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XControl XControl XC600 The modular, open industry control with

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Presentation on theme: "XControl XControl XC600 The modular, open industry control with"— Presentation transcript:

1 XControl XControl XC600 The modular, open industry control with
IT functionality by Moeller XControl is the key component of XSystem, the innovative automation system by Moeller. This presentation will demonstrate the features and benefits XControl has been equipped with and that this device will guarantee customer satisfaction even on ist own, without the support of the visualization components Xvison, the I/O components XI/ON and XI/OC and the other XSystem components.

2 XControl: The Main Market Requirements
High comfort of operation even without programming tool Ready for the most demanding control tasks To be successful in the marketplace a modern high end industrial controller has to fulfill a lot of criteria. Of course the controller has to be top end of the line as regards memory and processing speed in order to tackle the growing requirements from fas´ter industrial processes and in the view of more and more expensive down times. An optimum of handling without the need foir specialized tools is one of the keys to success. Another part of the puzzle is the communication capability reaching from data logging for management systems and coupling of SCADA systems down to the fast communication with the field level, i.e. from full OPC, Ethernet and WEB functionality to standard fieldbus systems. Designed for industry in any detail Open for teleservice, supervisory system connection and field communication

3 XControl XC600: Agenda 1 Hardware 2 Handling 3 Software

4 XC600: Hardware XControl XC600 1 Hardware

5 XControl: Open Hardware Platform
Robust, stapled frames Mounting without tools Communication modules Up to 3 extension modules Open for extensions Open for I/O‘s Open for modern automation tasks Motion control Image processing Secured hardware Lockable pins

6 XControl: The Modules „Modular“, „without tools“ and „made for industry“aren‘t necessarily contrasts Basic Module Mechanical Mounting (DIN rail) Voltage transformation Alimentation Module Up to 3 Fieldbus Modules or other extensions Extension Module Windows NTe with real time PLC system on Pentium processor CPU Module Display, Function selector switch, LED’s, Menue selector button Operation Module

7 XControl: The Operation Module
Easy access LED’s Display of actual status Display LCD 4 lines x 12 characters Function selector switch Run, Run-P, Stop, MRes Menu selection button Menu selection The operation module is unique. Just one small comparison: A Simatic S7-user not only has to program in another tool (ProTool) for the simplest displays. Moreover that person also needs a separate operating panel or a programming device to have a peek inside the controller. The operation module offer an instant access to important settings, messages and configuration data: Is a program running ? Which one ? Since when ? Was the hardware modifies? Which TCP/IP-Adresse has been assigned to the XControl ? etc. With the help of the Compact Flash card interface programs can be transferred to the controller and be started totally without prolgramming device. Buffering the real time clock Battery Load and export data Compact Flash Card

8 XC600: Assembly

9 Address setting of the optional modules
Address settings of the optional modules The communication between the CPU and the optional modules is handled via reserved memory areas in the PLCs memory. For correct operation you have to take care that the modules are coded correctly according to their location in the XControl. That is achieved via jumpers for the pins on the PCB of the respective module (see above). Please do not count the pins in the drawings of the manuals; strictly refer to the pin numbers printed ion the figures and on the PCB.

10 XControl: The CPU Module
Compact with highest performance: The head of XControl RAM Flash Disk Operating system, data, 1 – 8 MB IEC code, other programs Hard disk without moving parts CPU Pentium I Windows NT embedded OPC Server Real time PLC system … Ethernet Programming link Network coupling OPC for visualisation, ERP systems etc. Web / Teleservice RS 232 free for application specific coupling

11 XControl: The communication Modules
Configuration completely via XSoft Up to 31 slaves on 1 line Comm. Module Profibus-DP RS 485 or R R Via Repeater: Up to 124 slaves on 4 lines Up to 126 slaves on 1 Strang Comm. Module CANopen CAN Three Communication Modules can integrate up to 370 participants Slave = XI/ON as Gateway to analogue/digital signals or field equipment with fieldbus capability

12 XControl: Quality Data
IP 20 Protection degree Acc. to EN Type testing Acc. to EN (Industry) EMC Acc. to IEC Permanent shock strength Acc. to IEC Shock strength Acc. to IEC/EN Vibration strength °C Storage temperature °C Ambient temperature (operation) Designed for industry Mechanical Tests EMC Tests

13 XC600: Handling XControl XC600 2 Handling

14 XControl: Display + Menu selection button
4 lines with 12 digits Cursor blinks Choice of menue by turning 1 Comfortable diagnosis and handling even without programming tool or external visualisation 2 Confirm by pushing

15 User-specific Display
XControl: The Menus PACK_8=ON HAUBE_2=AUF AUSSCHUSS=7 Turn Basic menue User-specific Display Push Diagnosis Program Receipt Device System Back Main Menu

16 XControl: The Basic Menu
! = non-acknoledged event Position Function selector switch S = Stop P = Run-P R = Run ! PLC mode Loaded program Informed at a glance Push: To main menu Turn: To user-specific display

17 XControl: User-specific display
When programming: Choice of important variables , definition of strings 1 XSoft Within each control cycle: interrogation of chosen variables Control sends strings to display 3 2 PACK_8=ON HAUBE_2=AUF AUSSCHUSS=7 Actual and specific information at a glance

18 Logic menu paths: Quick finding without manual
XControl: Main menu Displays errors and events Reset, Copy, aktivate, Load, Delete Diagnosis Program Receipt Device System Back Define IP address, date/time, security, language, hardware configuration, software version Shut down, new start Logic menu paths: Quick finding without manual Back to basic menu

19 XControl: Menu diagnosis
List of events: Has the program been running without problems? Was it stopped or started? When was that? Starts / Stops Error diagnosis: All non-acknoledged program errors are shown with time of occurance Battery empty, hardware module missing, program missing … Strong support while commissioning, servicing and operating The diagnostics menu differentiates between errors and messages. The errors supervise Software and Hardware. The Software surveillance report errors e.g. when it detects a division by zero or a watchdog event if the cycle time is exceeded. But also the Hardware is under permanent supervision: Is one of the module reported missing, is there no program in the me´mory or is the battery empty? But what about the messages for events. Those gice an overview during the operation of the machine or system as regards for instance starting and stopping of the XControl. Thus the machine operator can recognize instantly, when and why the machine has been stopped.

20 XControl: Menus „Program“ und „Recipe“
RUN / RUN-P RAM LOAD Start Loaded program / receipt INTERNAL Activated program / receipt STOP Flash Disk (Hard memory on CPU module) Simple and safe data management and program starting ACTIVATE Program / receipt Programs and recipes will either be tranferred via XSoft directly via Ethernet to the XControl or to the Compact Flash Card after the programming. With the transfer possibility from the Compact flash card via operation module to the XControl you do not even need a programming PC on the site !. Both menus (internal/external) allow the copying from one memory to the other, the deleting (not shown on the slide) and the activating. There can well be several programs/recipes stored on the internal flash disk , but until one of them is activated the default program remains active. With the „Load“ operation the activated program will be transferred from the internal flash disk to the RAM memory. The XControl will be put into HALT. The program is then finally started via switching to RUN / RUN-P. Thanks to this „security buffer“ (activate and load before Start) unintended starts become very unlikely. Compact Flash (Plug-in at operation module) COPY EXTERNAL Program / recipe

21 + XControl: Security Programming only with switch position RUN-P
Protection against unauthorized programming Function selector switch at RUN + Display shows: “Function selector swich at RUN!” Activating password via menus “Lock switch”: Protection against unauthorized swich operation Activate The Xcontrol can be blocked for unauthorized access by putting the operation mode switch to RUN (STOP is also possible, but normally not very useful...) and by activating a password via the menus „device -> security“. Besides that you can define a password within the XSoft which will protect the programming connection to the XControl. Password Access only to Basic Menu and User-specific Menu Security Device Protection against unautorized menu manipulation Securing after commissioning

22 XControl: Menu „Program“ – Reset functionality
Example: Feed data of a shaft When performing a RESET some data is to be put back to its initial values while other data shall maintain their values 1 Safe starts through correct initialization Example: Statistic data 2 Within XSoft variables are declared precisely ... are maintained ... are reset VAR Persistant VAR Retain Persistant VAR Retain RUN STOP RUN WARM COLD M-RES 3 Or power cycle Resets during operation bring about the desired initialization

23 XControl: Menu „Device“
GATEWAY Define IP address Router Other network participants SECURITY Define password Definition as network participant IP ADDRESS SUBNETMASK NAME HARDWARE Interrogation of actual modules SOFTWARE Efficient configuration and interrogation Interrogation of actual version DATE / TIME LANGUAGE (English, German, Italian, French)

24 XControl: Menu „Device“ – Hardware configuration
Removal or malfunction of a hardware module Time Commissioning AUTOcONFIG = OFF “Freeze” of nominal configuration Error reported SF-LED shows red Essential for the operation of the controller is the constant supervision of the hardware components. On the other hand the open hardware platform (simple installation of modules without tools) must not lead to the effect that the customers can modify the hardware configuration without the OEM knowing about that. The „radical“ method was already mentioned: Sealing the latching pins of the modules. Much more friendly, however, would be the maintaining of the service capability. That means that for both module malfunctions and module replacements a supervision must be available. This is offered by the hardware configuration: After the completion of the commissioning the hardware configuration is „frozen“ (by turning off the „autoconfig“ option). At any program start the actual configuration will be compared to the defined configuration. Deviations will lead to an error message, in cooperation with the activation of the SF LED. Perfect supervision of hardware Operation

25 XControl: Integrated communication for remote applications
Teleservices Cost service Updates + access Remote Programming Transparency Process monitoring Visualisation Efficiency Process production data Coupling manag. systems Remote supervision + diagnosis Via OPC OPC Server Via Web Webserver Via TCP/IP + Router TCP/IP Advantage machine builder Cost service Advantage machine owner Failure safety The following remote applications can be realized without additional, external communication devices: Teleservice means remote monitoring and diagnosis. The advantages are numerous. The software on the teleservices‘ user‘s side can either be an OPCClient (via OPC/Ethernet) or an internet browser (via Web). Remote programming can be user for programm updating or for the full remote programming. The machine builder can save quite a lot of money. Via Ethernet/Router/telephone line XSoft can perform the entire programming procedure as if it were directly connected to the XControl. SCADA systems for efficient supervision can be connected via OPC client. No additional hardware necessary

26 XControl: Teleservices and Remote programming
Perfect support of Teleservices Pro- vider Error messages / preventive maintenance SMS Remote supervision Remote diagnosis Data viewer: Specific information about the machine Telephone network Web Router Generator Router PLC System TCP/IP XSoft Complete access TCP/IP Web Server Router Remote programming Telephone support for local service Service Support Machine with control unit XControl Well planned visit by service specialist

27 XControl: Coupling of management systems
Management level: OPC Client Visualisation (HMI), Management (ERP, SCADA…) etc. OPC = OLE for Process Control World standard for open, safe and quick process data communication Within XControl: OPC Server No need of additional and expensive coupling hardware and software

28 XControl: Open, but safe
Safety and system stability have priority one! Untested Software XControl: Tested hardware und software Software doesn’t fit to Windows updates Virusses Real time problems Industrie-PC Hersteller XY The possibbility of installing any available software tools is very tempting with a standard operating system like Windows. Would that not be the chance for very cost efficient user specific solutions ? Yes, certainly! BUT, whoever wants to have that will in the end be better off with a standard industrial PC. And they will have to accept that: virusses can paralyse the controller and thus the machine. And that may happen at a moment, when no service personnel is available. Windows is released in ever new version all the time. Who will guarantee that important functionality in user specific solutions will still be supported? Control processing normally is quite time critical. The real time behaviour can be endangered, id the operating system is burdened too much ba additional software. Industrial PCs have changing hardware components: Memory cards, CPUs etc. will be used according to their availability on the market. The machine builder might get into trouble (change of components, since the performance of the components may vary. The operating system must be installed by the machine builder or OEM. That costs a lot of unefficient time (and there is the danger that not all or too many components of the operating system will be installed). With XControl the customer gets the same variability as a buyer of an industrial PC but without making compromises about security! Service problems Waste of time XControl: Operating system installed + stable hardware Operating system has to be implemented by user Hardware components don’t change

29 XControl: The professional industrial control
Fieldbus modules Open for remote applications, system coupling and field communication OPC Server Webserver Extension modules Display + menus Highest speed High comfort operation even without programmer or external visualization Very large memory Strong for the most demanding control tasks Summary: XControl – is a high performance industrial control XControl – is modular and open, as concerns software and hardware XControl – is well equipped for a variety of IT applications and remote procedures: from data acquisition to remote diagnosis a very cost-efficient multi talent! No moving parts Fan-less operation Designed for industry

30 XControl XC100 + XI/OC I/O-Modules + XVision Text-Display
XControl and XIOC XControl XC100 + XI/OC I/O-Modules + XVision Text-Display The convincing machine and system control by Moeller

31 The components for small and medium applications
Control XControl XC100 Visualization XVision Text Display Input and Output with XI/OC Modules Software XSoft for all Xsystem applications

32 The compact controls with integrated I/O
XC100 XC100 XControl The compact controls with integrated I/O

33 XControl XC100: The operation elements
Operating mode switch: Run / Stop Display PLC-Status: Run / Stop, SF Battery for Retention and Real time clock Status display local I/O LEDs Slot for Multi-Media-memory card (16 or 32 MB) Local I/O 8 DI 24 VDC 6 DO VDC RS232 (RJ45-socket) CAN-interface with integrated T-connector (Connection of two CAN-lines via cage-clamp terminal)

34 XControl XC100: Local I/O Inputs / Outputs Flexible Connection
8 DI 24 VDC 6 DO VDC Flexible Connection Screw or cage clamp terminals Terminal blocks completely removable

35 XControl XC100: Setup of the CPU
Locale I/O - 8 digital Inputs 6 digital Outputs galvanically separated CANopen Multi-Media-Card - Fieldbus-Master Control networking (XControl to XControl) - Program Recipes Visu-Texts Real time clock RS 232 CPU Programming port Modem, Printer etc. configurable: 1.2 thru 115 kBaud XC100 = 0.5 ms / 1000 instructions PLC real time system Battery Working memory SRAM XV-Flash Internal Flash memory - Program 64 / 128 kB Retentive Data 4 / 8 kB Data 60 / 120 kB - with XV devices 512 kB for Visu-Texts - Operating system Data of the operating system

36 XControl XC100: Load, Backup and Start
Multi-Media-Card - 1 Program Recipes Visualization Texts Create boot project Program on Multi-Media- Card has priority CPU RS 232 (XC100/200) Ethernet (XC200) Programming access Modem Barcode reader etc. kBaud Download Battery Working memory SRAM STOP RUN - 1 Program kB Retentive Data 4-8 kB Data 60 / 120 kB The program in the SRAM is started

37 High performance PLC with IT-Functions in compact design
XControl XC200 High performance PLC with IT-Functions in compact design The automation system XControl XC200 - The automation system (PLC) XC200 is a very powerful compact controller and one of the components of the XSystem. The XC200 has been designed for the area of machine and system automation and features onboard I/O - For the local expansion the compact I/O system XI/OC is available. - In addition to the programming interface the XC200 offers a CANopen interface, an Ethernet and a USB interface.

38 XC200: The compact high performance machine controller
Ethernet Memory Processing speed Ethernet 8MB 0,02ms/K 512K 0,05ms/K - Via the programming interface the programming connection between the PC and the PLC is established. Via this interface Down- load, Online monitoring, process communication (OPC/DDE) etc. are achieved - The fieldbus interface opens the possibility of connecting CANopen communication partners like decentralized I/Os or other automation devices determined to exchange data with the XC200. - The I/O level is wired to a terminal block, which is pluggable in a very simple way. - The sytem bus allows the connection of backplanes for the attachment of more local I/O to the XC200. - The battery buffers the SRAM (Program/Retentive Data) and the real time clock. - The XC200 is available in different memory sizes; all other specifics are identical. CAN Profibus DP CAN XC600 128K (256K) 0,5ms/K XC200 CAN XC100

39 Decentralized HMI-machine controller in Ethernet network
Specialities Ethernet Fast PLC in compact design 0,05ms/K 2 integr. Counters 2 Interrupt inputs QS Ethernet Gateway CAN -Ethernet Ethernet Solves positioning tasks with integrated incremental decoder - Via the programming interface the programming connection between the PC and the PLC is established. Via this interface Down- load, Online monitoring, process communication (OPC/DDE) etc. are achieved - The fieldbus interface opens the possibility of connecting CANopen communication partners like decentralized I/Os or other automation devices determined to exchange data with the XC200. - The I/O level is wired to a terminal block, which is pluggable in a very simple way. - The sytem bus allows the connection of backplanes for the attachment of more local I/O to the XC200. - The battery buffers the SRAM (Program/Retentive Data) and the real time clock. - The XC200 is available in different memory sizes; all other specifics are identical. MMC Data logger for QM or production data on MC, access directly via Ethernet Decentralized HMI-machine controller in Ethernet network

40 Features (1) - Compact PLC for machine builders - Assembly on hat rail
- Power supply 24V DC - Elements for display and operation - Real time clock - Memory card for data backup, recipe handling and Data logging - Die XC200 was designed for machine and system builders. - Thanks to the compact design many features could already be integrated on the XC200. - The XC200 is mounted to the hat rail with the backplane units. - The central power supply and the supply for the onboard inputs and outputs is attached with the terminal block. - Operating and display elements of the XC200 are located on the front panel. Display elements show different pieces of status information for the XC200. - The XC200 features an interface slot for a Multi-Media-Memory card on the front panel.

41 Features (2) - RS232 Programming interface
10/100MBit Ethernet interface for programming, network data communication or service access Onboard local I/O - CANopen fieldbus interface - Battery for data buffering and real time clock - Two memory sizes - 256K/128K memory for user-program/-data - 512K/ 256K memory for user-program/-data - Via the programming interface the programming connection between the PC and the PLC is established. Via this interface Down- load, Online monitoring, process communication (OPC/DDE) etc. are achieved - The fieldbus interface opens the possibility of connecting CANopen communication partners like decentralized I/Os or other automation devices determined to exchange data with the XC200. - The I/O level is wired to a terminal block, which is pluggable in a very simple way. - The sytem bus allows the connection of backplanes for the attachment of more local I/O to the XC200. - The battery buffers the SRAM (Program/Retentive Data) and the real time clock. - The XC200 is available in different memory sizes; all other specifics are identical. - High processing speed Bit Processor with 0,05 ms/K instructions

42 Operating / display elements
Operation mode switch: Run / Stop Display PLC status: Run / Stop, SF Battery for retentive data and real time clock Status display local I/O LEDs _Interface slot for Multi-Media-memory cards USB-interface Local I/O 8 DI 24 VDC - 2 Interrupt - 2 Counter - 1 incremental encoder 6 DO VDC The display elements inform about: - XC200 in RUN or in Program mode - XC200 collective error. The exact error message can be obtained with the XSoft. - Status of the digital inputs - Status of the digital outputs Operating elements: - Switch for selcting between „Run“ and „Program“ mode - Slot for the Multi-Media-memory card - Interface for programming ( XC200 - PC connection ) - Interface for the fieldbus CANopen - Battery compartment RS232/Ethernet Programming / communication (RJ45-socket) CAN-interface Plugable, with integrated T-connector (connection via cage clamps)

43 Locale I/O extension <- max. 510 mm -> Generous extensibility:
- Up to 15 XI/OC modules, only 510mm wide - Max. 254 digital I/O - Max. 112 Analog I/O < max. 510 mm > Digital inputs / outputs 24VDC 8 and 16 point I/Q 24VDC configurable (4DI, 12 DI/DO, 4DO as 2A) 230VAC 16 DI Analoge inputs / outputs Current, Voltage, Temperature up to 8 channels per module Fast (1ms) 2AI-1AO or 4AI-2AO Many technology modules Counters, Incremental encoder inputs, Communication 0, 1, 2 , 3 , , 13, 14 , 15 - Thanks to the flexible connection external sensors and actors can be wired in advance. - Replacement of equipment thus becomes very easy. - The digital outputs 0..3 can be operated with up to 500 mA. - The digital outputs 4 and 5 can be operated up to 1 A. Flexible connectivity: - Pluggable terminals - tension cage clamp or screw

44 XVision Flexible combination of XC200 + Xvision
Textdisplay for HMI control 2 Display types (4*20, 8*40 characters) Cursor block, Numeric keyboard, Function keys 3 XI/OC extensions plugable Especially suited as a remote operating panel via ethernet Personal remarks:

45 CANopen networking with XC200
XC200 as CAN master XC200 as CAN slave CANOpen fieldbus master up to 500 KBaud Also usable as slave SDO communication Programmable via CAN Simple data exchange between controllers via network variables cyclic Event triggered XC200 in Multimaster configuration

46 Ethernet networking with XC200
10/100MBit Ethernet Network communication with network global variables Cyclic Event triggered Data communication via UDP telegrams Between controllers To PC applications To all devices with Ethernet interface ETHERNET Technical Data for the fieldbus CANopen with XC200 : - Event controller bus system - Maximum Baud rate 125kBit/s ( CANopen Spec =1000kBit/s) - Maximum net extension 1000 m (without repeaters) - Maximum number of participants: 127 - The desciption of an XC200 node is done in the EDS-file (Electronic data sheet) - Parametrizing of the stations is done via Service-Data-Objects (SDO). SDOs can also be used for data transmission. - Fast data transmission is done via Process-Data-Objects (PDO) Data exchange between XC200 controllers: - For a data transmission block a variable group with an identifier has to be defined. - For the partner station a variable group with the same properties has to be defined (Identifier, Variable). - This possibility of data transmission is NOT CANopen specific. - This data transmission is XControl specific and is done via CAN ( not CANopen).

47 Open interfaces Access via OPC Data exchange via OPC Visualisation
EXCEL Visual Basic OPC Client XSoft OPC Server ETHERNET Data exchange via OPC Access to all process variables Connection to all standard SCADA packages Connection to Office applications (EXCEL, ..) Connection to user-created WINDOWS applications (Visual Basic, ...)

48 XControl XC200: Summary Extremely powerful and fast machine control with very compact dimensions Saving of large amounts of data on MultiMediaCard A powerful IEC- Software package for all XControl PLCs Fast 100MBit/s Ethernet interface USB interface for attaching printers and external memory OPC Server supports direct connection to all OPC client applications Very good Expandability Locally up to 15 modules Decentrally via integrated CANopen interface Web Server for easy data access with standard WEB browsers

49 The user-friendly Text- Visualization for XControl
Xvision Text Display The user-friendly Text- Visualization for XControl

50 XVision Text-Displays
Function keys with inscription strips Character height: 5 mm/10 mm selectable LCD-Display with STN-Technology Back lighting switchable on and off via software Contrast control % Display PLC-Status: Run / Stop / SF XV-101-K84 8 lines à 40 characters XV-101-K42 4 lines à 20 characters Robust metal frame: front design customer specific on demand; protection class IP65

51 XSoft: Programming the Text-Display
Declare Instance of the function block Variable declaration IEC-Programm Call-up of the instance in the program Eventually including of the hardware inputs

52 XSoft: Function blocks of the visualization library

53 XSoft: Example „Write variable value“
Function block WRITEVALUE Strobe Row Column Font Digits Precision LeadingZero DataType IntValue FloatValue Reverse Blink Active Error Variable declaration [0...7] [0...39] [0...5] digits beh. dec.point [0...39] [0,1] [INT, UINT,..., REAL] Variable to be written Inverting [0,1] Value_output : WriteValue; IEC-Program CAL Value_output(Strobe:=TRUE , Row:=7 , Column:=30 , Digits:= 8, LeadingZero:=TRUE, DataType:=WRITE_INT, IntValue:=Input_value) CAL Value_output(Strobe:=FALSE)

54 XSoft: Open text and font editor
Up to 4 Fonts per Program Download

55 ... or loading of predefined fonts
XSoft: Font editor ... or loading of predefined fonts Manual Font creation ...

56 XSoft: Text editor Integration into the PLC-Program
LD 2 ST Text_column ... LD 1 ST Text_row WriteText Strobe Active Row Column Text_column Text_row File in Excel Format


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