Eaton easyControl EC4-200 User manual

10/10 MN05003003Z-EN
replaces 01/08 AWB2724-1584GB
User Manual
Programmable Logic Controller
easyControl EC4-200


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trademarks of the owner concerned.
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Original Operating Instructions
The German-language edition of this document is the original
operating manual.
Translation of the original operating manual
All editions of this document other than those in German language
are translations of the original German manual.
1st edition 2006, edition date 09/06
2nd edition 12/06
3rd edition 03/07
4th edition 01/08
5th edition 10/10
See revision protocol in the “About this manual“ chapter
© Eaton Industries GmbH, 53105 Bonn
Author: Peter Roersch
Production: Thomas Kracht, Barbara Petrick
Translation: OneWord
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any other process) or processed,
duplicated or distributed by means of electronic systems without
written permission of Eaton Industries GmbH, Bonn.
Subject to alteration without notice.

I
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that are live.
• Follow the engineering instructions (AWA) of the
device concerned.
• Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on
this device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the protective
earth (PE) or to the potential equalisation. The system installer
is responsible for implementing this connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference does not impair the
automation functions.
• Install automation devices and related operating elements in
such a way that they are well protected against unintentional
operation.
• Suitable safety hardware and software measures should be
implemented for the I/O interface so that a line or wire
breakage on the signal side does not result in undefined
states in the automation devices.
• Ensure a reliable electrical isolation of the low voltage for the
24 volt supply. Only use power supply units complying with
IEC 60364-4-41 (VDE 0100 Part 410) or HD 384.4.41 S2.
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation.
• Emergency stop devices complying with IEC/EN 60204-1 must
be effective in all operating modes of the automation devices.
Unlatching the emergency-stop devices must not cause restart.
• Devices that are designed for mounting in housings or control
cabinets must only be operated and controlled after they have
been installed with the housing closed. Desktop or portable
units must only be operated and controlled in enclosed
housings.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This should
not cause dangerous operating states even for a short time.
If necessary, emergency-stop devices should be implemented.
• Wherever faults in the automation system may cause
damage to persons or property, external measures must be
implemented to ensure a safe operating state in the event of
a fault or malfunction (for example, by means of separate limit
switches, mechanical interlocks etc.).
Eaton Industries GmbH Safety instructions
Danger!
Dangerous electrical voltage!

II

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About this manual 7
List of revisions 7
Additional documentation 7
Reading conventions 8
1 Device application 9
EC4-200 part number overview 9
2 Setup 11
Inputs 11
– Function and cursor buttons as inputs 12
– Diagnostics inputs 12
– Inputs for high-speed counters 12
Outputs 13
Memory card (MCC) 13
– Memory card data 13
– Data access on the memory card 13
RUN/STOP/SF and CAN/NET LEDs 13
Real-time clock 14
Interfaces 14
– Programming interface for connection to a PC 14
– Multi-function interface (MFI) 14
– Cable connections 15
CAN/easyNet interfaces 16
3 Expansion units 17
Inputs 17
– Diagnostics inputs 17
Outputs 17
4 Mounting 19
Mounting on top-hat rail 19
Mounting on mounting plate 19
5 Installation 21
Connecting the power supply 21
Connecting digital inputs 21
Connecting analog inputs 21
– Setpoint potentiometers connection 22
– Temperature sensor connection 22
– Connecting the 20 mA sensor 22
Connecting a pulse transmitter/incremental encoder 23
– Connecting pulse transmitter 23
– Connecting the incremental encoder 23
Connecting outputs 24
– Connect relay outputs 24
– Connecting transistor outputs 25
– Connecting the analog output 26
Memory card, CAN/easyNet, PC connection 27
– Fitting or removing the memory card 27
– CAN/easyNet, PC connection 27
Connecting expansion devices/network modules 28
– Local expansion 28
– Remote expansion 28
Contents

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6Operation 29
Keypad 29
Selecting menus and entering values 29
Selecting or toggling between menu items 29
– Cursor display 29
– Setting values 29
Choosing the main and system menu 30
– Status display 30
– Status display with time 30
Menu structure 31
– Main menu without password protection 31
– Main menu with password protection 32
– System menu 32
– System menu 33
7 Description of settings 35
Password protection 35
– Password setup 35
– Selecting the scope of the password 35
– Activating the password 35
– Access with password protection 35
– Changing or deleting the password range 36
Changing the menu language 37
Setting date and time 37
Startup behaviour 37
– Setting the startup behaviour 37
Setting LCD contrast and backlight 38
8 Configuration of the inputs/outputs (I/O) 39
Representation of the inputs/outputs in the configuration 39
Displaying the local inputs/outputs 39
Changing the folder function 39
Displaying the inputs/outputs of the expansion devices 40
9Operation 41
General 41
– Overview of memory sizes 41
– Memory definition 41
Startup behaviour 41
– Startup behaviour with boot project on the memory
card 41
Setting the startup behaviour in the programming
software 43
Program START/STOP 43
– Program start (STOP lRUN) 43
– Behaviour after shutdown/interruption of the power
supply 43
–Programstop(RUNlSTOP) 43
– Starting/stopping the program via external switch 44
Program processing and system time 44
Cycle time monitoring 44
Reset 44
– Warm reset 44
– Cold reset 44
–HardReset 44
– Restoring factory settings (factory set) 44
– Behaviour of variables after Reset 45

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Test and commissioning 45
– Breakpoint/single-step mode 45
– Single-cycle mode 45
– Forcing variables and inputs/outputs (Forcing) 45
– Status display in the programming software 45
High-speed counters (Counter) 45
– Counter functions (inputs/outputs) 46
Incremental input 47
– Explanation of the input/output signals (I/Q) 47
– Overview of input/output signals (I/Q) 48
– Functions of the input/output signals 48
– Referencing 48
System events 49
– START, COLD START, WARM START, STOP 49
– Interrupt inputs I1 … I4 50
– Counter interrupt 50
– Timer interrupt 50
Interrupt processing 52
– Steps for interrupt processing 52
– Example of interrupt processing 52
Direct I/O access 53
– Description of functions 53
Error code for “direct I/O access” 54
Generating and transferring a boot project 55
– Storing a boot project on a memory card 55
– Boot project and operating system (OS) on memory
card 55
– Erase boot project 55
Download/update operating system 56
– Transferring the operating system from the PC to the
PLC 56
– Transferring the OS from PC to the memory card 57
– Transferring the OS from the memory card to the
controller 57
10 Browser commands 59
– Setting Ethernet parameters 59
Description of important Browser commands 60
– canload 60
– setrtc 60
11 Libraries, function blocks and functions 61
Using libraries 61
Installing additional system libraries 61
EC4-200 specific functions 62
– EC_Util.lib library 62
– EC_Visu.lib/EC_Visu2.lib library 62
12 Connection setup PC – EC4-200 63
Connection setup via RS232 63
Defining/changing the PC’s communication settings 63
Changing the communication parameters (baud rate) of
the CPU 64
Connection setup via Ethernet 64
Scan/Modify the IP address 66

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4
13 Defining system parameters via the STARTUP.INI file 67
Overview 67
Structure of the INI file 67
Creating the Startup.INI file 67
Switching on the PLC with the fitted memory card
containing the Startup.INI file 67
Changing settings 68
Deleting the Startup.INI file 68
14 Programming:via a CANopen network (Routing) 69
Prerequisites 69
Routing features of the controller 69
Routing through XC200 69
Notes on routing 70
Setting the node ID/routing ID 70
Setting the master station 71
Setting the device station 71
PLC combinations for routing 72
15 RS232 interface in Transparent mode 73
16 Interactive display 75
Display form 75
– Switching between Status display and Entry/output
mode 75
– Function/function block overview 76
Description of important functions / function blocks 77
– FUNCTION Disp_EnableDisplay: BOOL (*Changing
Status display <-> Entry/output mode*) 77
– General programming procedure 80
– Example of text and values output 81
– Example of a screen output with texts and value
entries 83
Multifunction display MFD-CP4 on the EC4-200 86
–MFDsetup 86
17 EC4-200 network modules 87
EASY205-ASI 87
– Cyclic data exchange 87
– Configuration 88
– Setting the station address 88
EASY221-CO, EASY204-DP, EASY222-DN 88
– Cyclic data exchange 88
– Configuration 89
– Setting the station address 89
– Acyclic data exchange 89

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Appendix 93
Network CAN/easyNet 93
– Accessories 93
Example program for PLC START/STOP using external
switch 94
easy800-PC-CAB connection cable 95
Dimensions and weight 95
Technical data 96
– Transistor outputs 101
– Analog output 103
Character sets 104
Index 107
hThe previous Chapter 17: "The easyNet network" and
Chapter 18: "Programming via easyNet (routing)“ are
omitted.
You will find this information in far greater detail in the
manual MN05006004Z-EN (previously 08/07 AWB2786-
1593) "Data transfer between easy and IEC PLCs
(easyNet)".

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