipment in housings and installation spaces shall be designed safe to touch. Measuring points for test probes shall remain accessible. For example, it shall be possible to use measuring points upstream from the supply disconnecting device without removing the covers. All materials shall be flame retardant, self-extinguishing, and free from asbestos or silicone. Harmful reactions between different materials shall be avoided. (e.g. cables with PUR and PVC) The use of substances impairing the paintwork application shall be prohibited. Manufacturers' installation instructions shall be observed Building engineering/domestic installation components are not permitted in machines. Only devices that do not have fuses shall be used. This excludes fuses soldered in devices to provide arcing protection. Standard appliances shall be used only. Modification is not permitted. For components critical to safety as defined by the Machine Directive, the "mission time" (service life or B10 value) and the date of manufacture shall be indicated on the type plate. In the maintenance instructions, the machine manufacturer shall indicate how to replace the components. LED variants shall be used for indicator lamps. A reserve capacity of 20 % for special machines and 10 % for series-production machines shall be provided. Supplement, see chapter 11.1. All actuators and sensors shall be designed as plug connectors. Devices with protection class II (protective insulation) shall be preferred. Only devices with laser protection class 1 in accordance with DIN EN 60 825-1 (VDE 0837 Part 1) are approved. Unused slots on distributors or modules shall be provided e.g. with blind caps according to the protection type of the equipment. Devices with fixed (cast-in) connecting cables shall be connected by plug connectors. Maximum line length 2 m. Motors, solenoids, and similar devices shall be connected by plug connectors. These connectors shall be installed next to the relevant units. For three-phase sockets, the phase sequence L1-L2-L3 shall result in a clockwise rotating field. The maximum cable length between terminal board and plug connection shall be 1,5 m. Copyright Daimler AG MBN 9666-3 2020-07, page 12 All actuators shall be designed for a duty cycle of 100 %. If solenoids will be used, they shall be designed so that they are loaded to not more than 80 % of the specified retention force and so that a temperature of 60 °C cannot be exceeded at a 100 % duty cycle. Suitable fuses shall always be fitted. Only one conductor shall be connected to each terminal/connection point of a plug/socket combination. Individual cables shall be capable of being replaced easily and without the need for dismantling plug/socket combinations. The cable entry shall typically be from below. If lateral insertion is required, a drip loop will be necessary. Inserting from above shall only be possible in approved, exceptional cases. 4.2.2 Switchgear combination 4.2.3 Switchgears The top-hat rails/support strips shall be mounted horizontally. A minimum distance of 20 mm shall be maintained between the switchgear and the cable duct. All terminals (device connection terminals and terminal blocks) shall be designed using cage clamps. If device connections are established using a terminal block, only the block shall be designated. Switchgears for electromagnetic drives, such as in clutches, brakes, and solenoid valves shall be designed for a service life of at minimum 10 million duty cycles. 4.2.4 Limit values All components shall be operated within the limit values specified by the manufacturer (datasheet) only. 4.2.5 Component application All movements at all positions shall always be scanned individually and directly. All sensors and actuators which do not feature supply and switching status indicators or which are installed such that the LED is not directly visible from the access level (i.e. pointing towards it) shall require an LED indicator each on the connector of the supply line. Control units shall supply and process signals with a positive potential. For devices with removable operating displays (e.g. frequency converters), one operating display per switch cabinet field shall be provided. All sensors shall be adjustable along the X, Y, Z axis. Safety limit switches shall be permanently secured to the system using screws. Copyright Daimler AG MBN 9666-3 2020-07, page 13 All switches with proximity function shall be installed with clamping brackets including stop so that the position is restored exactly following replacement of a sensor. Optical sensors shall exclusively be permitted with visible beam (permanent or switch-on) to guarantee they remain adjustable. Extending actuator sensor lines (except for trailing lines) is not permitted! Depending on ambient conditions (e.g. chips, welding beads), the switching areas of sensors shall be installed vertically/pointing downwards. Unused components shall be removed. Hardware/software and documentation shall be adapted. The selection of the control units shall ensure a reliable contact even with the low currents at the inputs of the control systems without any additional switching measures. Parallel connection of control contacts to increase the switching capacity shall not be permitted. 4.3 Power supply 4.3.1 General information Different supply concepts may exist in the plants. See the project documentation for the respective supply concept. The load voltage is defined at AC 400 V/DC 24 V and the control voltage at DC 24 V. 4.3.2 AC supplies • The mains connector in the switch cabinet shall be designed for connections with five conductors • The phase sequence of all low-voltage systems including three-phase current plug connections shall be: L1-L2-L3 (clockwise rotating field) See the project documentation for the precise building-specific information. Single-phase load up to a maximum of 10 % of the connection value. A symmetric distribution to the three phases shall be ensured in the event of multiple single-phase consumers. Copyright Daimler AG MBN 9666-3 2020-07, page 14 The supplier shall provide the necessary connection possibilities ─ with sufficient space and strain-relief clamps ─ in accordance with Table 2: Table 2: Distance for machine connection Cross-section minimum distance to intermediate floor 6 mm² 200 mm 25 mm² 250 mm 50 mm² 350 mm 120 mm² 500 mm 240 mm² 800 mm If the machine shall be connected via parallel cores, the necessary terminals or rails shall be provided. 4.3.3 DC supplies DC 24 V control voltage for electronic controls, magnetic components (e.g. solenoid valves, magnetic clamping plates, solenoid actuators), indicator lamps, daisy chain, safety circuits, etc. The supply shall be divided into three fuse groups whereby each group shall be fused separately: • CPU, HMI, PC systems, network components • Sensors, bus electronics, ID systems, amplifiers; network components for field bus components • Actuators Circuit breakers with electronic tripping characteristics shall be used in DC 24 V systems. The design of the circuit breakers only allows single-step (no selection). 4.3.4 4.4 4.4.1 Special supply systems Physical environment and operating conditions General information All electrical and electronic components shall be selected and designed so that they are fully functional in the available plant networks without having to take any special precautionary measures, despite occurring voltage fluctuations and interference pulses. 4.4.2 Electromagnetic compatibility (EMC) Limiter elements shall be used to prevent overvoltage when switching off inductances, such as clutches, brakes, and solenoid valves. Copyright Daimler AG MBN 9666-3 2020-07, page 15 4.4.3 Ambient air temperature • Installation on platforms 5° - 55 °C • If the production building is air conditioned, the ambient temperature set plus 5 °C shall be used to calculate the switch cabinet cooling requirement. 4.4.4 Air humidity 4.4.5 Altitude 4.4.6 Contamination 4.4.7 Ionizing and non-ionizing radiation 4.4.8 Vibration, shock, and bump Plug connections shall be protected against vibrations. 4.5 Transport and storage Transport units shall be clarified specific to the project. Transport dimensions of switch cabinets shall be verified on site. Wiring shall be designed continuously within the transport units, i.e. without terminals or plug connections. 4.6 5 5.1 Provisions for handling Power supply and devices to disconnect and switch off Power supply See the project documentation for the supply. Cable entry systems including strain-relief shall form part of the machine's scope of supply. The power supply entry shall be designed as IP55 at minimum, as per DIN EN 60529. The power supply terminals shall be suitable for connecting conductors that are two cross-section levels above the cross-section of the connections in the switch cabinet (voltage drop, selectivity, etc.). 5.2 Terminal for connecting external protective conductor Copyright Daimler AG MBN 9666-3 2020-07, page 16 5.3 5.3.1 Supply disconnecting device General information The supply disconnecting device shall be installed in the power supply cabinet at center height of approx. 1200 mm from the access level. The following conditions shall be observed if the supply disconnecting device can be operated at the front: • • The supply disconnecting device shall be installed in the door up to a rated current of 63 A (wiring except for mains connection terminals). The door shall not lose its ability to move in the process. Supply disconnecting devices greater than 63 A shall be secured on the assembly plate. The operating element shall be installed on a plate in the same color as the switch cabinet that is secured to the cabinet and mechanically connected to the main switch via an extension of the axis. As a result, it shall also be possible to operate the main switch when the switch cabinet door is open. The switch cabinet door shall feature a corresponding door cutout and a rubber seal which shall guarantee at minimum IP 55 as per DIN EN 60529. Sidewall installations shall be coordinated during the course of the project. The contractor shall designate the supply disconnecting device as "Main switch". The supply disconnecting devices for the partial scopes supplied from this machine are section switches that shall be designated as "Section switches". The handle of the supply disconnecting device for switch cabinets supplied by the incoming-feeder panel of a central system shall be in black (no emergency-off function). If central parts are combined or grouped for a line, intermixing with a station shall not be permitted. Care should be taken to ensure clear physical separation. 5.3.2 Type Door couplings shall not be permitted. 5.3.3 Requirements The supply disconnecting device shall be secured by at least 3 padlocks, shackle diameter 8 mm. 5.3.4 Operating unit for the supply disconnecting device Copyright Daimler AG MBN 9666-3 2020-07, page 17 5.3.5 Excluded circuits Circuits that safeguard the supply of volatile memory and similar as well as external voltage that enters the switch cabinet via signal exchange are also not deactivated via the main switch. These circuits shall be routed in an orange flexible tube or as an orange multi-core cable ─ including in cable ducts ─ over the entire length. Routing shall be implemented with spatial separation, wherever possible. Single wires shall be designated in ORANGE in accordance with 13.2.4. If excluded circuits are supplied by way of a cross-section reduction, ensure that the installation is shortcircuit proof in accordance with DIN EN 61439-1. 5.4 Devices for interrupting the energy flow to prevent unexpected start-up Drives which shall be brought to standstill while the system is running (e.g. for maintenance purposes) shall be provided with lockable repair switches (black handle) in a location visible from the drive. 5.5 Devices for disconnecting electrical equipment 5.6 Protection against unauthorized, inadvertent and/or mistaken connection 6 Protection against electric shock 6.1 General information 6.2 Basic protection 6.2.1 General information 6.2.2 Protection by housing 6.2.3 Protection by insulation of live parts 6.2.4 Protection against residual voltages 6.2.5 Protection by barriers 6.2.6 Protection by placing out of reach or protection by obstacles Copyright Daimler AG MBN 9666-3 2020-07, page 18 6.3 Fault protection 6.3.1 General information 6.3.2 Measures for preventing the occurrence of a touch voltage 6.3.3 General information 6.3.3.1 Protection by provision of class II equipment or by equivalent insulation 6.3.3.2 Protection by electrical separation 6.3.4 6.4 Protection by automatic disconnection of supply Protection by PELV 6.4.1 General requirements Generation of the functional extra-low voltage by means of a current source with secure disconnection. (See DIN VDE 0100-410). 6.4.2 7 7.1 Sources for PELV Protection of equipment General information The overload and short-circuit protection of the components (e.g. drives, actuators, transformers) shall be fuse-free, with the exception of the power distributions (400 V) inside the switch cabinet. Outgoing circuits of busbar distributors that are mounted e.g. over an assembly line shall be designed without fuses. The short-circuit current limitation specified by the equipment manufacturer shall be observed. Any protective devices upstream shall be grouped with reference to their functions and output. All tripping units, such as circuit breakers, motor protection switches, etc. shall be provided with at least 1 feedback function (e.g. 1 normally closed contact as auxiliary contact) which shall be used potential-free for further processing. Auxiliary contacts of circuit breakers shall be grouped at most by protection sections; motor protection switches shall be represented visually with separate diagnosis capability. Phase failure shall be signaled in the visualization. 7.2 Overcurrent protection Copyright Daimler AG MBN 9666-3 2020-07, page 19 7.2.1 General information 7.2.2 Power supply cable 7.2.3 Power circuits Drives and actuators shall be fused separately. If motors are controlled by frequency converters, the power supply to the converters may be coordinated in a sensible fashion. 7.2.4 Control circuits A neutral conductor isolating terminal (for ground jumper, e.g. to neutral conductor, ground connection) shall be used. 7.2.5 Socket outlets and their associated conductors If an intelligent control system with service data interface is available in a cabinet field, an AC 230 V grounded contact-type socket (other sockets may be used according to country-specific requirements) shall be provided. The sockets shall be labelled with the respective voltage values/overcurrent protection. Ground contact-type sockets that are not continuously used (or comparable sockets, depending on the installation site) shall be protected with 6 A fuse protection. For equipment parts (e.g. printers, PCs) of a machine that are connected e.g. by shockproof plug, the plug shall be located inside the switch cabinet or in a terminal box. 7.2.6 Lighting circuits 7.2.7 Transformers 7.2.8 Location of overcurrent protective devices 7.2.9 Overcurrent protective devices 7.2.10 Rating and set values of overcurrent protective devices 7.3 Protection of motors against overheating 7.3.1 General information 7.3.2 Overload protection Copyright Daimler AG MBN 9666-3 2020-07, page 20 The heating up of motors above 2 kW with forced-air cooling, with electronic motor speed control, with a high number of switching actuations (> 5/h) or with heavy-duty startup shall be additionally monitored by temperature sensors installed in all windings. 7.3.3 Overtemperature protection 7.4 Abnormal temperature protection 7.5 Protection against supply interruption or voltage reduction and subsequent restoration 7.6 Motor overspeed protection Speed underrun performance shall also be monitored. 7.7 Additional ground fault/residual current protection 7.8 Phase sequence protection 7.9 Protection against overvoltages due to lightning and switching surges 7.10 Rated short-circuit current The rated short-circuit current shall be indicated on the type plate of the supply cabinet. 8 8.1 Equipotential bonding General information The supplier shall create an earthing concept for the system. The earthing concept shall represent the design of the shields, ground connections and equipotential bonding points with commentary and lettering. At all points in the system, the ground resistance shall be lower than the shield resistance of shielded cables (e.g. bus lines). The loop resistance values shall be measured and documented. Equipotential bonding shall be realized according to the "common bonded network" principle. "Mesh-BN" is then entered in the measurement log instead of the cross-section of the individual connection. The equipotential bonding connection point on the device/construction part/steel construction/... shall be marked as the measuring point. On the identification plate, use (NET) for functional earth and (POT) for potential equalization. Potential equalization (POT) shall be used for all connection points that most likely can have a touch voltage >= 50 V. 8.2 Protective earth conductor system Copyright Daimler AG MBN 9666-3 2020-07, page 21 8.2.1 General information The PE rail of the machine/system shall also be connected to the building potential connection point with an equipotential bonding conductor. All ground connections in the switch cabinet whose start and end points are not clear in conjunction with the routing schematic shall be labeled individually with the device name. Protective conductors (protective equipotential bonding and functional equipotential bonding) shall be labeled with their source and target designation if they are positioned on a PE rail or non-numbered terminals. Protective earth conductor connection points shall be installed at the corpus of the electrical equipment visible to the operator and without cover. 8.2.2 Protective conductor The connection of the PE rails within the machine/system ─ as well as the connection to the building equipotential bonding conductor ─ shall be realized in 35 mm² configuration (tin-plated, bright, class 2). In systems with open cable racks, the individual ground connections are connected to a 10 mm² bright, tinplated copper cable (class 5). 8.2.3 Continuity of protective conductor system 8.2.4 Protective conductor connecting points 8.2.5 Mobile machines 8.2.6 Additional requirements for electrical equipment with earth leakage currents greater than 10 mA 8.3 Measures for reducing high leakage current Copyright Daimler AG MBN 9666-3 2020-07, page 22 8.4 Functional equipotential bonding In grounded control circuits, the unprotected terminal of the control circuit shall be connected to the equipotential bonding system via an isolating terminal for test purposes. This connection shall be located in close proximity to the secondary side of the corresponding control transformer/power supply unit. This requirement shall also apply to all control circuits including the power supply for the input and output groups of electronic controls. 9 Control circuits and control functions 9.1 9.1.1 Control circuits Control circuit supply Transformers' primary windings shall be connected to the outer conductors. DC 24 V power supply units shall be connected in 3-phase configuration. Excluded are power supply units installed in a system (e.g. torque controller, measurement control system). Auxiliary circuits shall be divided and fused logically (e.g. in function groups) to facilitate troubleshooting. 9.1.2 Control voltages The control voltage is DC 24 V. 9.1.3 9.2 Protection Control functions 9.2.1 General information 9.2.2 Stop function categories Copyright Daimler AG MBN 9666-3 2020-07, page 23 9.2.3 Operating 9.2.3.1 General information After having interrupted automatic mode, it shall be possible to correctly resume the interrupted program. Operators shall be enabled to continue in the cycle with the operating equipment or move into the home position using the existing control devices. It shall be possible to individually switch all supply and auxiliary equipment (e.g. control voltage, hydraulic system, coolant) in manual or setup mode. 9.2.3.2 Start In case of interlinked plants and transfer lines, a start-up warning shall be provided wherever a collective start-up takes place. Depending on the design of the system, this warning shall be implemented using a sufficient number of signaling units. 9.2.3.3 Stop 9.2.3.4 Emergency operations (EMERGENCY STOP, EMERGENCY OFF) See Section 23 9.2.3.4.1 General information A link shall be established in each case with the adjacent machine, interlinking and similar where a danger at the transition point exists. The switch for emergency operations shall remain activated even when subsections are switched off. The supply of the interlinked emergency operation switches: • Shall be from the machine, interlinking or similar that is always required as minimum • Shall be picked off upstream from the main switch 9.2.3.4.2 EMERGENCY STOP 9.2.3.4.3 EMERGENCY OFF 9.2.3.5 Operating modes If standards for the operating modes are described in the project specifications, these shall be implemented. Depending on the specific process, differences in detail may be required that shall be indicated accordingly. Copyright Daimler AG MBN 9666-3 2020-07, page 24 9.2.3.5.1 Automatic mode In "automatic" (automatic linked operation) mode, all control devices for "set-up" operation shall have no effect. Exceptions include: "Retract unit", "Quick stop"/"Immediate stop" and "Stop at end of cycle" commands. In the event of changes to Automatic operating mode start-up shall be guaranteed or the lacking start-up conditions shall be displayed in detail. 9.2.3.5.2 Ghost operation Ghost mode is the automatic sequence with no workpieces. It shall be possible to control the use of media (e.g. coolants and lubricants). 9.2.3.5.3 Process monitoring Process monitoring mode facilitates monitoring under restricted operating conditions. 9.2.3.5.4 Single cycle In "Single cycle" mode the machine shall run through one (1) complete (automatic) cycle after the start signal. 9.2.3.5.5 Manual mode In "Manual" mode, all command stations for "Automatic" mode shall be ineffective. For reliable operation, all required interlocking devices shall also be effective in "Manual" mode. In "Manual" mode, all drive elements and actuators shall be capable of being operated individually using buttons. In rapid traverse and fine feed, this shall apply accordingly. The acceptance of the command and arrival at the position shall be indicated on the control panel. 9.2.3.5.6 Setup If required for the setting of the machine, interlocking devices necessary for the operation of the machine may be suspended. Safety interlocks shall remain effective. 9.2.3.5.7 Single-step mode In "Single-step mode", the unit is moved forward cyclically by incrementally advancing the sequence chain with the "Single-step" button. This button remains pressed. In order to reach the next step in the sequence, the stepping condition shall be reached and the stepping pushbutton released briefly and actuated again. Pre-selection of the step number shall not be required. The current step number shall be indicated. 9.2.3.5.8 Inching mode In "Inching mode" a pre-selected step or function shall be completed as long as the "Inching" pushbutton is operated. If the process allows, it shall be possible to move the step forward and back. Copyright Daimler AG MBN 9666-3 2020-07, page 25 9.2.3.5.9 "Stop at end of cycle" button The button (white) and the indicator light (white) in the central and local control panels shall be active in "Automatic" mode only. The initiated operating cycle of the machine shall be completed. The workpiece shall normally remain clamped. "Automatic" operating mode shall be reset. The indicator lamp "stop at end of cycle" shall flash on initiation of the function and remain on when "cycle end" is reached. 9.2.3.5.10 "Immediate stop" button Immediate stop: This function stops the system in the next defined system position. 9.2.3.5.11 "Immediate stop" button This button initiates the fastest possible shutdown using a defined shutdown sequence without causing damage to the tool or workpiece. The "Immediate stop" shall be implemented with a save function. 9.2.3.5.12 "All units back" button The button is active in "Automatic" mode only. All units immediately proceed to their home position; any interlocks required for operational reasons shall remain active; the "automatic" mode shall be canceled; start required at the central control panel. The button is yellow. 9.2.3.5.13 Automatic no-load traversing The "Automatic no-load traversing" function of the machine shall be provided for automatically loaded machines. 9.2.3.6 Monitoring of command actions 9.2.3.7 Hold-to-run controls 9.2.3.8 Two-hand control Type III shall be used. 9.2.3.9 Consent function 9.2.3.10 Combined start and stop controls 9.2.4 Wireless control system (CCS) Copyright Daimler AG MBN 9666-3 2020-07, page 26 9.2.4.1 General requirements 9.2.4.2 Monitoring the effectiveness of a wireless control system for controlling a machine 9.2.4.3 Control limits 9.2.4.4 Use of multiple wireless control points 9.2.4.5 Portable wireless control points Portable wireless control points that can control several machines shall continuously display the machine currently selected. 9.2.4.6 Intentional deactivation of wireless control points 9.2.4.7 Emergency stop devices at portable wireless control points 9.2.4.8 Emergency stop reset 9.3 Protective interlocks 9.3.1 Closing or resetting of interlocking safeguards 9.3.2 Exceeding operating limits 9.3.3 Operation of auxiliary functions 9.3.4 Interlocks between different functions and for contrary motions 9.3.5 Reverse current braking 9.3.6 Cancellation of safety functions and/or protective measures Copyright Daimler AG MBN 9666-3 2020-07, page 27 9.4 Control functions in the event of failure 9.4.1 General requirements All gaseous or liquid media required for the supply of the machine shall be monitored. If immediate shut down is required when reaching the limit value, the machine shall be shut down at the end of the cycle when the prewarning limit is reached. Sensors which issue a prewarning before reaching the limit value shall be used. This prewarning shall be generated in the PLC if analog sensors are used. Monitoring units shall be programmed in the control so that they are shut down at the following points in time, depending on the shutdown priority: • Immediately • Upon reaching the end of the cycle • After a configurable period • After a specific unit quantity The operation of monitoring units shall be displayed as part of the error display at sensor/signal-based level. 9.4.2 Measures to minimize risk in the event of failure 9.4.2.1 General information 9.4.2.2 Use of proven techniques and components 9.4.2.3 Partially or completely redundant design 9.4.2.4 Diverse design 9.4.2.5 Precautions for function tests 9.4.3 Protection against control circuit malfunctions Copyright Daimler AG MBN 9666-3 2020-07, page 28 9.4.3.1 9.4.3.1.1 Insulation error General information Auxiliary circuits in supply and disposal systems whose failure would directly cause important systems to shut down, shall be monitored using insulation monitoring units. Grounding of secondary circuits shall be omitted in this case. 9.4.3.1.2 Method (a) ─ Grounded control circuits supplied by a transformer 9.4.3.1.3 Method (b) ─ Ungrounded control circuits supplied by a transformer 9.4.3.1.4 Method (c) ─ Control circuits supplied by a transformer with grounded center tap 9.4.3.1.5 Method (d) ─ Control circuits not supplied by a transformer 9.4.3.2 Voltage Interruptions 9.4.3.3 Loss of circuit continuity 10 Operator interface and machine-mounted control units 10.1 General information 10.1.1 General requirements If position switches, proximity switches, valves, etc. are used, the activated status shall be indicated at the equipment or at the plug using LEDs. All operating devices required for the control system in automatic and setup operation as well as all operating mode and condition signaling units shall be grouped together in one central command center. The local control panel shall feature all operating and signaling units required for "manual" or "setup" mode as well as to reset the unit (machine) to "automatic" operation. 10.1.1.1 Functions of the standard control panel It shall be possible to activate any function or movement in manual or setup mode using a pair of buttons. The execution of the function/movement shall be displayed. The home position shall be arranged in "+" direction on the right as per DIN 66217. Copyright Daimler AG MBN 9666-3 2020-07, page 29 10.1.1.2 Functions on supplementary control panels For control panels with more than 6 operating and signaling units, the front panel shall be designed as a swiveling unit and feature a locking mechanism. The units shall be installed on the front panel (installed on the front with connection from rear). It shall be possible to open the control panel door from the front by a minimum of 120° (hinges on the side). 10.1.2 Location and installation 10.1.2.1 Visibility Control stations shall be located in a way which enables the operator to see any movement triggered by a control station. Additional control stations shall be installed if this is not possible. The use of portable control stations shall be clarified during the course of the project. 10.1.2.2 Accessibility It shall be possible to operate any equipment required for machine control (e.g. changing the parameters) without having to open the switchgear combination. The adjustment equipment shall be tamper-proof. 10.1.3 Protection type 10.1.4 Position sensors For drives that require shutdown at a precise position, this function shall be implemented using a frequency converter. The travel limiter (emergency limit rideover feature) switches off the triggering direction only. Manual travel in the opposite direction shall be possible. 10.1.5 Portable and pendant control stations 10.2 Operating units For frequently used functions, operating elements which can be exchanged individually shall be used. 10.2.1 Colors 10.2.2 Identification Copyright Daimler AG MBN 9666-3 2020-07, page 30 10.3 Indicator lights and displays 10.3.1 General information Activated emergency off devices as well as unclosed, electrically locked safeguards shall be indicated centrally and locally by individual messages on the control panels. It shall be possible to query and change process parameters without a programming unit. Status displays (such as end positions of movements, switch states), interlocking conditions, and static error displays shall be implemented. The status and error display shall be structured as follows: • Control system monitoring • Machine and process monitoring • Status polls (inputs, outputs, flags, etc.) 10.3.2 Colors A signaling column shall be provided. The colors shall indicate the following: • Red Machine stopped • Yellow Prewarning • Blue (if required) Special function such as quality stop • Green Machine running (automatic mode) • White Note, e.g. lack of material If the signaling column is used for different functions, this shall be marked in plain text. Indicator lamps shall not be connected in parallel with inputs/outputs. Steps shall be taken to ensure that the display does not change if the functions are mixed up. 10.3.3 Flashing lights and displays If the circuits for indicator lamps are not deactivated with "System/Machine Off", it shall be possible to deactivate them individually. 10.3.4 Visualization Machine and process monitoring visualization as well as user guidance shall be provided. The schematic machine diagram (diagnostic image) shall be accessible from any function or mode. Devices that have a Web interface shall be integrated into the visualization. Access control e.g. to the Web interface shall be realized via a user/password combination or an electronic key system. Visualizations shall be switched dark or switched to energy saving mode after a certain time. Copyright Daimler AG MBN 9666-3 2020-07, page 31 10.3.5 Machine and process monitoring The machine and process monitoring system shall selectively indicate the defective unit/assembly, the type of malfunction or intervention in the process sequence, as well as the identification/address of the component causing the malfunction/signal. The exclusive display of error codes shall not be permitted. Error detection shall record components including those listed below: • Monitoring of the making, start and indexing conditions, as well as interlocking and movement checks • Monitoring all applied supply, disposal and process media. • Plausibility check (e.g. position switch pair monitoring for simultaneous activation, pressure switches, flow sensors) • Cycle time monitoring of the complete machine, each station and each processing step (function monitoring). For the machine and station (robot), a distinction shall be made regarding the model series/type in addition to the total number. • For workpiece type checks, suitable switching actions shall be taken, e.g. drop verification or test circuit to prevent incorrect or duplicate assignment. Type checks shall be designed to be selfmonitoring in the software (signal change per cycle). Part checks (initiators) shall be provided to ensure correct position control/positioning of the workpieces. • Activation of the error display shall be stored. It shall only be possible to manually acknowledge it after the error has been eliminated. If the display is not in error display mode when a malfunction occurs, a message indicating the error shall be superimposed. If several errors occur at the same time, this shall be indicated on the screen/line with scrolling function. The errors shall be listed and saved chronologically with date and time. The monitoring units shall be effective in all operating modes, with the exception of cycle time monitoring in manual and setup mode. An error log shall be generated, saved and displayed on the HMI All required monitoring times shall be set correctly in line with the sequence. 10.4 Illuminated pushbuttons 10.5 Rotary control devices 10.6 Start devices Copyright Daimler AG MBN 9666-3 2020-07, page 32 10.7 EMERGENCY STOP devices See Section 23 10.7.1 Location of EMERGENCY STOP devices 10.7.2 EMERGENCY STOP device types 10.7.3 Operation of the supply disconnecting device to effect EMERGENCY STOP 10.8 EMERGENCY OFF devices See Section 23 10.8.1 Location of EMERGENCY OFF devices 10.8.2 Types of EMERGENCY OFF device 10.8.3 Operation of the supply disconnecting device to effect EMERGENCY OFF 10.9 Enabling controls 10.10 Lamp test A test circuit shall be provided for indicator lamps and displays (e.g. plain text, seven segment displays, LEDs). Testing shall be possible in all operating modes. 10.11 Filament lamps Bulbs (filament lamps) shall not be used. 11 Switchgears: location, mounting, structure and housings 11.1 General requirements Switchgear combinations (switch cabinets, housings, compartments) shall be dimensioned adequately so that after commissioning there is a minimum space reserve for subsequent installations of 10 % for standard machines and 20 % for special machines. More specifically, this space reserve is to accommodate the equipment of the individual function groups such as terminal blocks, wiring ducts, hinged frames, sockets, and program memories. Switch cabinet transport units shall be equipped with ring lugs to facilitate transportation of the assembled units. Copyright Daimler AG MBN 9666-3 2020-07, page 33 Construction parts and interior parts shall be made of flame-retardant materials as a minimum requirement. As a rule, cables shall be routed into switch cabinets from below. Where switch cabinets are not installed on pedestals, they shall be provided with integrated cable maneuvering space or separate plinths. Switch cabinet plinths with a height of 200 mm shall be used for floor-mounted units. In the case of pre-assembled data/bus lines, a separable cable flange shall be used for plug cutouts to lead through the cable. Measuring cables, servo cables, bus cables, connected and other shielded cables shall be routed into the switch cabinet using separable bushings. The cable entry shall be sealed. Cable bushings shall also be used for larger cross-sections. Where plug cabinets and clamping plug adapters are used, the separable bushing (sealed cable entries) shall be dispensed with. Where switch cabinets are screwed on mounting systems, adequately dimensioned threaded holes or captive nuts shall be used. Mounting aids shall be provided for heavy units. 11.1.1 Switch cabinet • • • Cover panels for door cutouts for mains switch shall be supplied by the switch cabinet manufacturer Dimensions (in accordance with DIN 41488-2) See table 3 for basic data on switch cabinets Table 3: Basic data for switch cabinets Width 400 mm, 500 mm, 600 mm, 800 mm, 1 200 mm Height Free-standing switch cabinet with plinth max. 2 050 mm Add-on switch cabinet max. 2 050 mm above access level Depth 400 mm, 500 mm, 600 mm Width per transport unit No taller than 2 500 mm Door width No taller than 600 mm Opening angle of doors Front at least 180° rear at least 130° • • • • • • • • • • • • • Doors with vertical hinges (3x) Extending rod lock in each door wing from 500 mm door width (height 2 050 mm) Lock, see 11.1.2 It shall be possible to engage the locking system of the cabinet doors without using a tool (key). Door ground clearance 22 mm Detachable side wall and roof sheet Three-part floor panel, cable entry area capable of dustproof sealing Cable clamp bar Metal circuit diagram pocket not glued; a sufficient quantity shall be ensured. A thermostat to monitor the maximum permissible switch cabinet temperature shall be installed. Hinged shelf inside in cabinet door for programming unit with extendable mouse pad for cabinets with programmable units Hoisting lugs in corner joint Degree of protection IP55 Copyright Daimler AG MBN 9666-3 2020-07, page 34 • • Foamed-in door seals If the doors close automatically, they shall be locked. 11.1.2 Locks for switch cabinets, control panels, terminal boxes, etc. • • • • • • Circumferential edge length of the door under 800 mm: Quick-release locks Circumferential edge length of the door from 800 mm: Turning bolt locks Door height over 1 000 mm: Extending rod lock with rollers and central locking, handle in locked position at bottom Locks prepared for exchangeability for: Socket wrench in accordance with sketch below (Figure 1 and Figure 2) Socket wrench DIN 43668 two-way Closing cap DIN 18252, DIN EN 1303 profile half cylinder 40 mm Doors from H = 1 200 with locking handle for interchangeable inserts (as above) and DIN 18252, DIN EN 1303 lock cylinder (40 mm) as well as snap fastener. Locked position downwards Figure 1: Socket wrench profile 1,5 7 10 12 Figure 2: Switch cabinet lock insert 11.1.3 Control panels • • • • • Only factory-built housings Door opening angle 180° Mounting plate sheet thickness H ≥ 300 2,5 mm, H ≥ 600 3 mm Lock, see 11.1.2 If electronic devices are used, a heat calculation shall be made and cooling provided accordingly. 11.2 Location and attachment All switch, technology, and switch cabinets shall be illustrated on the system layout. The positional arrangement shall be coordinated. Copyright Daimler AG MBN 9666-3 2020-07, page 35 11.2.1 Accessibility and maintenance All drive elements and actuators (clutches, brakes, motors, solenoid valves, and solenoids) as well as the associated connection boxes and plug connections shall be installed in a way that guarantees easy testing and maintenance when installed without the need for special tools. These shall not restrict access to other machine parts which require regular maintenance. Controlgear such as contactors, time relays as well as terminal blocks shall be mounted horizontally on DIN rails to DIN EN 60715 so that they are accessible from the front. Control units shall be considered easily accessible if, within 10 minutes, they can be replaced without the use of special tools. Sensors and actuators shall be installed such that they are accessible in the event of malfunctions within a maximum of five minutes. Assemblies and equipment shall not be arranged at multiple levels or on the side walls. Switchgears shall not be located behind hinged frames. Hinged frames shall only be equipped from one side (from the front). Hinged frames shall be lockable in their end positions. Components shall be arranged without mutual overlaps. Devices shall not be mounted at access levels or on the housing/switch cabinet floor. Electrical components in switchgear combinations shall be arranged such that the count within a group increases from left to right and from top to bottom. This shall also be implemented in the event of changes. Reserve surfaces shall be allocated accordingly. The distance between the devices and the wiring ducts shall be no less than 20 mm. The width of aisles and escape routes in front of switch cabinet combinations shall be at least dimensioned as per DIN VDE 0100-729. 11.2.2 Physical separation or grouping 11.2.3 Thermal effects 11.2.3.1 Switch cabinet/operating cabinet If the switch cabinet needs to be cooled, only temperature-controlled heat exchangers and cooling units may be used. Filter fans shall not be used. The switch cabinet cooling functions shall be monitored; any malfunctions or failures shall be signaled. The type of heat dissipation shall be coordinated during the course of the project. Switch cabinet cooling units shall be connected downstream of the main switch. The connections of the air conditioners shall be pluggable. Condensation shall be drained outside the switch cabinet and collected in a transparent tank. The air conditioning unit installations shall not restrict escape routes. Air ducting and dew points shall be taken into account. If water-based air conditioning units are used, care shall be taken to ensure sensible regulation (dew point). The cooling units shall switch off automatically on opening of switch cabinet doors. The thermostat integrated into cooling units shall be used to control the switch cabinet temperature. The integrated safety contact shall be used as prewarning. Copyright Daimler AG MBN 9666-3 2020-07, page 36 A separate thermostat shall be used to monitor the maximum permissible switch cabinet temperature. Diagnostic outputs on the unit shall be evaluated as (error) messages via the control system. The maximum permissible internal switch cabinet temperature shall be 10 % below the maximum permissible operating temperature of the most temperature-sensitive component within the switch cabinet. The cooling air shall be routed within the switch cabinet so that it flows around or through the main heat sources. For heat calculations: • For installation on level ground: The max. ambient temperature of the air as per chapter 4.4.3 shall be taken into account. • For installation on switch cabinet pedestals: An ambient temperature of 55 °C shall be taken into account. 11.2.3.2 Electronic control system The electronic control system shall be spatially separated from devices radiating heat and installed taking into account EMC requirements as specified by the manufacturer. 11.2.3.3 Power dissipation The total dissipation of every switchgear combination shall be determined in accordance with IEC/TR 60890. Appropriate cooling measures shall be derived on the basis of the determined total dissipation. Heat calculations shall be submitted. 11.3 Protection type Completely installed switch cabinets/terminal boxes (installation spaces) shall fulfill the requirements of protection type IP 54 as per DIN EN 60529 at minimum. IP2X devices at minimum shall be used in the switch cabinet. Position and proximity switches as well as e.g. valves/valve terminals shall provide an overall protection rating in installed condition of at minimum IP 65 as per DIN EN 60529. Outside the enclosure/protective fence, devices with IP 54 protection or higher shall be used. Inside the enclosure/protective fence, a minimum protection level of IP6X is required. 11.4 Housings, doors and openings The front doors (each leaf at max. 600 mm wide) shall feature an opening angle of at minimum 180° and be designed so that series assembly of the switch cabinets is possible. When using rear end doors (each leaf at max. 600 mm wide), an opening angle of at minimum 130° shall be guaranteed. The opening angle of the doors shall still be ensured after installation of the switch cabinets. Escape routes shall be taken into consideration when doors are open. Cutouts in doors or side walls shall not affect the switchgear cabinet's stability. A sufficient number of shelves or wiring diagram pockets and a circuit diagram compartment shall be provided on the inside of switch cabinet doors. The software documentation shall be stored in the PLC cabinet and the wiring diagrams in the supply cabinet. Sufficient compartments/wiring diagram pockets shall be provided. Copyright Daimler AG MBN 9666-3 2020-07, page 37 If there is insufficient space in the existing cabinets for the storage of circuit diagram documentation, separate metal cabinets shall be provided. From a height of 800 mm, door locks with extending rods and handles shall be used, from a height of 1600 with additional central locking. The switch cabinet dimensions, transport units, locking mechanisms and colors shall be clarified during the project. 11.5 Access to electrical equipment 12 Conductors, cables, and lines 12.1 General requirements 12.2 Conductor All conductors are made from copper. Solid cores are not permitted. 12.3 Insulation 12.4 Current-carrying capacity in normal service 12.5 Voltage drop for conductors and lines 12.6 Flexible cables 12.6.1 General information 12.6.2 Mechanical rating 12.6.3 Current-carrying capacity of cables wound on drums 12.7 Conductor wires, conductor bars and slip-ring assemblies 12.7.1 Basic protection 12.7.2 Protective conductor Copyright Daimler AG MBN 9666-3 2020-07, page 38 12.7.3 Protective conductor current collectors 12.7.4 Removable current collectors with disconnector function 12.7.5 Clearances 12.7.6 Creepage distances 12.7.7 Conductor system sectioning 12.7.8 Construction and installation of conductor wires, conductor bar systems and slip ring systems 13 Wiring practices 13.1 Connections and line routing 13.1.1 General requirements Terminals shall always be fixed/attached and be within view. Terminals shall be numbered in ascending order from left to right or from bottom to top. Units integrated into supply and disposal systems (e.g. thermostats, thermometers) shall be connected with sufficiently large loops (flexible cable) to ensure that they can be extended without need for disconnection. Cross connections at neighboring terminal blocks shall only be acceptable if adequate connection links have been used. Wire jumpers shall not be permitted. Analog signals shall be routed in shielded lines. 10 % reserve cores shall not refer to individual control lines, but to joint line routing, e.g. from the central switch cabinet to a unit, station or control panel (i.e. between electrical enclosures). 13.1.2 Trays for conductors and cables Definitions for cable ducts are provided in chapter 13.4.2. Terminals, cable connectors or other electrical equipment shall not be used. Exception: Ground connection with a tin-plated copper conductor as equalizer. In accessible areas, they shall be designed to be safe to step on and resist deformation. The trays shall generally be covered. Copyright Daimler AG MBN 9666-3 2020-07, page 39 Vertically routed cables shall be supported from a height of 1 m by metal clamps (with anti-squeeze protection) in 1 m gaps. Horizontal fixation shall not be permitted. For examples, see Figure 3. Figure 3: Vertical cable trays The following are housed in the chutes separated by separating ribs (Figure 4) (from left to right): • • • • [1] Control lines up to 50 V DC [2] Supply lines/power lines up to 400 V AC [3] Fieldbus systems and protective equipotential bonding conductors [4] Fluid lines shall always be separated from electrical media by a separating rib. Figure 4: Separating ribs in the trays In crossover areas, horizontal partitioning is required (using metal bridges). Cables shall be routed in a logical, orderly fashion 13.1.3 Conductors of different electrical circuits 13.1.4 Alternating current circuits ─ Electromagnetic effects (avoidance of eddy currents) Copyright Daimler AG MBN 9666-3 2020-07, page 40 13.1.5 Connection between the pick-up and pick-up converter of an inductive power supply system 13.2 Identification of conductors 13.2.1 General requirements 13.2.2 Identification of the protective conductor/protective equipotential bonding conductor 13.2.3 Identification of the neutral conductor 13.2.4 Identification by color 13.3 Wiring within housings Wiring shall correspond to the wiring diagram, i.e. the wiring sequence shall correspond to the drawing sequence from top to bottom and from left to right in the various sections of the diagram. In the case of duct wiring, a wiring duct shall be located upstream of the terminal block. Direct switching of solenoids (> 30 W), clutches and brakes shall not be permitted. Plug connections/control lines with more than 24 pins shall not be permitted. Cables leading to movable cabinet parts (e.g. in hinged frames, doors, panels) shall be routed in a flexible tube which can be separated lengthways. The flexible tube shall be attached using clamps at both ends. Any external cables routed into switchgear combinations, terminal boxes and/or junction boxes shall be routed to terminal block modules or terminal plug adapters. A DIN rail shall be installed in the switch cabinet to secure the incoming and outgoing cables. Duct wiring shall be used. Exception: A wiring system is defined in the project specifications. Individual wire identification shall be used for components where no pluggable direct allocation to the connections is possible. All shielded lines shall be laid flat on the equipotential bonding strip following insertion. 13.4 Wiring outside housings 13.4.1 General requirements Individual cables shall be capable of being replaced easily and without the need for dismantling plug connections. The circular connectors (DIN EN 61076-2) listed in Table 4 and their allocated assignments shall be used: Copyright Daimler AG MBN 9666-3 2020-07, page 41 Table 4: M12x1 connectors assigned to application Connector Application M12x1 A-coded, 4-pin Sensors and actuators (up to 30 W) in DC 24 V environment. The FE shall be connected separately, if required. M12x1 A-coded, 4-pin with yellow line Wiring of safety sensors and actuators M12x1 A-coded, 5-pin with yellow connectors and yellow line Wiring of safety sensors M12x1 L-coded, 4-pin DC 24 V supply with 1,5 mm². The FE shall be connected separately, if required. M12x1 D-coded Profinet M12x1 X-coded Gigabit The cable sheath colors listed in Table 5 shall be used. Table 5: Cable sheath colors for coding lines Wire Cable sheath color Measuring system Not yellow Profibus, hybrid cable Not yellow M12 sensor/actuator cable (standard) Not yellow M12 sensor/actuator cable (for 4-pin safe functions) Yellow RAL 1021 connector Black RAL 9005 cables M12 sensor/actuator cable (for 5-pin safe functions) Yellow RAL 1021 connector Yellow RAL 1021 cables Control line Gray RAL 7040 Power Black RAL 9005 Gray RAL 7040 External voltage, conductors and cables upstream of the supply disconnecting device Orange RAL 2003 Profinet cable Green RAL 6018 Copyright Daimler AG MBN 9666-3 2020-07, page 42 13.4.2 External cable ducts The installation paths for a machine/main switch area shall not be used for other scopes. They shall be realized in closed configuration. Exclusively closed metal ducts and wire mesh ducts with covers shall be permitted. Covers shall be protected against inadvertent detaching and removal from the duct. Brackets, screws, etc. shall be permanently attached. Covers over 80 mm in width shall be fitted with hinges and snap fasteners. Adequate ground connections shall be available. The covers shall be designed to be safe to step on (heavy loads) in accessible areas (preferred: R12 in accordance with DIN 51130). Assignment shall be made in accordance with the illustration provided in the chapter on trays. Where damage as a result of weld splatter is to be expected, exposed cable ends shall be protected at the unit connection using a flexible tube or by cables that are resistant to welding beads. Vertical installations larger than 1,5 m shall be provided with strain relief. Cable fasteners for inlets into switch cabinets, ladders, riser ducts and on terminal boxes shall be secured using clamps. Cables and lines installed in riser ducts shall be secured at regular intervals of no more than 900 mm using clamps. Cable ties/attachments shall not be permitted in cable ducts. Terminals, cable connectors or other electrical equipment shall not be used. Exception: Ground connection with a tin-plated copper conductor as equalizer. Variants with edge protection on corners, cutouts and deflections at the top and bottom shall be used. 13.4.3 Connections to moving machine parts Adequately dimensioned energy chains shall be installed or loops provided for cables leading to movable or adjustable parts. (Upward loops shall be avoided.) When using energy chains, steps shall be taken to ensure that the: • • • • • • • • • • • • Frame of the chain links comprises side links so that the ribs/covers can be opened at the "inner and outer radius" Chain links can be individually replaced Permissible bending radii and installation instructions are observed Trailing hoses/cables shall be routed in parallel at all levels Hoses/cables in energy chains are routed loose and without overlaps in the longitudinal direction symmetrically from the outside (large cross-section) towards the inside (small cross-section), with strain-relief clamps at both ends (hose lines using bulkhead connections) Hoses/lines are routed separately (separating ribs) Exclusively hoses/lines shall be used that are approved by the manufacturer for installation in energy chains. A hose shall not be routed in one piece through several chains. Electrical cables shall not be routed in one piece through several chains. Cables can be replaced without removing the chain and connectors. Manufacturer's requirements for the minimum radius and the installation guidelines for trailing lines are implemented Hoses/lines are routed without them becoming twisted Copyright Daimler AG MBN 9666-3 2020-07, page 43 • • • Reverse radii are not used In protective hoses/energy chains, no cable ties shall be used. Energy chains shall not be installed on top of each other. 13.4.4 Interconnection of operating equipment on the machine 13.4.5 Plug/socket combinations Cables which move when in operation and which are therefore at risk of breaking shall be designed with plug connections at both ends. Cables shall have plug-type connections upstream and downstream of an energy chain. The chain and its components as well as the cables used shall be documented accordingly (assembly drawing of the chain, parts list, assignment plan and cable list). Units, equipment and fixtures, drives, etc. that can be replaced completely for maintenance and repair purposes shall be provided with plug connectors. Motors shall be designed with plug connectors featuring separate, heavy plugs. Current collectors shall also be supplied with plug connectors. The operating conditions of the drives (starting current/frequency) shall be taken into account when selecting the plug connections for drives. The maximum cable length between terminal board and plug connection shall be 1,5 m. 13.4.6 Dismantling for shipment 13.4.7 Additional conductors 13.4.8 Connection technology for actuators/sensors and their power supply • • Nominal voltage DC 24 V Degree of protection at least IP67 See Table 6 regarding the specifications for cables with M8x1 and M12x1 circular connectors (DIN EN 61076-2). The following assignment shall apply unless specified otherwise in the respective chapters: Table 6: PIN assignment, M12x1 and M8x1 connectors PIN Core color LED color Signal 1 Brown Green DC 24 V 2 White White Signal 2 (NC contact, clogging signal, dimming, etc.) 3 Blue - 0V 4 Black Yellow Signal 1 (NC signal, illuminating) 5 Greenyellow/gray - Protective conductor/signal 3 Copyright Daimler AG MBN 9666-3 2020-07, page 44 • • • • • • Minimum cross-section: 0,34 mm² Bridges in plugs or cable boxes are not allowed Rolled spring contacts Direct contacting of connecting cores on spring contacts Screw collar rings, self-locking Mechanical connection between plug and socket: Screw or snap-in locking Specifications for cables with connectors in accordance with DIN EN 175301-803, type A: • • • • Connectors 3-pin + PE in accordance with DIN EN 175301-803, type A Connectors 2-pin + 2PE (PE bridged), in analogy with DIN EN 175301-803, type A With integrated varistor fuse Line box with LED (operation indicator) yellow 13.5 Cable ducts, terminal boxes and other housings 13.5.1 General requirements 13.5.2 Rigid metal electrical installation conduits and fastening Rigid, metal electrical installation conduits/metal profiles shall not be permitted. 13.5.3 Flexible metal electrical installation conduits and fastening 13.5.4 Flexible non-metal electrical installation conduits and fastening 13.5.5 Cable trunking systems Cable trunking systems (in metal) shall be used across the entire length. 13.5.6 Machine compartments and cable trunking systems The design version described here has not been approved by us as it does not safeguard accessibility across the entire length. 13.5.7 Terminal boxes and other housings Connection boxes shall be used in the following cases: • • • • Cable branching as per DIN EN 60529 does not comply with IP 65. Separation of conductors is required or expedient in terms of transportation or relocation of the machine Individual units are connected with fixed (cast-in) connecting cables (e.g. measurement sensors, proximity switches) A central connection for an assembly or the complete machine shall be created Copyright Daimler AG MBN 9666-3 2020-07, page 45 Connection boxes shall be arranged to ensure the following: • • • The opening is on the vertical plane. The opening is accessible outside of protection zones without dismantling other machine parts/protective grilles. The lower edge of the box lies at minimum 400 mm and the upper edge at maximum 2 000 mm above the access level. Further specifications: • • • • • • • • Connection boxes shall only accommodate terminals. Cables shall not be looped through connection boxes. Device connection boxes shall not be used as connection boxes. Exclusively non-metallic screw connections shall be used in plastic housings. Connection boxes and other boxes shall at least comply with IP 54 protection as per DIN EN 60529. All lines in the terminal boxes shall be introduced using screw connections or comparable systems. The lines shall preferably be introduced into the terminal box from below (in the event of insufficient space in exceptional cases, also from the side). It shall be possible to completely open the terminal box covers from the front (hinges on the side or bottom). 13.5.8 Motor connection boxes 14 Electric motors and associated equipment 14.1 General requirements As a rule, four-pin three-phase A.C. motor variants shall be used (1500 rpm). The insulation of the motors shall at minimum fulfill the requirements of insulation class "F" as per DIN EN 60085. Three-phase current motors ≥ 3 kW shall be designed in a delta connection for nominal voltages of AC 400 V so that they are suitable for star-delta starting. The starting conditions shall be specified on a plant-specific basis. An arrow showing the direction of rotation shall be located clearly visibly and at a fixed location next to the motor. Drive brakes shall be active when the system is in de-energized condition. The brake shall be designed with a plug connector. Designs without slip rings shall be used for clutches and brakes. Function monitoring shall be implemented. The minimal degree of protection shall be IP65. MBN9666-2 specifications shall be observed. 14.2 Motor housing 14.3 Motor dimensions 14.4 Motor mounting and compartments When using air filters, these shall be arranged in a maintenance-friendly way and their replacement shall be simple and quick. Maintenance shall be possible without putting anyone at risk. Maintenance shall be possible without the need to remove other components. Copyright Daimler AG MBN 9666-3 2020-07, page 46 14.5 Motor selection criteria 14.5.1 Three-phase current motors (general) See MBN9666-2 for mechanical requirements If motors are operated using converters, they shall be fitted with a thermal contact designed as a normallyclosed contact or a PTC thermistor. The sensors shall be evaluated in the converter. Motors > 11 kW shall have a thermal contact designed as a normally-closed contact or a PTC thermistor. The thermal contacts/PTC thermistors shall be evaluated. It shall be defined in the projects (via the MFL) whether a thermal contact or a PTC thermistor will be used. The connectors defined in the following chapters are referenced in the material release list for the project. Should the connectors not be released, the motor with the connection variant shall not be used. 14.5.1.1 One speed up to 7,5 kW (module max. 16 A) • Modular connectors • Bridges to be installed depending on application • See Figure 5 Figure 5: One speed up to 7,5 kW (module max. 16 A) Copyright Daimler AG MBN 9666-3 2020-07, page 47 14.5.1.2 Two speeds with separate windings up to 7,5 kW (module max. 16 A) • Modular connectors • See Figure 6 Slow Fast Figure 6: Two speeds with separate windings up to 7,5 kW (module max. 16 A) 14.5.1.3 One speed up to 7,5 kW (module max. 40 A) • Modular connectors • Bridges to be installed depending on application • See Figure 7 Figure 7: One speed up to 7,5 kW (module max. 40 A) Copyright Daimler AG MBN 9666-3 2020-07, page 48 14.5.1.4 Two speeds with separate windings up to 7,5 kW (module max. 40 A) • Modular connectors • See Figure 8 Slow Fast Figure 8: Two speeds with separate windings up to 7,5 kW (module max. 40 A) 14.5.1.5 Connection for 3-phase motors without brake and sensor up to 7.5 kW • Plug, 4-pin (3+PE) • Bridges to be installed depending on application • See Figure 9 1 speed Figure 9: Connection for 3-phase motors without brake and sensor up to 7,5 kW Copyright Daimler AG MBN 9666-3 2020-07, page 49 14.5.1.6 Motor connection for standard motors and geared motors up to 1,1 kW • Plug whose connector face is compatible with HAN 3 A • Bridges to be installed depending on application • 5-pin + PE (when using brake or thermal contact) • 7-pin + PE (when using brake and thermal contact) • See Figure 10 1 speed Figure 10: Motor connection for standard motors and geared motors up to 1,1 kW 14.5.1.7 Motor connection up to 7,5 kW (max.16 A) • Plug whose connector face is compatible with HAN 10 A • Bridges to be installed depending on application • See Figure 11 One speed Figure 11: Motor connection up to 7,5 kW (max. 16 A) Copyright Daimler AG MBN 9666-3 2020-07, page 50 14.5.1.8 Motor connection up to 7,5 kW (max.16 A) • Plug whose connector face is compatible with HAN 10 A • See Figure 12 Two speeds with separate windings Figure 12: Motor connection up to 7,5 kW (max. 16 A) 14.5.1.9 Motor connection over 7,5 kW • Direct connection and CEE plug ─ power plug socket 7-pin (6+PE) (IEC 60309-1) • Use CEE plug with nickle-plated contacts. • Bridges to be installed depending on application • See Figure 13 One speed Figure 13: Motor connection over 7,5 kW Copyright Daimler AG MBN 9666-3 2020-07, page 51 14.5.1.10 Motor connection over 7,5 kW • Direct connection and CEE plug ─ power plug socket 7-pin (6+PE) (IEC 60309-1) • Use CEE plug with nickle-plated contacts. • See Figure 14 2 speeds with separate windings Figure 14: Motor connection over 7,5 kW 14.5.2 D standard motors Standard motors shall be compatible with frequency converters Insulated motor bearings shall be used as of BG180. In accordance with DIN EN 60034-1 (VDE 0530 Part 1) Half-key balancing in accordance with DIN EN 60034-14 (VDE 530 Part 14) Plug-in version on terminal board for motors ≤ 7,5 kW, sizes BG132. The pin assignment shall be clarified during the course of the project. 14.6 Protective devices for mechanical brakes 14.7 Motor name plates If the motor is installed in a way that blocks the visibility of its name plate, a second, clearly visible name plate shall be fitted next to the motor. If a plate is inside an enclosure, all plates in the switch cabinet shall be affixed with the respective operating equipment designations (BMK). 15 Sockets and lighting 15.1 Sockets for accessories Final circuits/sockets for mobile operating equipment/accessories external to switch cabinets and terminal boxes shall not be permitted. (see chapter 7.2.5) Copyright Daimler AG MBN 9666-3 2020-07, page 52 15.2 Workstation lighting on machines and accessories 15.2.1 General information The working area of the machine shall feature antiglare lighting as per DIN EN 1837. Switch cabinet lighting shall be provided for each switch cabinet field and it shall be connected upstream of the main switch. The switch cabinet lighting shall be switched with a separate door position switch for each cabinet field. 15.2.2 Power supply The switch cabinet lighting shall be implemented using LED technology. 15.2.3 Protection 15.2.4 Mounts 16 Marking, warning signs and reference designations 16.1 General information 16.2 Warning signs 16.2.1 Electric shock hazard 16.2.2 Hot surfaces hazard 16.3 Functional identification The functional identification of command and signaling units shall be attached directly above these units. 16.4 Marking of housings for electrical equipment The switch cabinet combination type plate shall be attached on the outside near the main switch. Each switch cabinet field shall be labeled on the outside including its distinctive features (e.g. switch assembly, function group, unit). The plates shall be permanently affixed. 16.5 Reference designations (designations of operating equipment (BMK)) The identification plates shall not be attached to the unit itself to prevent them from being lost during unit replacements. Copyright Daimler AG MBN 9666-3 2020-07, page 53 The identification shall be applied permanently and so that it is visible once the equipment has been completely installed. This unit identification shall also be repeated on paneling and covers. All units outside of compartments shall be identified using engraved, embossed, or etched identification plates. These plates shall not be mounted by adhesive bonding. All devices connected to the input/output level of electronic control systems also reference the absolute address of the lowest connected input or output on the identification plate for the operating equipment designations (BMK). When replacing assemblies, identification plates shall remain attached to their slots. Permanent marking of the cables on both ends with engraved or equivalent plates (not handwritten marking). 17 Technical documentation 17.1 General information Technical documentation shall be collected in folders or ring binders together with a table of contents and an index. The format of the folder shall be identical to the paper format. These documents shall be properly stored directly on or in the machine. If sufficient space is not available, the procedure will need to be clarified as part of the project. If no specifications to this regard have been defined for the project, the standards referenced directly and indirectly in the DIN EN 60204-1 standards document shall be applied. The location and designation of switch cabinets, terminal boxes, control panels and control, command and signaling units, electrically monitored doors, drives, and other electrical equipment devices shall be illustrated in a layout diagram. Completing the title boxes in the electrical documentation shall form part of the scope of delivery. See the project documentation for labeling specifications. The "Proc." and "Insp." fields (Table 7) shall be completed with the names of the processor and inspector. Table 7: Excerpt from drawing frame Date Proc. Insp. Pressure Any modifications, enhancements or conversions to existing machines shall be implemented using the original drawing and designation system. All descriptions formulated for documentation shall be provided in editable format and as PDF files. Copyright Daimler AG MBN 9666-3 2020-07, page 54 All safety zones, personal safety shutdowns, and robot danger zones shall be documented in the plant layout/arrangement plan. 17.2 Information pertaining to electrical equipment 17.3 Software and data backups The program shall be created as per the specifications of the specialist department either as a contact diagram, function diagram, list of instructions, or in symbols (e.g. S7Graph) and it shall be supplemented by a list of cross-references of all program elements as well as a list of comments. All inputs, outputs, counters, times, flags, and segments shall feature comments. The following descriptions shall be provided: • For data modules: structure and content, for data items their meaning and potential limits • For functional modules: their effect, parameterization and any borderline case observations • For program modules: description of the mode of operation For electronic control systems, system-related data storage media shall be provided for data back-up purposes. The enclosed software and associated data carriers shall include the programs required for control and documentation, be up to date and they shall be reproducible on the operator's programming equipment. All documentation regarding operating and visualization systems used shall form part of the scope of delivery. This shall include, among other items, licenses, manuals and system descriptions, installation disks, boot disks, drivers used, description of structure/file storage and interfaces. Backup data records for configurable sensors/actuators shall also be provided in original form. For PC-based systems, a detailed description and batch file shall be supplied for reinstallation. Hard drive backups (images) shall also be made. The tool to be used for this purpose shall be agreed on during the course of the project. 18 Tests 18.1 General information All test and measurement records as per statutory regulations and specified standards shall be included in the documentation and made available along with any associated checklists as a requirement for acceptance. Bus measurement reports, for example, shall also be submitted. All test plans and test records including the measured results shall also be provided in an editable format. Copyright Daimler AG MBN 9666-3 2020-07, page 55 18.2 Verification of conditions for protection by automatic disconnection of supply 18.2.1 General information 18.2.2 Test 1 – Verification of the continuity of the protective conductor circuits 18.2.3 Test 2 – Fault loop impedance verification and suitability of the associated overcurrent protective device 18.2.4 Application of the test methods for TN systems 18.3 Insulation resistance tests 18.4 Voltage tests 18.5 Protection against residual voltages 18.6 Function tests The following shall be tested in advance in preparation to acceptance: 18.6.1 Voltage failure Simulations shall be carried out to ensure that it is possible to correctly resume the interrupted program after voltage dips and failures. The operating personnel shall be able to use the available command units to move on the machine within the cycle or to home position. 18.6.2 Home position run The machine automatically moves to the home position upon selecting this function. 18.6.3 Restart following EMERGENCY STOP It shall be possible to move the machine within the cycle or to the home position after an emergency stop. 18.6.4 Restart after having switched the main switch off/on After having switched the main switch to "On" and output of the start signal, the machine shall reboot with the old values. 18.7 Retesting Copyright Daimler AG MBN 9666-3 2020-07, page 56 19 Commissioning, technical acceptance, training 19.1 Commissioning During commissioning, the latest status of the documentation of software and hardware (e.g. technical documentation, data carriers) shall always be available to the operator on site. 19.2 Technical acceptance 19.2.1 General information Data backups shall be carried out by a general reset and restart of the plant from the client's archiving system. If deviations from the supply specifications which were not approved in writing become evident during the acceptance procedure of the machine, the supplier shall be obliged to correct any such defects free of charge. 19.2.2 Conditions for acceptance All technical values specified in the agreement shall be observed. A written confirmation stating that the electrical equipment fitted to the machine complies with DGUV V3 regulation requirements is available. The required documentation shall be available for special machines: • RF equipment which has been subjected to type approval carried out by BZT (Federal Agency for Approvals in Telecommunications) shall require a copy of the approval certificate specifying the assigned BZT number. • For RF equipment which has to be subjected to an individual test at the installation site of the orderer, all documentation needed to apply for an individual test shall be provided to the orderer prior to commissioning. • Machines in locations with potentially explosive atmospheres require a copy of the test certificate "Report on the test of power equipment in locations with potentially explosive atmospheres" as well as a written confirmation that the electrical components used are in accordance with DIN EN 60079-0. • For electrical equipment which is installed as protective equipment (e.g. overflow protection, leakage indicator) in machines with substances hazardous to water or with inflammable liquids, a type approval shall be required. The costs incurred for testing and certificates shall be included in the purchase price. 19.2.3 Submission of technical documents At the time of acceptance, the orderer shall obtain 1 set of technical documentation for each machine (no program printouts). The supplier shall keep one copy to complete the final plans. No later than 2 months after acceptance, the supplier shall make available to the orderer all technical documentation in its original, editable version. If the supplier fails to meet the deadline, the orderer shall reserve the right, after expiry of an appropriately Copyright Daimler AG MBN 9666-3 2020-07, page 57 defined second deadline, to have the missing documentation prepared at the cost of the supplier. The complete technical documentation shall be provided with a uniform printout date and a site-specific plant designation. Where third-party devices are supplied (e.g. tool breakage/wear monitoring, frequency converters, etc.), the supplier shall also supply the data back-up software and hardware (e.g. cables). 19.3 Instruction Service and maintenance personnel shall be trained at the machine. The training duration shall be adapted to the respective requirements. The following shall be included in detail: • Overall machine function • Automation concept • Safety concept • Hardware design • Installation concept • Operating and signaling concept (e.g. operation and error messages) • Software structure • Modules for units (interface blocks) • Data linking structure (e.g. data exchange between machine control and superordinate control) • Descriptions of the intervention options to change parameters and texts including practical examples • Troubleshooting and identification using the documentation, e.g. using a programming unit 20 Electronic equipment 20.1 General information This section shall apply to all types of electronic component, including programmable electronic equipment. Mains outlets required for operating programming equipment shall be installed within the switchgear combination in close proximity to the electrical components (see chapter 7.2.5). If control equipment combinations are installed separately (e.g. on switchgear cabinet platforms), one additional socket each for power connection and data transmission of a programming device shall be installed at the (main) operating station (see chapter 7.2.5). Copyright Daimler AG MBN 9666-3 2020-07, page 58 20.2 Basic requirements 20.2.1 Inputs and outputs Status displays of all digital inputs and outputs shall be provided. The inputs and outputs of control and field components shall be designed to resist short circuiting. Functional groups of a machine shall also be grouped together for address allocation. Signals may only be applied to binary inputs from one control unit each (e.g. pushbutton, position switch). Logic functions shall be realized within the control system. 20.2.2 Diagnostic messages All diagnostic messages provided by the bus subscribers shall be evaluated, displayed and forwarded to the MBE/BDE system 20.2.3 Measuring systems for linear and rotary axes Compressed air shall be applied via an independent filter combination to protect the measuring systems from coolant and lubricant mist. Data shall not be stored by the machine manufacturer in the internal memories of the position measuring systems. Such systems shall be exchangeable at any time with a standard measuring system of the measuring system manufacturer. In order to be able to quickly reset the NC axis following the replacement of the measuring system, the following specifications shall be observed: • An easily visible vernier (reference scale) shall be attached to the axis. • The reference dimension for input shall also be attached clearly visible next to the vernier (alternatively in the switch cabinet including a reference to the axis). • A drawing indicating the position of the vernier and the related reference dimension including machine data shall be enclosed with the documentation. • Measuring systems and sensor heads shall be exchangeable by using an installation aid such as dead stops (block dimension against ground surfaces), without the need for alignment with dial indicators. • Linear measuring systems shall be attached so that the sealing lips point towards the side not affected by splash water. If required, an additional mechanical cover shall be provided. Copyright Daimler AG MBN 9666-3 2020-07, page 59 21 Programmable equipment 21.1 Programmable controls The control configurations (centralized or decentralized) shall be implemented specific to the machine and require approval. All programmable/configurable devices/assemblies shall also be incorporated and listed. The software version specified in the projects shall be employed. If no specifications have been defined, the version shall be adapted accordingly should several control systems be in use. The hardware and software required to program/parameterize the equipment/assemblies used shall form part of the delivery scope of the machine. The source code shall also be supplied for all programs written for the machine. A "Comments/description" line shall be created for each line of program code. 21.2 Password protection If a system offers a password protection function, this function shall be used. The password shall be coordinated during the course of the project and be communicated to the responsible parties. 22 Energy efficiency measures DIN EN ISO 50001 shall be taken into account in addition to the following requirements. 22.1 Sleep mode Sleep mode shall be defined as the scheduled switching off of the machine in the event of prolonged standstill (not in use). Sleep mode shall form part of the energy saving concept. Sleep mode shall be activated using an (adjustable) time control and using sensors/controls (e.g. no workpiece on the infeed/outfeed conveyor) or using an external signal. The machines shall be switched off in the required sequence taking into account any (adjustable) run-down times at the end of a cycle. Design specifications: A switch-off triggered by an external signal shall only be completed after a configurable run-down time, default setting 2 minutes. The active external signal shall be shown on the control panel. Transport, buffer, loading conveyors shall be switched off after expiry of a period with no loading or unloading, including a configurable run-down time. In the event of machine and material flow defects, the cooling lubricant shall be switched off in principle. If the machine requires a warm-up phase, a suitable concept shall be devised and coordinated. Sleep mode shall be displayed on the main control panel and reported to the MBE/BDE system Copyright Daimler AG MBN 9666-3 2020-07, page 60 22.2 Heat/cooling supply If electrical heating/cooling is required, the associated connection and connection conditions shall be coordinated. The control concept shall be implemented in line with heating/cooling requirements. 23 Engineered safeguards The following chapters and standards shall be observed with respect to emergency operations: • 9.2.3.4 Emergency operations (emergency stop, emergency off) • Aspects of the emergency stop device are referenced in the DIN EN ISO 13850 publication • Aspects of the emergency off device are covered in the IEC 60364-5-53:2001, 536.4 publication • 10.7 Emergency stop devices • 10.8 Emergency off devices The connecting cables in the field shall be selected in accordance with Table 5. If an analysis device is required to convert the sensor signal, the device shall come from the same manufacturer. Suspension apparatuses shall be provided for temporarily inactive mobile control panels that cover the emergency stop/emergency off button. All safety-relevant scopes shall be documented in a shutdown matrix. This matrix shall be checked prior to acceptance, and the result shall be documented and submitted for each item (the test result shall be handed over together with the overall documentation). A distinction is not made between emergency stop and emergency off devices. The mandatory response of the machine/submachine shall be provided by the manufacturer in line with the respective hazards 24 Component approval list See the project documentation for material approvals. Copyright Daimler AG