Bucher JetControl 960EXT-E03-2 User manual

User Manual
JetControl 960EXT-E03-2
Controller
60887747_00

Bucher Automation AG has created this document with the requisite care and based on the current state of tech-
nology. Changes and further technical developments to our products are not automatically made available in a
revised document. Bucher Automation AG shall accept no liability or responsibility for errors of content or form,
missing updates or any damage or disadvantages arising therefrom.
Bucher AutomationAG
Thomas-Alva-Edison-Ring 10
71672 Marbach/Neckar, Germany
T [phone]
[email protected]
Technical hotline
T [phone]
[email protected]
Sales
T [phone]
[email protected]
www.bucherautomation.com
Translation of the german original User Manual
Revision 1.00
Date of issue 10/10/2023

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT-E03-2 iii
Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Information on this document ................................................................................................................. 7
1.2 Typographical conventions..................................................................................................................... 7
2 Safety..................................................................................................................................................... 8
2.1 General Information................................................................................................................................ 8
2.2 Purpose .................................................................................................................................................. 8
2.2.1 Intended use........................................................................................................................................... 8
2.2.2 Usage other than intended ..................................................................................................................... 8
2.3 Warnings used in this document ............................................................................................................ 9
3 Product description.............................................................................................................................. 10
3.1 JC-96xEXT-xxx product family overview ................................................................................................ 10
3.2 System overview .................................................................................................................................... 11
3.3 Design .................................................................................................................................................... 12
3.4 Product features ..................................................................................................................................... 13
3.5 Axis engineering guidelines.................................................................................................................... 13
3.6 Required axis licenses............................................................................................................................ 14
3.7 Status indication ..................................................................................................................................... 14
3.7.1 LED states during the boot process ....................................................................................................... 14
3.7.2 PWR and RSQ LED ............................................................................................................................... 15
3.8 Nameplate .............................................................................................................................................. 16
3.9 Scope of delivery .................................................................................................................................... 16
4 Technical data....................................................................................................................................... 17
4.1 Dimensions............................................................................................................................................. 17
4.2 Mechanical specifications....................................................................................................................... 18
4.3 Electrical properties ................................................................................................................................ 18
4.4 Real-time clock ....................................................................................................................................... 21
4.5 Environmental conditions ....................................................................................................................... 21
4.6 EMI values.............................................................................................................................................. 21
4.6.1 Housing .................................................................................................................................................. 21
4.6.2 Shielded data and I/O lines .................................................................................................................... 22
4.6.3 DC power supply inputs and outputs...................................................................................................... 22
5 Mechanical installation ........................................................................................................................ 24
5.1 Installing the controller............................................................................................................................ 24
5.2 Removing the controller.......................................................................................................................... 24
5.3 Installing JI-PCIE-Exx riser cards ........................................................................................................... 25
5.4 Replacing the fastening lugs .................................................................................................................. 28

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT-E03-2 iv
6 Electrical connection ........................................................................................................................... 31
6.1 Improving noise immunity....................................................................................................................... 31
6.2 Jack X101 – power supply...................................................................................................................... 32
6.3 Jack X102 – Ethernet ............................................................................................................................. 32
6.4 Jacks X103, X104 – Ethernet ................................................................................................................. 32
6.5 Jack X105-X108 – USB.......................................................................................................................... 33
6.6 PCI express slots X81, X82, X91, X92 ................................................................................................... 33
6.6.1 JX2 system bus interface ....................................................................................................................... 34
6.6.2 JX6-IO submodules for local I/Os........................................................................................................... 35
7 Control elements .................................................................................................................................. 38
7.1 Mode selector S11.................................................................................................................................. 38
7.2 PWR button ............................................................................................................................................ 39
7.3 RSQ button............................................................................................................................................. 39
8 Identification ......................................................................................................................................... 40
8.1 Electronic Data Sheet (EDS) .................................................................................................................. 40
8.1.1 EDS file "eds.ini"..................................................................................................................................... 40
8.1.2 EDS registers ......................................................................................................................................... 42
8.2 Version registers..................................................................................................................................... 43
8.2.1 Hardware revisions................................................................................................................................. 43
8.2.2 Operating system version....................................................................................................................... 43
9 Configuration ........................................................................................................................................ 44
9.1 Default values......................................................................................................................................... 44
9.2 Configuration file "config.ini"................................................................................................................... 46
9.2.1 Changing the configuration using the configuration file.......................................................................... 47
9.2.2 Section [IP] ............................................................................................................................................. 47
9.2.3 Section [HOSTNAME] ............................................................................................................................ 49
9.2.4 Section [PORTS] .................................................................................................................................... 50
9.2.5 Section [FILES]....................................................................................................................................... 50
9.3 Non-volatile configuration settings via registers ..................................................................................... 51
9.4 Setting the IP address automatically via USB flash drive....................................................................... 52
9.5 Setting the IP address during runtime .................................................................................................... 53
9.6 Changing the IP address using the JetIPScan command line tool......................................................... 54
10 Operating system ................................................................................................................................. 57
10.1 Operating system update of the controller.............................................................................................. 57
10.1.1 Operating system update using the programming tool........................................................................... 57
10.1.2 Updating the operating system by means of FTP .................................................................................. 57
10.1.3 OS update from a USB flash drive ......................................................................................................... 58
10.1.4 Updating the OS from within the application program ............................................................................ 58

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT-E03-2 v
11 File System............................................................................................................................................ 60
11.1 Properties ............................................................................................................................................... 60
11.1.1 Flash disk - Properties............................................................................................................................ 61
11.1.2 USB flash drive - Properties ................................................................................................................... 61
12 Programming ........................................................................................................................................ 62
12.1 Abbreviations, module register properties and formats .......................................................................... 62
12.2 Storage options - Overview .................................................................................................................... 63
12.2.1 Operating system memory ..................................................................................................................... 63
12.2.2 File system memory ............................................................................................................................... 63
12.2.3 Application Program Memory ................................................................................................................. 63
12.2.4 Memory for volatile application program variables ................................................................................. 64
12.2.5 Memory for non-volatile application program registers........................................................................... 65
12.2.6 Special registers ..................................................................................................................................... 66
12.2.7 Registers on I/O modules ....................................................................................................................... 67
12.2.8 Flag......................................................................................................................................................... 67
12.2.9 Digital inputs and outputs ....................................................................................................................... 68
12.3 Saving and loading an application program ........................................................................................... 68
12.4 Addressing of registers and I/Os ............................................................................................................ 69
12.5 Local JX6-IO module register slot numbering ........................................................................................ 70
12.5.1 Register numbers of the submodule JX6-SB(-I)..................................................................................... 71
12.5.2 Register numbers of JX2 slave modules connected to the JX2 system bus .......................................... 72
12.5.3 JX2 and JX3 module register numbers and I/O numbers on the JX2 system bus ................................. 74
12.5.4 Register numbers and I/O numbers of the JX6-IO16CB digital submodule ........................................... 76
12.5.5 Register numbers of the JX6-SV1-ES counter module .......................................................................... 80
12.6 Addressing JX3-IO expansion modules on the Ethernet system bus..................................................... 85
12.6.1 Numbering registers and I/Os................................................................................................................. 85
12.6.2 Expansion modules connected to an Ethernet bus node ....................................................................... 86
12.7 Addressing JM-2xx-ETH servo amplifiers on the Ethernet system bus.................................................. 89
12.8 Option model .......................................................................................................................................... 89
12.8.1 Available firmware functions................................................................................................................... 89
12.8.2 License File ............................................................................................................................................ 91
12.9 System commands ................................................................................................................................. 92
12.10 Real-time clock ....................................................................................................................................... 92
12.11 Startup delay time................................................................................................................................... 93
12.12 System runtime registers........................................................................................................................ 93
12.13 Monitoring interface activities ................................................................................................................. 93
12.14 Ethernet system bus............................................................................................................................... 93
12.15 JCF-SV1 "simple servo function"............................................................................................................ 94

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT-E03-2 vi
12.16 E-mail feature ......................................................................................................................................... 95
12.17 Modbus/TCP........................................................................................................................................... 96
12.17.1 Modbus/TCP server................................................................................................................................ 97
12.17.2 Modbus/TCP client with STX functions .................................................................................................. 99
12.18 User-programmable IP interface ............................................................................................................100
12.19 Motion control .........................................................................................................................................100
12.20 MQTT client ............................................................................................................................................102
12.21 OPC UA server.......................................................................................................................................102
12.22 OPC UA client ........................................................................................................................................103
13 FTP server .............................................................................................................................................104
14 HTTP server ..........................................................................................................................................105
15 Device Dashboard ................................................................................................................................106
16 FTP client ..............................................................................................................................................108
17 Automatic copying of controller data (AutoCopy) ............................................................................109
18 Registers - Overview ............................................................................................................................110
19 Maintenance..........................................................................................................................................131
19.1 Repairs ...................................................................................................................................................131
19.2 Storage and shipment ............................................................................................................................131
19.3 Return and disposal................................................................................................................................132
20 Service...................................................................................................................................................133
20.1 Customer service....................................................................................................................................133
21 Spare parts and accessories...............................................................................................................134
21.1 Accessories ............................................................................................................................................134
21.1.1 Ethernet Cable........................................................................................................................................134
21.1.2 PCI express expansion cards.................................................................................................................134
21.1.3 USB flash drives .....................................................................................................................................135
21.1.4 Fastening lugs for upgrading from JC-94x to JC-96x .............................................................................135

Bucher Automation AG Introduction | 1
User Manual – JetControl 960EXT-E03-2 7
1 Introduction
1.1 Information on this document
This document forms an integral part of the product and must be read and understood
prior to using it. It contains important and safety-related information for the proper use
of the product as intended.
Target groups This document is intended for specialists with appropriate qualifications.
Only competent and trained personnel is allowed to put this device into operation.
During the whole product life cycle, safe handling and operation of the device must be
ensured. In the case of missing or inadequate technical knowledge or knowledge of this
document any liability is excluded.
Availability of
information
Make sure this document is kept at the ready in the vicinity of the product throughout its
service life.
For information on new revisions of this document, visit the download area on our web-
site. This document is not subject to any updating service.
Start | Bucher Automation - We automate your success.
For further information refer to the following information products:
– JetSym software Online Help
Detailed description of software functions with application examples
– Application-oriented manuals
Cross-product documentation
– Version updates
Information about new versions of software products or of the operating system of
your device
1.2 Typographical conventions
This manual uses different typographical effects to support you in finding and classify-
ing information. Below, there is an example of a step-by-step instruction:
üThis symbol indicates requirements which have to be met before executing the fol-
lowing action.
►This sign or a numbering at the beginning of a paragraph marks an action instruc-
tion that must be executed by the user. Execute the instructions one after the
other.
ðThe target after a list of instructions indicates reactions to, or results of these ac-
tions.
INFO Further information and practical tips
In the info box you will find helpful information and practical tips
about your product.

Bucher Automation AG Safety | 2
User Manual – JetControl 960EXT-E03-2 8
2 Safety
2.1 General Information
When placed on the market, this product corresponds to the current state of science
and technology.
In addition to the operating instructions, the laws, regulations and guidelines of the
country of operation or the EU apply to the operation of the product. The operator is re-
sponsible for compliance with the relevant accident prevention regulations and gener-
ally accepted safety rules.
2.2 Purpose
2.2.1 Intended use
This device has been designed to control machinery, such as conveyors, production
machines, and handling machines.
Operate the device only in accordance with the intended conditions of use, and within
the limits set forth in the technical specifications.
Intended use of the product includes its operation in accordance with this manual.
SELV The operating voltage of this device is classified as Safety Extra Low Voltage and is
therefore not subject to the European Low Voltage Directive. The device may only be
operated from a SELV source.
2.2.2 Usage other than intended
This device must not be used in technical systems which to a high degree have to be
fail-safe.
Machinery Directive This device is no safety-related part as per Machinery Directive 2006/42/EC, and must,
therefore, not be used for safety-relevant applications. This device is NOT intended for
the purpose of personal safety, and must, therefore, not be used to protect persons.

Bucher Automation AG Safety | 2
User Manual – JetControl 960EXT-E03-2 9
2.3 Warnings used in this document
DANGER
High risk
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
Medium risk
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Low risk
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
Material damage
Indicates a situation which, if not avoided, could result in malfunc-
tions or material damage.

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT-E03-2 10
3 Product description
The JC-960EXT-E03-2 control system has been designed to deliver upper-range per-
formance. Offering extensive scalability options, it is suited to all areas of industrial au-
tomation.
Besides traditional controller functions, the JC-960EXT-E03-2 offers an optional motion
control feature allowing for the programming of servo drives in a point-to-point (PtP),
axis group and complex path control setup.
Thanks to the option model, users are flexible to extend the range of functions even at
a later date.
3.1 JC-96xEXT-xxx product family overview
The following provides a summary of the features offered by individual models of the
JC-96xEXT-xxx family:
JC-960EXT JC-960EXT-
E03-2
JC-965EXT JC-965EXT-
E03-2
Item number 10002329 10002331 10002330 10002332
JI-PCIE-Exx ex-
tension
No Yes No Yes
EtherCAT® No No Yes Yes
Extension via
JCF9 software
licenses
Yes Yes Yes Yes
Tab.1: Product family overview