Schleicher XCx 300 User manual

Operating Manual
XCx 300 / 500 / 540
Compact Controllers for PLC and
CNC Solutions
Operating Manual XCx 300 / 500 / 540 Version 09/08
Part No. R4.322.2140.0 (322 383 83)

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Operating Manual XCx 300 / 500 / 540 Version 09/08
Target Group
These operating manual have been written for trained personnel with
specialised knowledge. There are special demands on the selection
and training of the personnel who work on the automation system.
Suitable personnel are, for example, electricians and electrical
engineers who have had the relevant training (see also Safety-related
information, "Selection and Qualification of Personnel").
Applicability of these operating manual
Version Hardware XX / Software XX
Previous versions of these operating manual
06/02 08/02 04/03 01/04 08/04 02/05 04/05 06/05 07/05
Where can I obtain manuals?
You can download all our programming and operating manuals free of
charge from our web site at http://www.schleicher.berlin
or order them by writing to the following address (please quote order
no.):
Schleicher Electronic Berlin GmbH
Wilhelm-Kabus-Straße 21-35
10829 Berlin
Germany
Additional manuals
Designation
Artikel-Nr.
Inbetriebnahmehinweise für Feldbussysteme
322 152 48
Commissioning Field Bus Systems
322 152 49
CNC-Programmierung XCx und ProNumeric deutsch
322 381 61
CNC Programming XCx and ProNumeric englisch
322 381 62
RIO Erweiterungsmodule deutsch
322 154 14
RIO Expansion Modules englisch
322 154 15
Copyright by
Schleicher Electronic Berlin GmbH
Wilhelm-Kabus-Straße 21-35
10829 Berlin
Germany
Phone [phone] - 0
Fax [phone] - 344
Internet http://www.schleicher.berlin
E-Mail: [email protected]lin
Errors and omissions excepted. Subject to modifications.

Operating Manual XCx 300 / 500 / 540 Version 09/08
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Contents
1Overview .............................................................................................................................................................. 8
2Installation ......................................................................................................................................................... 15
2.1 XCx...................................................................................................................................................................... 15
2.1.1 Installation position.............................................................................................................................................. 15
2.1.2 Installation clearances......................................................................................................................................... 15
2.1.3 Fixing the XCx to DIN rail .................................................................................................................................... 16
2.1.4 Fixing with screws ............................................................................................................................................... 18
2.1.5 Connecting the voltage supply XCx .................................................................................................................... 19
2.2 XRIO Installation ................................................................................................................................................. 21
3Displays, Connections and Controls............................................................................................................... 25
3.1 Overview ............................................................................................................................................................. 25
3.2 LED Displays....................................................................................................................................................... 26
3.3 CompactFlash ..................................................................................................................................................... 28
3.4 X7 PRG RS232 Interface for Programming Devices........................................................................................... 28
3.5 X6 ETH RJ 45 EtherNet Connection ................................................................................................................... 28
3.6 X5 CANopen Field Bus Connection .................................................................................................................... 29
3.7 X4 X RIO Connection .......................................................................................................................................... 29
3.8 X3 USB Connection (Universal Serial Bus)......................................................................................................... 29
3.9 X1 RS422 Interface for Connecting Operator Panels and Displays.................................................................... 30
3.10 X2 Connection for Supply Voltage, Direct I/O and BUSY Contact ...................................................................... 30
3.11 Mode Switch........................................................................................................................................................ 30
3.12 RESET Button ..................................................................................................................................................... 31
3.13 IRDa Infrared Interface........................................................................................................................................ 31
4Quick Introduction ............................................................................................................................................ 32
4.1 Starting up Communication ................................................................................................................................. 32
4.1.1 Communication connections ............................................................................................................................... 32
4.1.2 Starting up the serial connection via the RS232 interface................................................................................... 32
4.2 Starting up the Ethernet Interface ....................................................................................................................... 34
4.2.1 Output current IP address of XCx via the RS232 interface ................................................................................. 34
4.2.2 Setting the IP address of the service PC............................................................................................................. 34
4.2.3 Setting up and checking the Ethernet connection ............................................................................................... 35
4.3 Changing the IP Address of the XCx................................................................................................................... 35
4.4 Installing the MULTIPROG, AddOns and OPC Server ...................................................................................... 37
4.4.1 Installing MULTIPROG........................................................................................................................................ 37
4.4.2 Starting MULTIPROG and opening a new project .............................................................................................. 41
4.4.3 Setting the Ethernet connection in MULTIPROG ................................................................................................ 42
4.4.4 Compiling a project and sending to the XCx ....................................................................................................... 43
4.5 Accessing the I/O Level with XRIO ..................................................................................................................... 45
4.5.1 XRIO connection ................................................................................................................................................. 45
4.5.2 Example of an XRIO configuration ...................................................................................................................... 45
4.5.3 Inserting the XRIO configuration ......................................................................................................................... 46
4.5.4 The first I/O access by the PLC program ............................................................................................................ 49
4.5.5 Diagnosis............................................................................................................................................................. 50
4.6 CANopen for Remote I/O .................................................................................................................................... 51
4.6.1 Specifications ...................................................................................................................................................... 51
4.6.2 Connection and wiring......................................................................................................................................... 52
4.6.3 Settings on the RIO 8 I/O CANopen module....................................................................................................... 53
4.6.4 Declaring the I/O driver for CANopen.................................................................................................................. 53
4.6.5 Declaring network variable in MULTIPROG........................................................................................................ 55
4.6.6 Configuring the CANopen network with ProCANopen ........................................................................................ 56
4.6.7 Installing ProCANopen ........................................................................................................................................ 56
4.6.8 Integrating ProCANopen in MULTIPROG ........................................................................................................... 57
4.6.9 First connections with ProCANopen.................................................................................................................... 58
4.7 The Web-Server Functions of the XCx................................................................................................................ 62
4.7.1 General functions and concept............................................................................................................................ 62
4.7.2 Schleicher-specific applet.................................................................................................................................... 62
4.7.3 Declaring variables for visualization .................................................................................................................... 63
4.7.4 Application example ............................................................................................................................................ 63
4.7.5 Browser / components......................................................................................................................................... 63

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Operating Manual XCx 300 / 500 / 540 Version 09/08
5XRIO.................................................................................................................................................................... 64
5.1 Recognition of XRIO Configuration by XCx Operating System........................................................................... 65
5.1.1 The sysinfo.txt file XRIO section ......................................................................................................................... 66
5.2 Addressing I/O Modules ...................................................................................................................................... 68
5.3 XRIO Flags in Shared Memory Validity of Process Data .................................................................................... 68
5.4 The XRIO Driver.................................................................................................................................................. 69
5.5 Calculating Estimated Transmission Time .......................................................................................................... 69
5.6 Expansion Modules from the RIO System .......................................................................................................... 71
5.6.1 Overview ............................................................................................................................................................. 71
5.6.2 Tables of module types and module classes ...................................................................................................... 74
5.7 Expansion Module XRIO ..................................................................................................................................... 75
5.7.1 Displays and Connections................................................................................................................................... 75
5.7.2 Technical data ..................................................................................................................................................... 75
6CANopen Field Bus........................................................................................................................................... 76
6.1 Fundamentals...................................................................................................................................................... 76
6.1.1 Process Data Objects (PDO) .............................................................................................................................. 77
6.1.2 Service Data Objects (SDO) ............................................................................................................................... 77
6.1.3 Nodeguarding...................................................................................................................................................... 77
6.1.4 Lifeguarding......................................................................................................................................................... 78
6.2 CANopen-Specific PLC Addresses ..................................................................................................................... 79
6.2.1 Parameterizing and diagnosis data ..................................................................................................................... 79
6.2.2 Network variables................................................................................................................................................ 79
6.2.3 Access to network variables and I/O configuration ............................................................................................. 80
6.2.4 Accessing direct network variables ..................................................................................................................... 82
6.2.5 Accessing parameterizing and diagnosis functions............................................................................................. 82
6.3 SDO Function Blocks .......................................................................................................................................... 83
6.4 Parameterizing and Diagnosis Functions............................................................................................................ 84
6.4.1 Function 1 Set and read CANopen node number ............................................................................................. 85
6.4.2 Function 2 Set and read data transmission rate................................................................................................ 85
6.4.3 Function 7 Output CANopen error number ....................................................................................................... 86
6.4.4 Function 8 Read CANopen firmware version ................................................................................................... 86
6.4.5 Function 20 Set CANopen startup delay ........................................................................................................... 86
6.5 Error messages ................................................................................................................................................... 87
6.6 Expansion Module XF-CAN ................................................................................................................................ 88
6.6.1 Displays and Connections................................................................................................................................... 88
6.6.2 Technical data ..................................................................................................................................................... 88
7The XCx Multi-Tasking System ........................................................................................................................ 89
7.1 Overview ............................................................................................................................................................. 89
7.2 User Tasks .......................................................................................................................................................... 90
7.2.1 Cyclical tasks....................................................................................................................................................... 90
7.2.2 Event tasks.......................................................................................................................................................... 91
7.2.3 System tasks ....................................................................................................................................................... 92
7.2.4 Default task ......................................................................................................................................................... 94
7.3 User Task Information ......................................................................................................................................... 95
7.4 Task Priorities...................................................................................................................................................... 97
7.5 Tasks and Watchdogs......................................................................................................................................... 98
7.6 Inserting Tasks and Assigning Programs............................................................................................................ 99
8The PLC............................................................................................................................................................ 101
8.1 Programming..................................................................................................................................................... 101
8.2 PLC Operating States and Starting Behaviour.................................................................................................. 101
8.2.1 Operating states ................................................................................................................................................ 101
8.2.2 Changing operating states with MULTIPROG................................................................................................... 102
8.2.3 PLC starting behaviour after power supply is switched on................................................................................ 103
8.3 System Variables .............................................................................................................................................. 103
8.4 Libraries and Function Blocks in MULTIPROG ................................................................................................. 104
8.4.1 CANopen_Vxxx library ...................................................................................................................................... 106
8.4.2 CFB_Vxxx Library ............................................................................................................................................. 106
8.4.3 CNC_Vxxx library .............................................................................................................................................. 107
8.4.4 Date_Time library .............................................................................................................................................. 107
8.4.5 MMI Library ....................................................................................................................................................... 108
8.4.6 PLC library......................................................................................................................................................... 108

Operating Manual XCx 300 / 500 / 540 Version 09/08
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8.4.7 Profibus_Vxxx Library ....................................................................................................................................... 108
8.4.8 Serial Library ..................................................................................................................................................... 109
8.4.9 SchleicherLib_Vxxx library ................................................................................................................................ 109
8.4.10 XCx7_Vxxx Library............................................................................................................................................ 109
8.5 PLC Operating System ProConOS ................................................................................................................... 110
8.5.1 ProConOS.INI initialization file .......................................................................................................................... 110
9The CNC ........................................................................................................................................................... 111
9.1 Configuration of the shared RAM PLC-CNC ..................................................................................................... 111
9.2 Important Notes on the Multi-Tasking System and CNC................................................................................... 112
10 SLM Drive Module XP-SLM............................................................................................................................. 113
10.1 General.............................................................................................................................................................. 113
10.1.1 Displays and Connections................................................................................................................................. 114
10.1.2 Assignment of Sockets on Module (Top View).................................................................................................. 115
10.1.3 Technical data for SLM drive module XP-SLM ................................................................................................. 117
10.1.4 Interfaces........................................................................................................................................................... 118
10.1.5 Application example .......................................................................................................................................... 120
10.1.6 Wiring Example with MultiAx ............................................................................................................................. 121
10.1.7 Wiring example with M'Ax ................................................................................................................................. 123
11 SERCOS Module XP-SRC ............................................................................................................................... 125
11.1 Displays and Connections................................................................................................................................. 126
11.2 Technical Data .................................................................................................................................................. 127
11.3 Application Example.......................................................................................................................................... 127
12 PROFIBUS-DP Modules .................................................................................................................................. 129
12.1 PROFIBUS-DP Master XF-DPM ....................................................................................................................... 129
12.2 Displays and Connections XF-DPM .................................................................................................................. 130
12.3 Technical Data XF-DPM.................................................................................................................................... 130
12.4 PROFIBUS-DP Slave XF-DPS.......................................................................................................................... 131
12.5 Displays and Connections XF-DPS................................................................................................................... 132
12.6 Technical Data XF-DPS .................................................................................................................................... 132
12.7 PROFIBUS-DP Configuration Data................................................................................................................... 133
13 Error messages ............................................................................................................................................... 135
13.1 Structure of Error Messages ............................................................................................................................. 135
13.2 PLC Error Messages ......................................................................................................................................... 137
13.2.1 0x0100 PLC runtime error ................................................................................................................................. 137
13.2.2 0x0110 General PLC errors .............................................................................................................................. 142
13.2.3 0x0120 XRIO errors .......................................................................................................................................... 143
13.3 CNC Error Messages ........................................................................................................................................ 144
13.3.1 0x0200 General CNC errors.............................................................................................................................. 145
13.3.2 0x0210 Subsystem-specific CNC errors ........................................................................................................... 146
13.3.3 0x0211 Decoder errors...................................................................................................................................... 147
13.3.4 0x0212 Error in automatic record insertion ....................................................................................................... 152
13.3.5 0x0213 Error in tool nose radius compensation ................................................................................................ 153
13.3.6 0x0214 Error in interpolation preparation .......................................................................................................... 153
13.3.7 0x0220 Axis errors ............................................................................................................................................ 155
13.3.8 0x0221 SERCOS diagnosis status.................................................................................................................... 157
13.3.9 0x0222 SERCOS status class 1........................................................................................................................ 158
13.3.10 0x0223 Manufacturer-specific SERCOS errors................................................................................................. 159
13.3.11 0x0224 Manufacturer-specific SERCOS error texts.......................................................................................... 159
13.3.12 0x0230 Drive errors........................................................................................................................................... 160
13.4 CAN Error Messages ........................................................................................................................................ 165
13.4.1 0x0300 CAN-specific operating system errors .................................................................................................. 165
13.4.2 0x0301 CAN driver errors.................................................................................................................................. 166
13.5 User-defined Error Messages ........................................................................................................................... 167
13.5.1 0x0400 User-defined error messages ............................................................................................................... 167
13.6 NC Memory Access Errors................................................................................................................................ 168
14 Technical data ................................................................................................................................................. 170
15 Dimensions ...................................................................................................................................................... 172
16 Appendix.......................................................................................................................................................... 173
16.1 Trademarks ....................................................................................................................................................... 173
17 Safety-related Information.............................................................................................................................. 174
17.1 Correct Use of the System ................................................................................................................................ 174

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Operating Manual XCx 300 / 500 / 540 Version 09/08
17.2 Selection and Qualification of Personnel........................................................................................................... 174
17.3 Configuring, Programming, Installation, Commissioning and Operation ........................................................... 175
17.4 Maintenance...................................................................................................................................................... 175
17.5 High Voltages .................................................................................................................................................... 175
17.6 Dealing With Used Batteries ............................................................................................................................. 176
18 Pictures and Index .......................................................................................................................................... 177

Operating Manual XCx 300 / 500 / 540 Version 09/08
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Document conventions
This manual uses the following signs to indicate a safety-related
warning:
Possible injuries or damage to the equipment if
relevant safety precautions were not to be taken.
Warning!
Bedeutet, dass Personen, das Automatisierungssystem
oder eine Sache beschädigt werden kann, wenn die
entsprechenden Hinweise nicht eingehalten werden.
Gibt Hinweise zur Vermeidung der Gefährdung.
Important! or Note
Important information on the handling of the automation
system or the respective part in the operating manual.
Other objects are represented as follows.
Object
Example
File names
MANUAL.DOC
Menus / Menu Items
Insert / Graphic / From file
Paths / Directories
C:\Windows\System
Hyperlinks
http://www.schleicher.berlin
Program listings
MaxTsdr_9.6 = 60
MaxTsdr_93.75 = 60
Keys
<Esc> <Enter> (press first key, let go and press next key)
<Ctrl+Alt+Del> (press all keys at the same time)
Configuration data identifier
Q34 und Q.054
Names of shared RAM variables
cncMem.sysSect[n].flgN2P.bM345Act

Safety-related Information
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Operating Manual XCx 300 / 500 / 540 Version 09/08
1Safety-related Information
The term automation system as used in this manual includes control
units, their components (modules), other parts (such as racks, cables),
operator panels, and the software used for programming,
commissioning and operating the control units. This operating manual
can only describe a fraction of the automation system (e.g. modules).
The technical design of SCHLEICHER automation systems is based
on the EN 61131-2 (IEC 61131-2) product norm. The systems and
devices have CE marking according to the EMC directive 89/336/EEC
and, if applicable, the low-voltage directive 73/23/EEC.
The machinery directive 89/392/EEC is not applicable, because the
safety objectives of the directive are covered by the low-voltage and
EMC directives.
When SCHLEICHER automation systems are part of the electrical
equipment of a machine, the manufacturer must include them in the
conformity evaluation process. In this case the DIN EN 60204-1 norm
must be observed (safety of machines, general requirements for
electrical equipment of machines).
When an automation system is properly maintained and used for its
intended purpose it will not normally cause damage to property or
present health hazards. However, improper configuration, installation,
maintenance or operation of the system or machine, ignoring the
instructions in this manual, or intervention by insufficiently qualified
personnel may result in connected actuators (such as motors,
hydraulic units, etc.) becoming a source of danger.
1.1 Correct Use of the System
SCHLEICHER automation systems are state-of-the-art products and
manufactured to recognised safety requirements. All the same, their
use can cause danger to the health and safety of operators and others,
or damage machines, systems or other property.
The automation system must only be used in perfect technical
condition for its intended purpose, with attention given to safety and
danger, and observing the operating manual. Correct transport,
storage, installation, operation and maintenance of the system are all
prerequisites for smooth and safe operation of the control system.
Malfunctions, in particular those which may affect safety, must be
immediately resolved.
Automation systems are designed exclusively to control machines and
systems. Automation systems are not intended for any other use than
the above. The manufacturer will therefore accept no liability for any
damages resulting from the incorrect use of the systems.
When using automation systems, all instructions given in this manual
regarding mechanical and electrical setup, commissioning and operation
must be observed.

Safety-related Information
Operating Manual XCx 300 / 500 / 540 Version 09/08
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1.2 Selection and Qualification of Personnel
Important!
All configuring, programming, installation,
commissioning, operation and maintenance work on the
automation system must be carried out by trained
personnel such as electricians or electrical engineers.
Personnel responsible for configuring and programming
the system must be familiar with all safety-related issues
in automation technology.
System operators must be instructed on the operation of
the control system and be familiar with the relevant
operating instructions.
All personnel responsible for installing, commissioning
and maintaining the system must have had appropriate
training qualifying them to work on automation systems.
1.3 Configuring, Programming, Installation, Commissioning and Operation
The automation system will in most cases be a part of a larger system
in which machines are controlled. When configuring, installing and
commissioning automation systems to control machines the machine
manufacturer and the user must observe the safetyregulations as
defined in the machinery directive 89/392/EWG. For specific applications
national accident prevention regulations such as VBG 4.0 will apply.
Safety-related components on the controlled machine must be
designed such that they operate independently from the control
system. Emergency stop components must be operational in all control
modes. In an emergency stop the power supply to all switching
elements controlled by the control system must be cut off.
Measures must be taken for restarting an interrupted control program
following voltage dips or power failures. Operating conditions should
never cause danger, not even for a short time. In the event of danger
the emergency stop must be immediately triggered.
In order to prevent an open-circuit in the signal circuit causing non-
controllable conditions in the control system, the relevant hardware and
software safety precautions must be taken for I/O interfacing. Control
elements and their assigned control panel elements must be installed
in a place where they are sufficiently protected against inadvertent
use.
1.4 High Voltages
Warning!
When the cabinet is opened or casing is removed from
system components certain parts of the automation
system are exposed. These parts may be subject to
dangerous high voltages.
The user must prevent any unauthorised and incorrect access to the
system (for example, by ensuring that the cabinet is locked).
Personnel must be familiar with all sources of danger and measures for
commissioning and maintaining the system in line with the instructions
given in this manual.

Safety-related Information
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Operating Manual XCx 300 / 500 / 540 Version 09/08
1.5 Maintenance Measuring and testing on active devices must be carried out in
accordance with the regulations and instructions of the VBG 4.0
accident prevention regulation. The appropriate power tools must be
used.
Repairs on control components must be carried out at repair shops
authorised by SCHLEICHER. Opening the components and repairs by
unauthorised personnel may lead to personal injury or damage to
property.
Always be disconnected the device from the mains before opening it
(either disconnect the mains plug or use the cut-out switch).
Control modules may only be replaced when the power is switched
off. Disassembly and assembly must be carried out according to the
directives for mechanical assembly.
Fuses may only be replaced with those types specified in Technical
Data.
Batteries mayonly be replaced with those types specified in Technical
Data. Batteries must always be disposed as hazardous waste.
1.6 Dealing With Used Batteries
When the batteries in the automation system are dead they must be
disposed of in a battery return system or through public waste
disposal facilities.
Batteries should be fully discharged before disposal. A battery is
discharged when the function of the device is impaired due to
insufficient battery capacity.
When batteries for disposal are not fully discharged precautions must
be taken to prevent short circuits. For example by sticking tape over
the poles of the battery.