-
Ethernet Switch
Gat
eway
U
nit
LEC
P6
Ste
pp
er
Co
ntr
olle
r
Rotary Electric
Side
LEC
P6
Ste
pp
er
Co
ntr
olle
r
Vertical Slide
Electric Side
LEC
P6
Ste
pp
er
Co
ntr
olle
r
Vertical Gripper Electric
Side
LEC
P6
Ste
pp
er
Co
ntr
olle
r
Linear Actuator
Front
Electrical Concept Block Diagram
CompactLogix PLC
Discrete Inputs
Discrete Outputs
Discrete Inputs
Discrete Outputs
LECSA Servo Controller
Linear Actuator
Rear
EX600
SY3000 SV
Auto Switch Auto
Switch
Ver
tica
l Slid
e V
acu
um
Sid
e
SY3000 SV
Auto Switch Auto
Switch
Ho
rizo
nta
l Gri
p
Cen
ter
SY3000 SV
Auto Switch Auto
Switch
Ro
tary
Cen
ter
SY3000 SV
Auto Switch Auto
Switch
Ro
tary
R
ear
SY5000 SV
Auto Switch Auto
Switch
Ho
rizo
nta
l Slid
e
Vac
uu
m S
ide
SY5000 SV
Auto Switch Auto
Switch
Lift
er T
able
C
ente
r
Safety Relay
Dis
cret
e
Inp
uts
Discrete
Ou
tpu
ts
E-Stop
Door Interlock Switch
Light Curtain
Safety Mat
Safety Dump Valve Limit Switch 1
Safety Dump Valve Limit Switch 2
MCR1
MCR2 0 VDC
MCR1 MCR2
Incoming 120 VAC
15 A CB (1)
10 A CB (2)
120 VAC Outlet
24 VDC 20 A Power Supply
20 A CB (4)
Discrete Inputs
3 A CB (5)
PLC VDC+
PLC FP+ (Discrete Outputs)
3 A CB (7)
1
1
1
Safety Dump Valve
E-Stop
E-Stop
E-Stop E-Stop E-Stop E-Stop
Reset (from PLC)
3 A CB (6)
Master On Switch
Upper/Lower Display Lights
Linear Actuator – Rear Servo Controller
Ethernet Switch
Rotary – E Side Controller
Vertical Slide – E Side Controller
Electric Gripper 2 Controller
Linear Actuator – Rear Controller
(Brake Wires) Brake
24 VDC 5 A Power Supply
1
MCR3
MCR4
1 0 VDC
EX600 CPU
5 A CB (3)
-
Safety Relay Wiring
CR30 Safety Relay
24 VDC
0 VDC
00 01 02 03 04 05 06 07 08 09 10 11
A1
A2
12 13 14 15 16 17 18 19 20 21
E-Stop PB
- +
E-Stop Light
DO 3.2
- +
OSSD1
1
2
OSSD2
4
3
1
3 - +
OSS
D1
OSS
D2
4 2
RX
TX
5
1
3 - +
5
Ligh
t C
urt
ain
A-Side B-Side
Brown
White
Blue
Black
Safety Mat
Reset PB
MCR1
MCR2
Safety Dump Valve Limit Switch 1
Safety Dump Valve Limit Switch 2
3
Door Interlock
2 4 OSSD1+ OSSD2+
Red/White Red/Black
Red/White Red/Black
Gra
y
Pin
k
Bro
wn
Brown
Blue Blue
Gray Gray
Bla
ck
Wh
ite
Note 1
Note 1: The Light Curtain Transmitter is mounted on the
machine’s Vacuum side (right side when viewing from the front). The
Light Curtain Receiver is opposite.
2
4
White
Black
(Jumpered)
TB 155
Bla
ck -
Red
Ora
nge
- G
reen
TB 156
TB 157
TB 158
TB 159
TB 160
TB 161
TB 162
TB 163
TB 164
Red
– W
hit
e/B
lack
Gre
en –
Wh
ite/
Bla
ck
Red
- G
reen
Blu
e -
Bla
ck
Bla
ck –
Wh
ite/
Red
Red
- W
hit
e
Wh
ite
- R
ed
Ora
nge
- R
ed
Blu
e -
Wh
ite
Bla
ck -
Red
TB 171
TB 170
TB 165
TB 166
TB 167
TB 168
TB 169
Red
Bla
ck
Wh
ite
Ora
nge
- B
lack
Gre
en
Ora
nge
Red
- B
lack
Wh
ite
- B
lack
Bla
ck -
Wh
ite
Blu
e
Wh
ite
– B
lack
/Red
Gre
en -
Bla
ck
Red
Yellow
Brown
Blue
-
Ethernet Switch
PLC Power and Communication Wiring
VDC +
VDC -
NC
FP +
FP -
CompactLogix PLC
24 VDC
0 VDC
3A CB
3A CB
TB 100
Red
Black
White
TB 103
Orange
Green
TB 101
TB 104
TB 102
-
Window Light Wiring
VDC +
Blue Light
Green Light
Red Light
Window Light
24 VDC
0 VDC
TB 99
Brown
Blue
Black
TB 97
White
TB 98
CR2
Blue Blue
Blue
Brown
From PLC DO 0.11
-
Linear Actuator Brake and E-stop Wiring
EM1
B1
B2
Linear Actuator Rear Servo Controller
24 VDC
(E-stop)
0 VDC
TB 155
Yellow Black
B1 (Black)
Brown
B2 (Black)
-
Ethernet Communications Routing
Ethernet Switch
Gateway Unit LESH16DK-50 LEFB32T-600 LERH50K-2 LEHF10K2-16
Safety Relay CompactLogix
PLC
Ethernet Port Front Ethernet Port
1
2
3
4
5
Ethernet Ports
CN3
CN2
CN 1
CN2 Stat Switch
Left Position (“On”)
EX600
“Bus In” Connector
CN4
CN4
CN4
CN4
-
PLC Terminal Blocks Discrete I/O Wiring (Typical)
3 Wire Device
Triple Decker TB
PLC
24 FDC
0 VDC
Device
Dis
cret
e In
pu
ts
2 Wire Device
Double Decker TB
PLC
24 VDC
Device
1 Wire Device
Single Decker TB
PLC
Device
3 Wire Device
Dis
cret
e O
utp
uts
2 Wire Device
Double Decker TB
PLC
0 VDC
Device
1 Wire Device
Single Decker TB
PLC
Device
N/A
-
Stepper Controller Layout
LER
H5
0K
-2
Ro
tary
- E
lect
ric
Sid
e
LESH
16
DK
-50
V
erti
cal S
lide
- El
ectr
ic S
ide
LEH
F10
K2
-16
V
erti
cal G
rip
per
- E
lect
ric
Sid
e
LEFB
32
T-6
00
Li
nea
r A
ctu
ato
r -
Fro
nt
-
SY Mixed Manifold Layout
Cen
ter
Pic
k &
Pla
ce R
ota
ry (
CP
PR
) R
ear/
Cen
ter
Rea
r R
ota
ry (
RR
ota
te)
Ho
me/
Del
iver
Vac
uu
m P
ick
& P
lace
Ver
tica
l (V
PP
V)
R
ais
e/Lo
wer
Cen
ter
Pic
k &
Pla
ce G
rip
per
(C
PP
G)
Clo
se/O
pen
Vac
uu
m P
ick
& P
lace
Ver
tica
l (V
PP
V)
B
rake
Rel
ease
(i
ncl
ud
es a
Pre
ssu
re R
egu
lato
r)
Cen
ter
Pic
k &
Pla
ce V
erti
cal (
CP
PV
) R
ais
e/Lo
wer
Vac
uu
m P
ick
& P
lace
Slid
e (V
PP
S)
Ho
me/
Del
iver
These are Blocked Center Valves
This Valve includes a Regulator.
-
EX600
EX600-DXPD Discrete Inputs
0: VPPS_Homed
1: VPPS_Delivered
2: CPPV_Raised
3: CPPV_Lowered
4: CPPG_Closed
5: CPPG_Opened
6: CPPR_Rear
7: CPPG_Center
8: RRotate_Homed
9: RRotate_Delivered
10: VPPV_Raised
11: VPPV_Lowered
12: Not Used
13: Not Used
14: Not Used
15: Not Used
Note: The unit labels the I/O: 0 thru 15; the software map the
same I/O: 0.0 thru 1.7.
EX600 Power
Outputs - +
CPU + -
1
0 VDC
24 VDC
Ligh
t B
lue
Bla
ck
Bro
wn
Wh
ite
-
PLC Embedded Discrete Input Wiring
CompactLogix PLC
DI 0
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
DI 9
DI 10
DI 11
DI 12
DI 13
DI 14
DI 15
Center Slide Autoswitch - Home
Center Slide Autoswitch - Extend
Linear Actuator Rear Servo – Trouble
Linear Actuator Rear Servo - Travel Complete
Linear Actuator Rear Servo – Ready
Spare
Pressure Switch – Hi
Pressure Switch – Low
Start Button
Stop Button
Front Slide Part Presence - Extend Side
Front Slide Part Presence - Home Side
Center Slide Part Presence – Delivered Side
Center Slide Part Presence - Home Side
Rear Slider Part Presence - Home
Rear Slide Part Presence - Extend
24 VDC
0 VDC
Autoswitch
Autoswitch
Linear Actuator Rear Servo Controller
Pressure Switch Brown
Blue Black
White
Photo Switch Brown
Blue
Black
Photo Switch Brown
Blue
Black
Photo Switch Brown
Blue
Black
Photo Switch Brown
Blue
Black
Photo Switch Brown
Blue
Black
Photo Switch Brown
Blue
Black
Piezo PB NO NO
0 VDC LED +
Piezo PB 0 VDC LED +
NC NC
Black
Black
Brown
Blue
Brown
Blue
Pink / Red
Pink / Black
Orange / Red
Blue
Black
Brown White
Blue
Black
Brown White
TB 105
TB 106
TB 107
TB 108
TB 109
TB 111
TB 112
TB 113
TB 114
TB 115
TB 116
TB 117
TB 118
TB 119
TB 120
White - Red
Red - Black
White – Red/Black
Red – Black/White
Black – Red/White
Orange - Black
Black - Red
Blue
Red - Green
White - Black
Blue - Red
Red - White
Orange - Green
Blue - White
Green – Black/White
Blue - Black
V V
Orange - Red
Green - Black
V V Green - White
Black - White
DO 0.13 TB148
DO 0.14 TB149
Not Used
Not Used
TB 152U
TB 153U
TB 152L
Blue
Black
Green/White
TB 110
-
PLC Slot 1 Discrete Input Wiring
CompactLogix PLC
DI 0
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
No Alarms from Safety Relay (MCR1 and MCR2)
Reset Button
Vacuum Pick and Place – Vacuum Engaged
Linear Actuator Center Push Unit Autoswitch - Home
Linear Actuator Center Push Unit Autoswitch - Forward
Vacuum Supply Bypass Button Spare Spare
Piezo PB NO NO
0 VDC LED +
24 VDC
0 VDC
MCR1 MCR2
ZK2 Vacuum Unit (other wiring shown on Embedded DO)
Vac Sw
Black
Autoswitch Brown
Blue
Black
Autoswitch Brown
Blue
Black
Piezo PB NO NO
0 VDC LED +
Blue
Black
Brown White
Blue
Black
White
TB 121
Blue - Black
TB 122
White - Black
TB 123
Black - White
TB 124
Red - Black
TB 125
Red - White
TB 126
Orange - Black
Green - White
Blue - White
Brown
DO 0.15 TB150
DO 0.08 TB135
-
PLC Slot 2 Wiring
CompactLogix PLC
DI 0
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
Spare
Spare
Spare
Spare
Spare
Spare Spare Spare
24 VDC
0 VDC
Green – White/Black
Black – Red/White
Orange
Black
Black - Red
Green - Black
White - Red
Orange - Red
-
PLC Embedded Discrete Output Wiring
CompactLogix PLC
DO 0
DO 1
DO 2
DO 3
DO 4
D0 5
DO 6
DO 7
Center Slide Brake SV Release
Center Slide SV - Home
Center Slider SV - Extend
Linear Actuator Rear Servo – Servo On (not used) Spare
Linear Actuator Rear Servo – Auto (not used) Spare
Linear Actuator Rear Servo – Position Bit 1
Linear Actuator Rear Servo – Position Bit 2
Linear Actuator Rear Servo – ST1 (Forward Jog/Drive)
Bypass PB LED
Vacuum Pick and Place – Vacuum Engage
Vacuum Pick and Place – Bypass SV
Window Light - Red
Vacuum Pick and Place – Vacuum Release
Start PB LED
Stop PB LED
Reset PB LED
DO 8
DO 9
DO 10
DO 11
DO 12
DO 13
DO 14
DO 15
ZK2 Vacuum Unit 24 VDC
0 VDC Engage
Release
Gray
White
Blue
Brown
MCR3 MCR4
MCR3 MCR4
MCR3 MCR4
White / Red
Yellow / Red
White / Black
- +
- +
- +
- +
- +
Linear Actuator Rear Servo Controller
TB 127
Orange
TB 128
Green – Black/White
TB 129
Orange - Black
Red - White
White - Black
TB 132
Red Black/White
TB 133
Blue - Black
TB 134
Black - White
TB 135
Green
TB 136
Green - Black
TB 137
Red
TB 138
White
TB 139
Black - Red
TB 148
White - Red
TB 149
Black
TB 150
White – Red/Black
C C
Blue - White
Green - White
C C Red - Black
Blue
24 VDC
0 VDC
TB 130
TB 131
CR2
Not Used
Not Used
TB 153L
TB 154L
TB 151U
Orange
Red/Black
White
-
PLC Slot 3 Discrete Output Wiring
CompactLogix PLC
DO 0
DO 1
DO 2
DO 3
DO 4
D0 5
DO 6
DO 7
Red Light (Wall Mounted)
Green Light (Wall Mounted)
E-Stop Light
Safety Mat Engaged Red Status Lights
Safety Dump =Valve 1 Air Supply On Light
Safety Dump =Valve 2 Air Supply On Light
Safety Dump =Valve 1 Air Exhaust Light
Safety Dump =Valve 2 Air Exhaust Light
24 VDC
0 VDC
TB2
TB1
TB0
Wall Mounted
Alarm Lights Black
Brown
Blue
- +
- +
- +
- +
- +
- +
TB 140
Red – White/Black
TB 141
White – Red/Black
TB 142
Blue
TB 143
Orange - Green
TB 144
White
TB 145
Red – Green
TB 146
Red
TB 147
Blue - Red
Red Black
-
Upper Panel Layout
PLC Power Terminal
Blocks
PLC Input Terminal Blocks
PLC Output Terminal Blocks
Safety Relay Terminal Blocks
MCR 3
MCR 4
LESCA Terminal
Blocks
-
Lower Panel Layout
Grounding Terminal Block
MCR 1
MCR 2 CB
4 Window
Lights Terminal
Blocks
LER
H5
0K
-2
Ro
tary
- E
lect
ric
Sid
e
LESH
16
DK
-50
V
erti
cal S
lide
- El
ectr
ic
Sid
e
LEH
F10
K2
-16
V
erti
cal G
rip
per
-
Elec
tric
Sid
e
LEFB
32
T-6
00
Li
nea
r A
ctu
ato
r -
Fro
nt
Eth
ern
et S
wit
ch
Eth
ern
et G
atew
ay
(fo
r St
epp
er M
oto
r C
ont
rolle
rs)
Stepper Motor Controllers
Eth
ern
et G
atew
ay
Lin
ear
Act
ua
tor
Rea
r Se
rvo
Mo
tor
Co
ntro
llers
Allen-Bradley Motor
Controller
(Future)
Allen-Bradley Motor
Controller
(Future)
24 VDC Terminal Blocks C
B5
CB
6
CB
7
Light Power
Terminal Blocks
CB
1
CB
2
CB
3
24
VD
C P
ow
er S
up
ply
5
Am
p (
Use
d f
or
ligh
tin
g.)
24 VDC Power Supply 20 Amp
(Used for everything except lighting.)
120 VAC Terminal
Blocks
