Bucher JetControl 960EXT User manual

User Manual
JetControl 960EXT
Controller
60887748_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 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 Status indication ..................................................................................................................................... 13
3.5.1 LED states during the boot process ....................................................................................................... 14
3.5.2 PWR and RSQ LED ............................................................................................................................... 15
3.6 Nameplate .............................................................................................................................................. 15
3.7 Scope of delivery .................................................................................................................................... 15
4 Technical data....................................................................................................................................... 16
4.1 Dimensions............................................................................................................................................. 16
4.2 Mechanical specifications....................................................................................................................... 17
4.3 Electrical properties ................................................................................................................................ 17
4.4 Real-time clock ....................................................................................................................................... 19
4.5 Environmental conditions ....................................................................................................................... 19
4.6 EMI values.............................................................................................................................................. 20
4.6.1 Housing .................................................................................................................................................. 20
4.6.2 Shielded data and I/O lines .................................................................................................................... 20
4.6.3 DC power supply inputs and outputs...................................................................................................... 21
5 Mechanical installation ........................................................................................................................ 22
5.1 Installing the controller............................................................................................................................ 22
5.2 Removing the controller.......................................................................................................................... 22
5.3 Replacing the fastening lugs .................................................................................................................. 23
6 Electrical connection ........................................................................................................................... 25
6.1 Improving noise immunity....................................................................................................................... 25
6.2 Jack X101 – power supply...................................................................................................................... 26

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT iv
6.3 Jack X102 – Ethernet ............................................................................................................................. 26
6.4 Jacks X103, X104 – Ethernet ................................................................................................................. 26
6.5 Jack X105-X108 – USB.......................................................................................................................... 27
7 Control elements .................................................................................................................................. 28
7.1 Mode selector S11.................................................................................................................................. 28
7.2 PWR button ............................................................................................................................................ 29
7.3 RSQ button............................................................................................................................................. 29
8 Identification ......................................................................................................................................... 30
8.1 Electronic Data Sheet (EDS) .................................................................................................................. 30
8.1.1 EDS file "eds.ini"..................................................................................................................................... 30
8.1.2 EDS registers ......................................................................................................................................... 32
8.2 Version registers..................................................................................................................................... 33
8.2.1 Hardware revisions................................................................................................................................. 33
8.2.2 Operating system version....................................................................................................................... 33
9 Configuration ........................................................................................................................................ 34
9.1 Default values......................................................................................................................................... 35
9.2 Configuration file "config.ini"................................................................................................................... 36
9.2.1 Changing the configuration using the configuration file.......................................................................... 37
9.2.2 Section [IP] ............................................................................................................................................. 37
9.2.3 Section [HOSTNAME] ............................................................................................................................ 39
9.2.4 Section [PORTS] .................................................................................................................................... 40
9.2.5 Section [FILES]....................................................................................................................................... 40
9.3 Non-volatile configuration settings via registers ..................................................................................... 41
9.4 Setting the IP address automatically via USB flash drive....................................................................... 42
9.5 Setting the IP address during runtime .................................................................................................... 43
9.6 Changing the IP address using the JetIPScan command line tool......................................................... 44
10 Operating system ................................................................................................................................. 47
10.1 Operating system update of the controller.............................................................................................. 47
10.1.1 Operating system update using the programming tool........................................................................... 47
10.1.2 Updating the operating system by means of FTP .................................................................................. 47
10.1.3 OS update from a USB flash drive ......................................................................................................... 48
10.1.4 Updating the OS from within the application program ............................................................................ 48
11 File System............................................................................................................................................ 50
11.1 Properties ............................................................................................................................................... 50
11.1.1 Flash disk - Properties............................................................................................................................ 51
11.1.2 USB flash drive - Properties ................................................................................................................... 51
12 Programming ........................................................................................................................................ 52
12.1 Abbreviations, module register properties and formats .......................................................................... 52

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT v
12.2 Storage options - Overview .................................................................................................................... 53
12.2.1 Operating system memory ..................................................................................................................... 53
12.2.2 File system memory ............................................................................................................................... 53
12.2.3 Application Program Memory ................................................................................................................. 53
12.2.4 Memory for volatile application program variables ................................................................................. 54
12.2.5 Memory for non-volatile application program registers........................................................................... 55
12.2.6 Special registers ..................................................................................................................................... 56
12.2.7 Registers on I/O modules ....................................................................................................................... 56
12.2.8 Flag......................................................................................................................................................... 57
12.2.9 Digital inputs and outputs ....................................................................................................................... 57
12.3 Saving and loading an application program ........................................................................................... 58
12.4 Addressing JX3-IO expansion modules on the Ethernet system bus..................................................... 58
12.4.1 Numbering registers and I/Os................................................................................................................. 59
12.4.2 Expansion modules connected to an Ethernet bus node ....................................................................... 59
12.5 Addressing JM-2xx-ETH servo amplifiers on the Ethernet system bus.................................................. 61
12.6 Option model .......................................................................................................................................... 62
12.6.1 Available firmware functions................................................................................................................... 62
12.6.2 License File ............................................................................................................................................ 63
12.7 System commands ................................................................................................................................. 65
12.8 Real-time clock ....................................................................................................................................... 65
12.9 Startup delay time................................................................................................................................... 65
12.10 System runtime registers........................................................................................................................ 66
12.11 Monitoring interface activities ................................................................................................................. 66
12.12 Ethernet system bus............................................................................................................................... 66
12.13 JCF-SV1 "simple servo function"............................................................................................................ 67
12.14 E-mail feature ......................................................................................................................................... 67
12.15 Modbus/TCP........................................................................................................................................... 68
12.15.1 Modbus/TCP server................................................................................................................................ 69
12.15.2 Modbus/TCP client with STX functions .................................................................................................. 72
12.16 User-programmable IP interface ............................................................................................................ 73
12.17 Motion control ......................................................................................................................................... 73
12.18 MQTT client ............................................................................................................................................ 75
12.19 OPC UA server....................................................................................................................................... 75
12.20 OPC UA client ........................................................................................................................................ 76
13 FTP server ............................................................................................................................................. 77
14 HTTP server .......................................................................................................................................... 78
15 Device Dashboard ................................................................................................................................ 79
16 FTP client .............................................................................................................................................. 81

Bucher Automation AG Table of contents
User Manual – JetControl 960EXT vi
17 Automatic copying of controller data (AutoCopy) ............................................................................ 82
18 Registers - Overview ............................................................................................................................ 83
19 Maintenance..........................................................................................................................................104
19.1 Repairs ...................................................................................................................................................104
19.2 Storage and shipment ............................................................................................................................104
19.3 Return and disposal................................................................................................................................105
20 Service...................................................................................................................................................106
20.1 Customer service....................................................................................................................................106
21 Spare parts and accessories...............................................................................................................107
21.1 Accessories ............................................................................................................................................107
21.1.1 Ethernet Cable........................................................................................................................................107
21.1.2 USB flash drives .....................................................................................................................................107
21.1.3 Fastening lugs for upgrading from JC-94x to JC-96x .............................................................................107

Bucher Automation AG Introduction | 1
User Manual – JetControl 960EXT 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 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 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 10
3 Product description
The JC-960EXT control system has been designed to deliver upper-range perfor-
mance. Offering extensive scalability options, it is suited to all areas of industrial auto-
mation.
Besides traditional controller functions, the JC-960EXT offers an optional motion con-
trol 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

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT 11
3.2 System overview
Display
JV-1xxx
Controller
JC-960EXT
Controller
JC-965EXT
Ethernet switch
EtherCAT ®
1 2 3 4 5 6 7 8
Servo amplifier
JM-200-ETH
(5)
Servo amplifier
JM-100/200
(2)
Servo amplifier
JM-1000/3000
(3)
3rd-party
EtherCAT ® modules (4)
Ethernet bus node
JX3-BN-ETH + JX3-I/Os (3,4)
EtherCAT ® bus node
JX3-BN-EC
+ JX3-I/Os (1,2)
(1)
Requires JI-PCIE-E01/2/3 or /4
(2)
max. 15 servo amplifiers per JX2 system bus *)
(3)
max. 199 JX-BN-ETH bus nodes **)
(4)
max. 16 JX3-IO modules per JX3-ETH bus node
(5)
max. 199 servo amplifiers ***)
*) max. 6 MC axes per JX2 bus, max. 3 JX2 system buses
with MC axes => max. 18 MC axes on the JX2 system bus
**) the ovarall count of JX3-BN-ETH and JM-200-ETH must not
exceed 199 nodes
***) of which max. 128 MC axes
(1)
max. 99 JX3-BN-EC modules
(2)
max. 32 JX3-IO modules per JX3-BN-EC bus node
(3)
max. 128 servo amplifiers JM-1000/3000
(4)
JetSym V 6.0 and higher
A maximum of 256 devices can be connected to the
EtherCAT
®
system bus
Ethernet TCP/IP
JX2 system bus
(1)
with 2x PCIe (E03/E04) Ethernet TCP/IP
Fig.1: System overview of JC-960EXT/-E-03-2 and JC-965EXT/-E03-2

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT 12
3.3 Design
1 2 3
10
1
5
6
7
8
11
13
12
4
9
Fig.2: Front
1 Fastening lugs with 2 keyholes each
2 X110: n.c.*
3 LED status indicators
4 PWR button and LED
RSQ button and LED
5 X107, X108: USB 2.0 ports
6 X105, X106: USB 3.0 ports
7 X104 (ETH3): Ethernet port
8 X205: n.c.*
9 X101: Voltage supply (DC24V)
10 X102 (ETH1): Ethernet port
11 X103 (ETH2): Ethernet port
12 X109: n.c.*
13 Selector S11: Mode selector

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT 13
*n.c. = not connected (= without function)
14
16
15
Fig.3: Housing
14 Cover
15 Nameplate (on the right-hand side of the housing)
16 Cooling fins
3.4 Product features
– Intel i5 processor
– 3x Ethernet
– 4x USB for flash drive
– Web server including Device Dashboard for convenient diagnostics via web
browser
– AutoCopy function
– Licensing scheme for flexible and easy extension with software options
– Up to 128MCX axes
3.5 Status indication
The status LEDs are located in the upper part of the JC-960EXT front panel.
THERM
DRIVE
SD
WD
GP1
GP4
GP3
GP2
Fig.4: Status indication
LED Feature Color Description
THERM Temperature Red, flashing System is shutting down
due to overheating
DRIVE SSD/HDD drive is
busy
Green Drive is busy
SD n. c.*
WD n. c.*
GP1 RUN Green Application program is
running

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT 14
LED Feature Color Description
Green, flashing
(1Hz)
Application program is not
running
OFF --- No power supply or failure
GP2 D1- OFF --- Normal operating condi-
tion
Amber Special states
GP3 ERR OFF --- No error
Red Error; refer to error regis-
ter
GP4 n. c.*
*n.c. = not connected (= without function)
Tab.2: Status indication
3.5.1 LED states during the boot process
If the following requirements are met, the controller boots without error:
– There is a valid OS.
– There is a valid application program.
The GP1 and GP3 LED flashing patterns indicate the different stages of the boot
process.
RUN GP1 D1 GP2 GP3
ERROR
State
Phase 1 Reset
OFF OFF Red ON Reset
Phase 2 Runtime environment
OFF Yellow ON OFF Initializing the runtime environment of the
application program and real-time com-
munication.
Phase 3 Motion control
OFF Yellow ON OFF Motion control start
Phase 4 Additional features
Green ON Yellow ON OFF Initializing additional functions (Web, Mod-
bus/TCP etc.)
Phase 5 Normal operating condition
Green ON OFF OFF Normal condition; the application program
is running
Tab.3: LED states during the boot process

Bucher Automation AG Product description | 3
User Manual – JetControl 960EXT 15
3.5.2 PWR and RSQ LED
PWR
RSQ
1
2
Fig.5: PWR and RSQ
LED
Position Element Description
1 PWR LED – Permanently green for normal op-
eration
– Flashes green after shut-down via
PWR button
2 RSQ LED Flashes red if the backup flash has
been selected for booting.
3.6 Nameplate
123
6
5
8
7
4
Fig.6: Sample nameplate
1 Company logo
2 Serial number
3 Data matrix code
4 Item number
5 Hardware revision
6 Warning and mandatory signs
7 Power supply specifications
8 Item name
3.7 Scope of delivery
Scope of delivery Item number Quantity
JC-960EXT 10002329 1
Refer to chapter Spare parts and accessories [}107] for suitable accessories.
Refer to chapter Option model [}62] for available feature extension options.

Bucher Automation AG Technical data | 4
User Manual – JetControl 960EXT 16
4 Technical data
This chapter contains electrical, mechanical data and operating data of the JC-960EXT.
4.1 Dimensions
4 x Ø 5.5
72
290
236
265
117
222
210
22.5
Fig.7: Dimensions in mm
INFO CAD data
CAD data of the device can be found in the download area of our
homepage.

Bucher Automation AG Technical data | 4
User Manual – JetControl 960EXT 17
4.2 Mechanical specifications
Parameter Description Standards
Mounting orientation Vertical
Cooling Fanless; natural convection
Weight 3.8kg
Vibration resistance
Frequency sweeps 1octave/minute,
sinusoidal
DINEN60068-2-6
Constant amplitude 3.5mm 5Hz ≤ f ≤ 9Hz
Constant acceleration 1g 9Hz ≤ f ≤ 150Hz
Number and direction 10sweeps for all 3spatial axes
Shock resistance
Type of shock Half-sine wave DINEN60068-2-27
Intensity and duration 15g for 11ms
Number and direction 3shocks in the directions of all 3spatial axes
Degree of protection
Degree of protection IP20 DINEN60529
Tab.4: Mechanical specifications
4.3 Electrical properties
Power
supply (terminal
X101)
Parameter Description
Supply voltage DC24V
Permissible voltage range -15%…+20%
Input current 1.5A max., typically 1.25A
Power consumption 36W max.
Tab.5: Power supply (terminal X101)
ETH Ethernet port
(X102, X103, X104)
Parameter Description
Connecting RJ45 jack
Port count 3
Bit rate 10 Mbit/s, 100 Mbit/s, 1,000 Mbit/s
Auto-crossover Yes
Tab.6: ETH Ethernet port (X102, X103, X104)

Bucher Automation AG Technical data | 4
User Manual – JetControl 960EXT 18
USB ports NOTICE
Data loss due to connection of unsuitable devices
The USB ports must NOT be used to charge external devices
(e.g. mobile phones), as this will cause the supply power to be in-
sufficient to store non-volatile application data (%V, %RL) when
powering the system down or in the case of a voltage drop.
► Only connect USB flash drives to the USB ports.
USB1 and USB2 port
assignment for USB
flash drive
– While there are 4USB ports, the JC-960EXT controller is able to process only
2USB flash drives at a time.
– The port where the first USB flash drive is plugged is automatically designated
USB1. When connecting a second USB flash drive, the corresponding jack will be
designated USB2.
NOTICE
Be careful to observe the correct USB flash drive assignment
for the AutoCopy feature.
For the AutoCopy function to work properly, it is mandatory that
the USB flash drive be connected to the port specified in the /Sys-
tem/config.ini file.
► Therefore, ensure that the USB flash drive for the AutoCopy
function is the only flash drive connected at the given time.
INFO Relocating the USB port
If required, USB ports may be routed to the exterior of the control
cabinet, e.g. Using a Weidmüller USB coupling IE-FCM-USB-AB.
To do so, use a Lindy USB cable of 2m length.
For more information, go to lindy.com/en/.
USB port (X105,
X106)
Parameter Description
Maximum output current 1A
Observe the above note “Data loss due to connection of
unsuitable devices”
USB type Type A (host)
Specification USB3.0
Maximum permissible ca-
ble length
3m
Tab.7: USB port (X105, X106)

Bucher Automation AG Technical data | 4
User Manual – JetControl 960EXT 19
USB port (X107,
X108)
Parameter Description
Maximum output current 0.5A
Observe the above note “Data loss due to connection of
unsuitable devices”
USB type Type A (host)
Specification USB2.0
Maximum permissible ca-
ble length
5m
Tab.8: USB port (X107, X108)
Electrical safety Parameter Description Standard
Class of protection III DINEN61131-2
Dielectric test voltage Functional ground is internally connected to chassis
ground.
Overvoltage category II
Tab.9: Electrical safety
4.4 Real-time clock
Parameter Description
Deviation Maximum 1 min per month
Power reserve (if the controller
has been running for at least 1
hour.)
50days for ambient temperature (Tu) 25°C max
(typically)
30days for ambient temperature (Tu) 50°C max
Tab.10: Real-time clock
4.5 Environmental conditions
Parameter Description Standards
Operating temperature 0 …+50°C DINEN61131-2
Storage temperature -40 …+70°C DINEN60068-2-1
Humidity 5...93%, non-condensing IEC60068-2-78
Max. operating altitude 2,000m above sea level DINEN61131-2
Corrosion immunity and
chemical resistance
No special protection against corrosion. Ambient air
must be free from higher concentrations of acids, alca-
line solutions, corrosive agents, salts, metal vapors, and
other corrosive or electroconductive contaminants.
Degree of pollution – Elec-
tronics
Level2 DINEN61131-2
Usually, the pollution is non-conductive. However, tem-
porary conductivity due to condensation may occur.
Tab.11: Environmental conditions

Bucher Automation AG Technical data | 4
User Manual – JetControl 960EXT 20
4.6 EMI values
4.6.1 Housing
Emitted interference Parameter Values Standards
Frequency band 30MHz…230MHz DINEN61000-6-3
DINEN61131-2
DINEN55011
Limit value 30dB (µV/m) at 10m dis-
tance
Frequency band 230MHz…1,000MHz
Limit value 37dB (µV/m) at 10m dis-
tance
ClassB
Tab.12: Emitted interference
Immunity to
interference
Parameter Values Standards
Magnetic field with mains frequency
Frequency 50Hz DINEN61131-2
DINEN61000-6-2
DINEN61000-4-8
Magnetic field 30A/m
RF field, amplitude-modulated
Frequency band 80MHz…1GHz DINEN61131-2
DINEN61000-6-2
DINEN61000-4-3
1.4…2.0GHz
3V/m
2.0…2.7GHz
1V/m
Test field strength 10V/m
AM 80% with 1kHz
CriterionA
ESD
Discharge through air:
Test peak voltage
8kV DINEN61131-2
DINEN61000-6-2
DINEN61000-4-2
Discharge through air
Test peak voltage
4kV
CriterionA
Tab.13: Immunity to interference
4.6.2 Shielded data and I/O lines
Immunity to
interference
Parameter Values Standards
RF field, asymmetric, amplitude modulated
Frequency band 0.15MHz…80MHz DINEN61131-2
DINEN61000-6-2
DINEN61000-4-6
Test voltage 10V
AM 80% at 1kHz
Source impedance 150Ω
Criterion A
Bursts