Schleicher ProNumeric XCI 600 Operating Manual

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Operating Manual

ProNumeric XCI 600

Operating Manual ProNumeric XCI 600 Version 07/16 Article No. R4.322.2510.0 (322 386 02)

Operating Manual ProNumeric XCI 600 Version 07/16

Target Group

This Operating Manual has been written for qualified professionals. There are special requirements for selecting and training personnel who work with the automation system. Suitable personnel are, for example, electricians and electrical engineers who have received appropriate training (see: Selection and Qualification of Personnel).

Applicability of this Operating Manual

Hardware Version 01 or higher / Software version V14.04/1

Previous Versions of this Operating Manual

08/14 , 05/15 , 06/16

Where to Get Operating Manuals

You can download all our operating manuals free of charge from our website at http://www.schleicher.berlin or order them by writing to the following address (please quote the Order No.): SCHLEICHER Electronic GmbH & Co. KG Wilhelm-Kabus-Strasse 21-35 10829 Berlin Germany

Copyright by

SCHLEICHER Electronic GmbH & Co. KG Wilhelm-Kabus-Strasse 21-35 10829 Berlin Germany

Phone +49 30 33005-0 Telefax +49 30 33005-344 Hotline +49 30 33005-304 Internet http://www.schleicher.berlin E-mail info@schleicher.berlin

Errors and omissions reserved.

Operating Manual ProNumeric XCI 600 Version 07/16

1 Safety instructions ..................................................................................................................... 6

1.1 Intended Use ................................................................................................................................ 6

1.2 Selection and Qualification of Personnel ...................................................................................... 7

1.3 Configuring, Programming, Installation, Commissioning and Operation ...................................... 7

1.4 Hazards due to Electrical Energy ................................................................................................. 8

1.5 Maintenance ................................................................................................................................. 8

1.6 Dealing with Used Batteries ......................................................................................................... 8

2 Additional operating manuals ................................................................................................... 9

3 System Overview ...................................................................................................................... 10

3.1 Designation / Variants................................................................................................................. 10

3.2 Installation of XCI 600................................................................................................................. 11

3.3 Connections and interfaces ........................................................................................................ 11

3.3.1 Top view .................................................................................................................................................... 11

3.3.2 Bottom view ............................................................................................................................................... 11

3.4 Description of Interfaces ............................................................................................................. 12

3.4.1 ETH RJ45 Ethernet ports ........................................................................................................................... 12

3.4.2 D-Sub 9 serial ................................................................................................................................ ............ 13

3.4.3 USB 2.0 ..................................................................................................................................................... 13

3.4.4 XCI 600 Control interface .......................................................................................................................... 13

3.4.5 DVI-I interface (digital and analog) ............................................................................................................ 14

3.4.6 PCIe slot .................................................................................................................................................... 14

3.5 Integrating the XCI 600 in an industrial infrastructure ................................................................ 15

3.6 Keyboard and mouse.................................................................................................................. 15

3.7 SSD............................................................................................................................................. 15

3.8 Retentive memory ....................................................................................................................... 15

3.9 Installed software ........................................................................................................................ 16

3.10 Operating systems ...................................................................................................................... 16

4 Commissioning ......................................................................................................................... 17

4.1 Switching on the operating voltage ............................................................................................. 17

4.2 Installing MULTIPROG, Schleicher add-ons, OPC server, and EC-Engineer ........................... 18

4.2.1 System requirements ................................................................................................................................. 19

4.2.2 MULTIPROG Installation ........................................................................................................................... 20

4.2.3 Installing the OPC Server .......................................................................................................................... 20

4.2.4 Installing Schleicher add-ons for MULTIPROG ......................................................................................... 21

4.2.5 Installing EC-Engineer ............................................................................................................................... 21

4.2.6 Install Schleicher Dialog ............................................................................................................................ 22

4.3 Starting up the Network Interface ............................................................................................... 23

4.3.1 Preparation ................................................................................................................................................ 23

4.3.2 Communication-schematic ........................................................................................................................ 24

4.3.3 Assigning a computer name for the XCI 600 ................................ ............................................................. 24

4.3.4 Customizing the XCx-TCP/IP settings ....................................................................................................... 25

4.3.5 Communication for programming with MULTIPROG ................................................................................. 25

5 First Steps with MULTIPROG .................................................................................................. 30

5.1 Start MULTIPROG, open and save a new project ..................................................................... 30

5.2 Compiling a project and sending it to the XCI 600 ..................................................................... 32

5.3 Incorporating shared memory ..................................................................................................... 33

5.4 Configuration of the EtherCAT network ...................................................................................... 36

5.4.1 Steps for configuring the EtherCAT network .............................................................................................. 38

5.4.2 Alteration to the EtherCAT configuration when the topology is changed ................................................... 43

5.4.3 The EtherCAT variables in MULTIPROG .................................................................................................. 46

5.4.4 Renaming EtherCAT variables .................................................................................................................. 46

6 Operation ................................................................................................................................... 49

6.1 Multi Function Application (MFA) ................................................................................................ 49

6.1.1 Starting the Schleicher MFA ...................................................................................................................... 49

6.1.2 The MFA window ....................................................................................................................................... 49

6.1.3 MFA functions ............................................................................................................................................ 50

6.1.4 Log files ..................................................................................................................................................... 52

6.1.5 Basic initialisation ...................................................................................................................................... 53

6.2 Schleicher Dialog ........................................................................................................................ 54

6.2.1 Structure of the User Interface ................................................................................................................... 54

6.2.2 Schleicher Dialog PLC/CNC ...................................................................................................................... 55

7 The PLC ..................................................................................................................................... 59

Operating Manual ProNumeric XCI 600 Version 07/16

7.1 Programming .............................................................................................................................. 59

7.2 PLC Operating states and Start behaviour ................................................................................. 59

7.2.1 Operating states ........................................................................................................................................ 59

7.2.2 Change the Operating States with MULTIPROG ...................................................................................... 60

7.2.3 PLC starting behaviour after power supply is switched on ......................................................................... 61

7.3 System variables ........................................................................................................................ 61

7.4 Libraries and Function blocks in MULTIPROG .......................................................................... 62

7.4.1 Information on the Variable Declarations of the Example Programs of FBs .............................................. 64

8 PLC Operating System ProConOS ......................................................................................... 64

8.1 ProConOS.INI initialisation file ................................................................................................... 64

9 The multi-task system .............................................................................................................. 65

9.1 Overview ..................................................................................................................................... 65

9.2 Monitoring task ........................................................................................................................... 65

9.3 User tasks ................................................................................................................................... 65

9.3.1 Cyclical tasks ............................................................................................................................................. 66

9.3.2 Event tasks ................................................................................................................................................ 67

9.3.3 Default task ................................................................................................................................................ 68

9.3.4 Operating system tasks ............................................................................................................................. 68

9.3.5 System tasks ............................................................................................................................................. 69

9.4 User task information .................................................................................................................. 71

9.5 Task priorities ............................................................................................................................. 73

9.6 Tasks and watchdogs ................................................................................................................. 74

9.7 Inserting Tasks and Assigning Programs ................................................................................... 75

10 The Shared Memory ................................................................................................................. 76

10.1 Information on the Selection of the Shared memory Version ..................................................... 77

10.2 Variables and Tasks ................................................................................................................... 78

10.3 Access to the Shared memory ................................................................................................... 78

10.4 Help about Shared Memory ........................................................................................................ 79

10.5 Further Background Information on Shared Memory ................................................................. 80

11 The CNC ..................................................................................................................................... 81

12 RS232 Serial Interface .............................................................................................................. 82

13 Other Operating Software ........................................................................................................ 83

13.1 Schleicher X-Manager ................................................................................................................ 83

13.1.1 "IP Configuration" ...................................................................................................................................... 83

13.1.2 “EWF Configuration” .................................................................................................................................. 86

13.1.3 “NFS and Hardlink” .................................................................................................................................... 88

13.1.4 “RTOS Settings” ........................................................................................................................................ 89

13.2 Remote Desktop UltraVNC ......................................................................................................... 90

13.3 TeamViewer ................................................................................................................................ 91

13.4 MicroBrowser .............................................................................................................................. 91

13.5 EC-Engineer ............................................................................................................................... 91

13.6 SSD and SSD Monitor SW (e.g. SSD Scope Pro) ..................................................................... 91

14 Technical Data .......................................................................................................................... 92

15 Glossary .................................................................................................................................... 94

15.1 Trademark entries ....................................................................................................................... 97

15.2 List of figures .............................................................................................................................. 98

15.3 List of Tables ............................................................................................................................ 100

15.4 Index ......................................................................................................................................... 101

16 Appendix ................................................................................................................................. 103

16.1 Schleicher UEFI Setup Default ................................................................................................. 103

Operating Manual ProNumeric XCI 600 Version 07/16

Warning!

Indicates possible injury to persons or damage to the automation system or the equipment if relevant warnings are not observed.

Specifies information on preventing a hazard.

Important! or Note

Emphasises important information on handling the automation system or the respective part in the Operating Manual.

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 one after the other) <Ctrl+Alt+Del> (press all keys at the same time)

Identifier for configuration data

Q23

Name of variables

mcMem.axSect[n].bContRel

Document conventions

This programming manual uses the following symbols to indicate safetyrelated and handling warnings:

Other objects are represented as follows:

Safety instructions

Operating Manual ProNumeric XCI 600 Version 07/16

1 Safety instructions

The term automation systems 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 part 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 standard for programmable logic controllers. The systems and devices are generally subject to CE marking according to EMC Directive 2004/108/EC and, where applicable, the Low Voltage Directive 2006/95/EC. The Machinery Directive 98/37/EC or 2006/42/EC 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 Intended Use

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 technically flawless condition and in compliance with its intended purpose, with attention given to safety and hazards, and adherence to the Operating Manual. Correct transport, storage and installation, operation and maintenance of the system are all prerequisites for smooth and safe operation of the control unit. Malfunctions, in particular those which may affect safety, must be immediately resolved. Automation systems are designed exclusively to control machines and systems. Any other application beyond this is not in compliance with the intended use. 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 adhered to.

Safety instructions Operating Manual ProNumeric XCI 600 Version 07/16

Important!

All planning, programming, installation, commissioning, operation and maintenance work in conjunction with the automation system must be performed only 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.

1.2 Selection and Qualification of Personnel

1.3 Configuring, Programming, Installation, Commissioning and Operation

The automation system will in most cases be 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 safety regulations as defined in the Machinery Directive 2006/42/EC. For specific applications, national accident prevention regulations such as in Germany BGV A3 shall apply. All safety-related components of the controlled machine must be designed such that they operate independently from the control system. Emergency stop components must remain operative in all operating modes of the controller. In an emergency stop, the power supply to all switching elements controlled by the control system must be brought to a safe state. 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. If necessary, an emergency stop must be immediately triggered. To ensure that an open-circuit on the signal side cannot cause undefined conditions in the control system, corresponding safety precautions must be taken for the I/O interfacing both on the hardware as well as the software side. Control elements and their assigned control panel elements must be installed in a place where they are sufficiently protected against inadvertent use.

Safety instructions

Operating Manual ProNumeric XCI 600 Version 07/16

Warning!

When the cabinet is opened or the housing is removed from system components, certain parts of the automation system carrying dangerously high voltages become accessible.

Switch off the voltage before working on the devices. Avoid short circuits when measuring live components.

1.4 Hazards due to Electrical Energy

The user must prevent any unauthorised and improper access to the system (for example, by ensuring that the switch cabinet is locked). Personnel must be thoroughly familiar with all sources of danger, and measures for commissioning and maintaining the system must be in line with the instructions given in this Operating Manual.

1.5 Maintenance

When it becomes necessary to perform measurement or tests on active devices, this work must be performed in accordance with the regulations and instructions of national accident prevention regulations such as in Germany BGV A3. Appropriate power tools must be used. Repairs on control components must be carried out by authorised repair shops only. Opening the components and repairs by unauthorised personnel may lead to personal injury or damage to property. Always disconnect the device from the mains before opening it (either disconnect the mains plug or use the cut-out switch).

1.6 Dealing with Used Batteries

When the batteries in the automation system are dead they must be disposed of through a common battery return system or through appropriate public waste disposal facilities. Batteries should be fully discharged before they are returned. A battery is discharged when the function of the device that it powers 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 adhesive tape over the poles of the battery.

Additional operating manuals Operating Manual ProNumeric XCI 600 Version 07/16

Important!

The XCI 600 controller is part of the XCx controller family that is based on a common software concept. For this reason, the following operating manuals must be used in addition to this Operating Manual.

Table 1: Additional operating manuals

Description

Order No. or reference

For commissioning field buses

EMC Directives German

R4.322.1060.0

EMC Guidelines

R4.322.1070.0

Notes on commissioning field bus systems

R4.322.1600.0

For programming the PLC and the CNC

MULTIPROG programming system according to IEC 61131-3

MULTIPROG manual (German) (Quickstart_MWT.pdf) in the MULTIPROG installation path

CNC Programming for XCx and ProNumeric

R4.322.2080.0

Shared memory allocation of the XCx

Online help for the XCx software package

Getting Started MULTIPROG

R4.322.2460.0

Operating Manual XCI 600

R4.322.2520.0

2 Additional operating manuals

All operating manuals are available as PDF files on the XCI 600 service CDROM and can be downloaded for free from our website

http://www.schleicher.berlin.

System Overview

Operating Manual ProNumeric XCI 600 Version 07/16

Type

Item number

Designation/Distinctive features

XCI 600P

R4.287.0360.0

IPC Controller (PLC only)

XCI 600E

R4.287.0370.0

IPC CNC Controller Export version max. 4 interpolating CNC axes in the subsystem, max 16 subsystems

XCI 600

R4.287.0380.0

IPC CNC Controller Standard version with 4 CNC axes max. 32 interpolating CNC axes in the subsystem, max 16 subsystems

3 System Overview

The XCI 600 is a CNC/PLC controller based on an industry standard PC. The operating system used is a combination of VxWorks and Windows Embedded 8. All peripheral devices are networked via EtherCAT®, including all CoE and SoE devices. The maximum configuration attainable is 32 axes and 16 subsystems.

3.1 Designation / Variants

In the export version, the number of interpolating CNC axes per NC set is limited to a maximum of 4. In the standard version, 4 CNC axes are always enabled and can be selected as a subsystem. The software option "Number of CNC axes" (CNC 02, "AXE 2" / Article R4.287.0390.0) provides a means for expanding your system in sets of 2 CNC axes each, up to a maximum of 32 axes. The "CNC subsystems" (CNC 03) option enables up to a maximum of 16 subsystems. The options are respectively available as a single license and a general license.

System Overview Operating Manual ProNumeric XCI 600 Version 07/16

Figure 1: XCI 600 View from the top

Figure 2: XCI 600 View from the bottom

 Vertical installation position.  Attachment to the mounting plate or optionally to a DIN rail.  Ventilation slots subject to change.  Installation in switch cabinet (a switch-cabinet fan is recommend).

 Sensor-controlled fan  2x Ethernet 10/100/1000 MB

X107 LAN 1: Intel® 82579LM Gigabit network card (ID 0x8086 0x1502) X110 LAN 2: Intel® 82574L Gigabit Ethernet controller (ID 0x8086

0x10D3)

 X108, X109, X111, X112 4x USB 2.0  X113 DVI-I (DVI, VGA)  X201 Serial (RS 232)

 1x PCIe Slot x1 Add-on low profile cards  X101 7 Pin Phoenix connector (Power supply 24V)  2x Ethernet 10/100/1000 MB

X102 LAN 3: Intel® 82574L Gigabit Ethernet controller (ID 0x8086 0x10D3) X103 LAN 4: Intel® 82574L Gigabit Ethernet controller (ID 0x8086 0x10D3) EtherCAT®

 X104, X105, X106 3x USB 2.0

3.2 Installation of XCI 600

3.3 Connections and interfaces

3.3.1 Top view

Description:

3.3.2 Bottom view

Description:

System Overview

Operating Manual ProNumeric XCI 600 Version 07/16

Warning!

Please note that on the Slave modules it is important not to interchange the IN and OUT ports for EtherCAT®. Please connect the XCI 600 to the IN port.

LAN RJ45

Type

Vendor ID

Device ID

OS Remarks (Default settings)

LAN 1 X107

Intel® 82597LM Gigabit Ethernet controller

0x8086

0x1502

Windows

Connection to local area network (DHCP)

LAN 2 X110

Intel® 82574L Gigabit Ethernet controller

0x8086

0x10d3

Windows

Service (fixed IP) E.g. for visualisation, programming, diagnostics

LAN 3 X102

Intel® 82574L Gigabit Ethernet controller

0x8086

0x10d3

VxWorks

Control units, "industrial Ethernet" applications such as Modbus/TCP, EtherCAT® (redundancy)

LAN 4 X103

Intel® 82574L Gigabit Ethernet controller

0x8086

0x10d3

VxWorks

EtherCAT®

ETH RJ45

Description

Explanation

TX+

Transmitted data plus

TX-

Transmitted data minus

RX+

Received data plus

Not connected

RX-

Received data minus

Not connected

3.4 Description of Interfaces

3.4.1 ETH RJ45 Ethernet ports

The XCI 600 provides a total of 4 Ethernet ports (4x RJ45). The port used for EtherCAT® is X103, but it can also be configured differently for specific applications.

System Overview Operating Manual ProNumeric XCI 600 Version 07/16

D-Sub 9

Type

Explanation

DCD

(Data) Carrier Detect

RxD

Receive Data

TxD

Transmit Data

DTR

Data Terminal Ready

GND

Ground

DSR

Data Set Ready

RTS

Request to Send

CTS

Clear to Send

Ring Indicator

USB 2.0

Description

Explanation

VCC

+5 V 2 D-

Data -

D+

Data +

GND

Ground

7 Pin Phoenix connector

Description

Explanation

GND/Shield

Ground

PWR state (10mA)

Output (optically isolated) (Output with internal series resistor 2350 Ω, 10 mA for LED control)

Only ON

Input (optically isolated) Signal starts the IPC (but can not be used for turning off)

PWR ON/OFF

Input (optically isolated) PC power button

(short press causes shutdown, pressing >= 5 s forces switch-off)

PWR COM

Ground (optically isolated) for all opto-isolated signals

24V-

Power supply – (Ground)

24V+

Power Supply +

3.4.2 D-Sub 9 serial

3.4.3 USB 2.0

3.4.4 XCI 600 Control interface

System Overview

Operating Manual ProNumeric XCI 600 Version 07/16

DVI-I

Type

Explanation

TDMS

Data 2-

TDMS

Data 2+

TDMS

Shield data 2.4

TDMS

Data 4-

TDMS

Data 4+

TDMS

DDC clock pulse

TDMS

DDC data

TDMS

V-Sync

Plug & Play

Data 1-

Plug & Play

Data 1+

Plug & Play

Shield data 1.3

Plug & Play

Data 3-

Plug & Play

Data 3+

Plug & Play

5 V

Plug & Play

Ground for 5 V

Plug & Play

Hotplug-detect

Analog

Data 0-

Analog

Data 0+

Analog

Shield data 0.5

Analog

Data 5-

Analog

Data 5+

Analog

Shield clock pulse

Analog

Clock pulse +

Analog

Clock pulse -

Plug & Play

Red

Plug & Play

Green

Plug & Play

Blue

Plug & Play

H-sync

Plug & Play

Ground

3.4.5 DVI-I interface (digital and analog)

A DVI connector is used to connect a monitor (DVI-I integrated, i.e. digital and analog): Resolution, max: 2560x1600, 16.7 million colours (DVI 1920x1200 WUXGA)

3.4.6 PCIe slot

The XCI 600 provides a PCI Express slot (PCIe 1x adapter for low profile slot). Operation requires a riser card PCI Express x1 oriented left (included in scope of supply). The PCIe slot is empty on delivery.

System Overview Operating Manual ProNumeric XCI 600 Version 07/16

Figure 3: Integrating the XCI 600 in an industrial infrastructure

(01): Corporate network (02): 2 x Gigabit Ethernet (03): Top view XCI 600 (04): External monitor, mouse and keyboard (05): Bottom view XCI 600 (06): 2 x real-time Ethernet (07): Field-bus network, Add-on card (08): Real-time Ethernet sensor / Actor

gateway (09): Field-bus sensor / Actor gateway (E.g. via optional CAN card)

(10): Sensor / Actor (11): Sensor / Actor

Note

To minimize write accesses to the SSD, Windows Embedded is used and the EWF (Enhanced Write Filter) is set by default.

3.5 Integrating the XCI 600 in an industrial infrastructure

3.6 Keyboard and mouse

3.7 SSD

3.8 Retentive memory

Keyboard and mouse can be connected to the USB interfaces. Operation without a keyboard, mouse and monitor is generally possible.

An SSD is available to save the operating systems and applications.

128 KB NVRAM are available on the XCI 600. In order not to slow down the processor unnecessarily, accesses to the NVRAM do not take place directly, but are buffered via the random access memory (SDRAM). A special background process takes over synchronization between RAM and NVRAM.

System Overview

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 4: Type-1 hypervisor

 VxWorks takes over the real-time part, i.e. execution of the PLC, CNC

and motion control functionalities.

 Without need for real-time requirements under defined system conditions,

Windows ensures straightforward functional extensibility (visualization / operation / programming / application / networking).

Hardware

Hypervisor

Windows

VxWorks

3.9 Installed software

The operating system software resp. the CNC and PLC operating software are installed on the SSD. The SSD is divided into 3 partitions (C, E, D). Drive "C" contains the Windows operating system and the system software. Drive "D" contains the Schleicher folder for the system files that are necessary for real-time operation, plus Schleicher Tools (e.g. X-Manager, Schleicher Dialog, Schleicher MFA). Drive "E" has the setup files, which can be used to reinstall programs, if necessary.

3.10 Operating systems

The XCI 600 controller incorporates a combination of VxWorks and Windows Embedded as guest operating systems under the control of a parent (Type

1) real-time hypervisor application:

The RTS real-time hypervisor takes over the exclusive allocation of processor cores and memory areas for operating multiple mutually independent operating systems. With the help of the hypervisor a separation of almost 100% is achieved, and decoupled operation of the operating systems is ensured. Windows operates in virtualized mode. On the other hand, the VxWorks operating system, crucial for PLC/CNC control, works without additional restrictions and to ensure "hard" real-time in privileged mode. The boot sequence is configurable, and it is possible to configure an independent re-boot for an operating system. The parallel-running operating systems communicate via shared memory resp. a network with virtual network cards.

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Note

The screenshots shown for the software installation and startup examples in the following chapters are only examples. Version numbers of software or unit designations may differ from the current version.

Figure 5: Wiring of 7-pin Phoenix connector

(01): Power supply with 24V auxiliary voltage (02): 24 V power supply without auxiliary voltage

4 Commissioning

Follow the commissioning instructions and ensure that the framework conditions (e.g., the I/O configurations) are maintained.

4.1 Switching on the operating voltage

The XCI 600 starts automatically when the supply voltage is applied (see section 14). The controller can then be switched on and off by briefly pressing the PC power button. In principle, it is possible at any time to hard switch off the XCI 600 by disconnecting the supply voltage or by holding the PC power button. The Enhanced Write Filter must be set to allow this. The Enhanced Write Filter is a component in the Windows Embedded 8 PC operating system. It serves to protect one or more partitions. (see: section

13.1.2)

Commissioning

Operating Manual ProNumeric XCI 600 Version 07/16

Important!

The programming software consists of the MULTIPROG 5.x software components, the OPC server, Schleicher add-ons for MULTIPROG and the Schleicher Dialog.

EC-Engineer is not a part of the software package. Before continuing with the commissioning process, all software

components must be installed one after the other in the order described below.

The programming software can be installed both on an external PC as well as on the PC of the control system. The following section describes the installation process on an external PC.

Table 2: Contents of the CDROM

Name

Contents

MULTIPROG

 MULTIPROG programming software  OPC Server

Service Pack

 Controller software for all Schleicher control units  Schleicher add-ons for MULTIPROG  Schleicher Dialog  Other tools such as documentation and service information  OPC Server

4.2 Installing MULTIPROG, Schleicher add-ons, OPC server, and ECEngineer

If ordered by the customer, the controller will be delivered with two CDROMs:

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Table 3: System requirements

Windows-PC

Pentium 4, 2 GHz

RAM

512 MB

Hard disk

330 MB free memory1

Monitor

1024 x 768 (True Color) 1

Communication

TCP/IP or RS232

Mouse

PC operating system

Microsoft Windows XP with SP3 or Microsoft Windows Vista with SP2 or Microsoft Windows 7 (32 or 64 bit) or Microsoft Windows 8 Microsoft .NET Framework 4 Client Profile

Microsoft Visual C++ 2005 3Redistributables and Microsoft Visual C++ 2008 3Redistributables.

These are the minimum requirements. Better facilities are recommended for comfortable working.

Microsoft .NET Framework 4 Client Profile is not included in the delivery.

Microsoft Visual C++ 2005 Redistributables and Microsoft Visual C++ 2008 Redistributables are included in the delivery.

4.2.1 System requirements

The following system requirements must be ensured to install and operate the software on an external PC:

Commissioning

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 6: Installation of MULTIPROG

Note

The selected installation folder must not be below C:\Programme, C:\Program Files or C:\Program Files (x86).

4.2.2 MULTIPROG Installation

Insert the MULTIPROG CD into the drive of the PC. The AutoRun.exe function in the main CD folder starts an Internet browser. Choose MULTIPROG 5.x and start the installation (see: Figure 6). It is recommended to install MULTPROG under D:\Schleicher\MULTIPROG5.

4.2.3 Installing the OPC Server

To install the OPC server, select ProConOS OPC server in the Internet browser and start the installation (see: Figure 6).

Install the OPC server under d:\Schleicher. A subdirectory named OPCxx is generated automatically. After installation, restart the PC.

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Figure 7: Installing the Schleicher add-ons for MULTIPROG

4.2.4 Installing Schleicher add-ons for MULTIPROG

Insert the Service Pack CD into the drive. The AutoRun function on the CD starts an Internet browser. Now select Schleicher Add-Ons for MULTIPROG under the heading for the existing controller and start the installation (see: Figure 7). Follow the instructions. The add-ons are installed in the MULTIPROG folder.

4.2.5 Installing EC-Engineer

The EC-Engineer program is an EtherCAT configuration and diagnostic tool. Run the separate setup program to install EC-Engineer on the target PC. A USB dongle is required to operate the program. (EC-Engineer with dongle: Article number: R4.320.0790.0) WinPcap 4.1 must not be installed, if this question should be asked during the installation.

Commissioning

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Figure 8: Installing Schleicher Dialog

4.2.6 Install Schleicher Dialog

Insert the Service Pack CD into the drive. The AutoRun function on the CD starts an Internet browser. Now, in the Internet browser, select and start Version xx.xx under the heading Schleicher Dialog (see: Figure 8). Follow the instructions.

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Important!

Before proceeding, consult the network administrator of the respective in-house network to clarify the specific features of the network and the actions to be taken.

All the identifiers and addresses stated or specified in the following installation information are examples and must be adapted by you to your local circumstances.

All examples of these instructions refer to Windows Embedded 8. The procedure for other operating systems may differ from those described here.

 A digital monitor, directly to the DVI interface X113 (or an analog monitor

via a VGA-DVI adapter).

 Keyboard and mouse, each to one of the USB interfaces X104, X105,

X106, X108, X109, X111 or X112.

 As an alternative to direct input, it is also possible to run the VNC remote

control software (page 90) via an Ethernet connection. For this purpose, connect an Ethernet cable to X107. Use the following described standard IP address (10.208.3.212, vxHost) in the PC for the initial connection with VNC.

4.3 Starting up the Network Interface

4.3.1 Preparation

To prepare commissioning of the network interface to the controller, connect the following devices:

Commissioning

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 9: Communicationschematic XCI 600

(01) Assignment of an in-house network address for connecting the

controller to an existing in-house network; the specified IP address is an example, the alias name (vxHost) is specified by the manufacturer.

(02) Change the Windows address; the specified address (192.168.212.1)

should be retained if possible.

(03) Change the VxWorks address; the specified address (192.168.212.2)

should be retained if possible; the alias name (vxTarget) is specified by the manufacturer.

(04) Set up a PC address for communication with the controller via the in-

house network (programming with MULTIPROG).

4.3.2 Communication-schematic

The XCI 600 contains the VxWorks real-time operating system and a Windows component. Both communicate with each other via a common memory (shared memory). Commissioning the network interfaces is described in four steps in the following chapter:

The X-Manager is used to simplify the adaptation of these complex settings to the local network (see: section 13.1). Manually changing selected parameters is described in the following sections.

4.3.3 Assigning a computer name for the XCI 600

To change the computer name of the XCI 600, use the Schleicher XManager (see: section 13.1).

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Important!

First clarify the adaptation of the IP addresses with your network administrator for your in-house network.

Figure 10: Run window

Important!

For the corresponding IP address, refer to the Schleicher X-Manager (see: section 13.1) on the XCI 600.

You will require administrator rights to set up the route on the external PC.

Figure 11: Setting up the network route for programming with MULTIPROG

4.3.4 Customizing the XCx-TCP/IP settings

To make the TCP/IP settings for the network card, use the Schleicher XManager (see: section 13.1).

4.3.5 Communication for programming with MULTIPROG

To use MULTIPROG for programming on an external PC, set up a network route on the respective PC. To do so, press <Windows+R> simultaneously. Type in <cmd> and confirm by pressing <OK>.

Entering an exemplary IP scheme:

route –p add 192.168.212.0 mask 255.255.255.0

10.208.3.212 (-p for permanent), confirm with <Enter>.

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Figure 12: Calling the resource settings in MULTIPROG

Use the PING command to subsequently perform a test to see whether the communication connection is working (the XCI 600 controller must be connected and started):

ping 192.168.212.2 <Enter>

Display for correct connection:

Response from 192.168.212.2: Bytes=32 Time<1ms TTL=63 Response from 192.168.212.2: Bytes=32 Time<1ms TTL=63 Response from 192.168.212.2: Bytes=32 Time<1ms TTL=63 Response from 192.168.212.2: Bytes=32 Time=1ms TTL=63

Ping statistics for 192.168.212.2: Packages: Sent = 4, Received = 4, Lost = 0 (0% Loss),

Approx. time in milliseconds: Minimum = 0ms, Maximum = 1ms, Mean = 0ms

You can now start MULTIPROG on the external PC. Select <New Project> <XCI600> (or open an already existing project. For a more detailed

description of the procedure, see section(5). In the PLC project, right-click on the entry <Resource: XCI600> and select <Settings> in the context menu (see: Figure 12).

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Figure 13: Resource settings MULTIPROG specifications

Figure 14: Entering the IP address in the hosts file

Figure 15: Entering the IP address in MULTIPROG

u = User name pw = Password

The IP addresses can be specified in the Resource settings for XCI 600 dialog box (see: Figure 15).

After creating a new project, you will find the following specifications in the resource settings:

The alias addresses vxTarget and vxHost can be maintained as they are, and then you will need to assign the appropriate IP addresses in the hosts file under Windows. You can find the hosts file under C:\Windows\System32\Drivers\etc.

It is also possible to enter the IP addresses directly:

-ip192.168.212.2 -TO2000 u=pc_cnc pw=pp ipftp=10.208.3.212

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Figure 16: Calling the connection to the XCI 600 controller in MULTIPROG

Figure 17: Resource window when there is NO online connection to the XCI 600 controller

After confirming with <OK>, the connection to the XCx 600 controller is called via <Online> <Project control> and then button Info in the Resource window (see: Figure 16).

When the 'Resource:Resource' window opens (see: Figure 18), this indicates that a connection has been established. The window can be closed again. In the case of a faulty connection, the window does not open and Timeout (see: Figure 17) is reported. In this case, check all the settings again (see: section 4.3) or consult the network administrator for assistance. Other settings may have to be considered for the subnetwork determination for gateways.

Commissioning Operating Manual ProNumeric XCI 600 Version 07/16

Figure 18: Resource window when there IS an online connection to the XCI 600 controller

First Steps with MULTIPROG

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 19: Opening a new project in MULTIPROG

Figure 20: Selecting controller type for new project

5 First Steps with MULTIPROG

5.1 Start MULTIPROG, open and save a new project

Start MULTIPROG, select File / New project (see Figure 19).

Select a project for the available controller type (XCI 600 here) and click <OK> to execute (see Figure 20).

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 21: Example for project tree in MULTIPROG

Figure 22: Calling memory dialog

Figure 23: Dialog window "Save project"

If the project is opened successfully, the project tree is displayed in the project window (see Figure 21). The project tree already contains logical POUs that are fully functional and sufficient for a simple quick startup.

Save the project under a new name under <File> <Save project as> (see: Figure 22 and Figure 23).

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Figure 24: Compile Project

Figure 25: Transferring project to the controller

(1) Click the <Project control dialog> button. Click the <Send> button in the

subsequent Resource control dialog.

(2) Under the Project heading, select Send again to overwrite the existing

project in the XCI.

(3) Use the <Cold> (cold start) button in the Resource control dialog to start

the program on the XCI.

5.2 Compiling a project and sending it to the XCI 600

To compile the project, select, <Code> <Make> (see: Figure 24) (alternatively <F9> or the <Make> button).

The message window below displays the progress of the compiler. Error messages, warnings and other information are displayed here. Click the selection box for "Errors", "Warnings", etc., to display the message in more detail. In conjunction with the XCI 600 controller, the message after the first compiler run is always a warning that says "No I/O configuration is specified". Only after the I/Os have been configured with EtherCAT®, does this warning disappear after the next compiler run. If errors are displayed, you can branch directly to the line of the PLC program that caused the error by double-clicking in the error line. Next, send the project to the controller via the Ethernet connection (see: Figure 25).

If no connection to the controller is established, check the settings (see: section 4.3).

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 26: Online display of variables

Figure 27: Information on controlling and the shared-memory version (must scroll to see)

The <Debug on/off> button can be used to display the contents of the variables on the worksheet online (see: Figure 26).

5.3 Incorporating shared memory

The shared memory is a comprehensive data structure that is used for communication between the PLC, CNC and visualisation systems. Information such as the version number and error memory can also be accessed via the shared memory. An introduction on the subject of shared memory is given on page 76. A detailed description of all variables of the shared memory is provided in the online help of the "Schleicher Dialog" software, or can be accessed via the Help menu of MULTIPROG.

To gain full access to the the predefined variables, incorporate the shared memory structure into the project. These are not yet included in the project templates of MULTIPROG. They must be incorporated into the PLC project by the user himself, with the aid of the shared-memory Schleicher add-ons for MULTIPROG.

Make sure that you work with the appropriate shared-memory variant. If you are not aware of the correct variant of shared memory, please find this information on the PC of the controller (see: Figure 27)

D:\schleicher\ram0\OS\LOG\Sysinfo.txt

Open the file Sysinfo.txt, there you will find the shared-memory version next to Version_SM. You can access the file from the service PC via UltraVNC or an FTP connection.

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Figure 28: Calling the "PLC/MC/CNC shared memory" dialog window

 Insert in configuration / Resource:

Selection of the resource of the PLC project where the shared memory variables are to be inserted.

 Version of shared memory:

Selection of the shared memory version.

 Number of CNC sub-systems / CNC axes:

Entry of the number of sub-systems and CNC axes for CNC controllers (both these edit boxes are deactivated for pure PLC controllers).

 <OK> button:

Press OK to exit this dialog window and incorporate the shared memory data types and variables in the PLC project.

 <Cancel> button:

Click Cancel to exit the dialog window and the PLC project is not changed.

Incorporating the shared memory data types and variables in a PLC project is performed via the <Extras> <PLC/MC/CNC shared memory menu see: Figure 28).

A dialog window opens with the following selection and entry options (see: Figure 29):

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 29: "PLC/MC/CNC shared memory" dialog window

Important!

The selected shared-memory version of the operating software and the version in the PLC project must match.

(see: section 10.1)

The PLC project must be recompiled and transferred to the controller after the shared memory data types and variables have been incorporated.

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Figure 30: Schleicher add-ons for MULTIPROG Figure 31: Schleicher EtherCAT configuration

use cases: 1 through 6

 Call up the "EC-Engineer" configurator.  Transfer the ENI file to the controller. This requires an FTP connection to

the controller; for the necessary settings, see section 4.3.5.

 Incorporate I/O variables and I/O configuration entries for the participants

in the EtherCAT network in the PLC project.

5.4 Configuration of the EtherCAT network

To configure and diagnose the EtherCAT network, use the EtherCAT add-on for MULTIPROG and the "EC-Engineer" configuration tool. The EtherCAT add-on is a component of the "Schleicher add-ons for MULTIPROG" (see: section 4.2.4 and 4.2.5). The EtherCAT add-on is started from MULTIPROG as follows: Select MULTIPROG menu <Extras> menu item <Schleicher add-ons …> EtherCAT configuration and <Start> (see: Figure 30).

The EtherCAT add-on for MULTIPROG performs the following tasks:

The EtherCAT® add-on offers different use cases. Figure 31 shows the possible choices that are available and briefly describes these below. For a description of the configuration procedure, see section 5.4.1. Press <Continue> to move to the starting point of the configuration process.

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

 Here, you can create a new EtherCAT configuration within the PLC

project.

 Any EtherCAT configuration already present there is deleted.  You can make changes to the EtherCAT configuration within the EC-

engineer.

 Next, you can insert the I/O variables for EtherCAT into the PLC project

and transfer the ENI file to the controller.

 After a device has been connected, removed or relocated within the EC

network (i.e. after the topology has been changed), this is where you can modify the EtherCAT configuration already existing in the PLC project.

 You can make changes to the EtherCAT configuration within the EC-

engineer.

 Next, you can insert the I/O variables for EtherCAT into the PLC project

and transfer the ENI file to the controller.

 Here you can modify the EtherCAT configuration already existing in the

PLC project after an alteration was made to the EtherCAT configuration, but no topology change was made.

 You can make changes to the EtherCAT configuration within the EC-

engineer.

 Next, you can insert the I/O variables for EtherCAT into the PLC project

and transfer the ENI file to the controller.

 Here you can transfer the EtherCAT configuration already existing in the

PLC project to the controller.

 This is necessary in the event that the PLC project is to be taken over by

another controller, and the EtherCAT configuration that it incorporates is to be taken over into this new controller without any modification.

 Next, you can insert the I/O variables for EtherCAT into the PLC project

and transfer the ENI file to the controller.

 Here you can alter the EtherCAT configuration already existing in the

PLC project without going online to the controller.

 You can make changes to the EtherCAT configuration within the EC-

engineer.

 Next, you can insert the I/O variables for EtherCAT® into the PLC project. 

 Here you can call the EC-Engineer in diagnostic mode.

(Use Case 1) Create new EtherCAT configuration

(Use Case 2) Alteration to the EtherCAT configuration when the topology is changed

(Use Case 3) Alteration to the EtherCAT configuration when the topology was not changed

(Use Case 4) Taking over an existing EtherCAT configuration

(Use Case 5) Offline alteration to the EtherCAT configuration

(Use Case 6) Diagnostics

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Figure 32: Step 1 Schleicher EtherCAT configuration

Figure 33: Step 2 Schleicher EtherCAT configuration

Figure 34: Step 3 Schleicher EtherCAT configuration

Restart the controller and only press <Continue> after the controller is powered up.

Figure 35: Step 4 Schleicher EtherCAT configuration

Now start the EC-Engineer.

5.4.1 Steps for configuring the EtherCAT network

The description given here is based on the example in Use Case 1 since it includes all possible steps. In other Use Cases not all steps are used.

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 36: Step 5 Schleicher EtherCAT configuration

Now you can re-read the configuration under <Network> <Browse EtherCAT Network> and the slave modules are displayed. see: Figure 37) This requires that the EtherCAT® modules must be supplied with power and that they are connected to the controller. The ESI must be present so that the modules can be detected.

Figure 37: Browsing EC-Engineer EtherCAT network.

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In most cases, the ESI file will be present; if the file is not present, proceed as follows. You can add the file with the ESI administration (see: Figure 38). The ESI data are provided by the manufacturer of the slave modules.

Figure 38: EC-Engineer ESI administration

The existing ESI files are displayed in the <File> menu and <ESIAdministration> (see: Figure 39). To add a new file, click on <Add file>.

Figure 39: EC-Engineer ESI file list

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

The location of the ESI file must be known. Select the appropriate file and accept it with <Open>.

Figure 40: EC-Engineer ESI file manufacturer list

Now you can re-read the configuration under <Network> <Browse EtherCAT Network> and the slave modules are displayed. see: Figure 37) Terminate the EC-Engineer and save the project. The system returns you to the Schleicher add-on.

Figure 41: Step 7 Schleicher EtherCAT configuration

Click on <Continue> to move to the next window.

Figure 42: Step 8 Schleicher EtherCAT configuration

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You can take over the configuration into MULTIPROG by pressing <Continue> (see: Figure 43). If you want to transfer the ENI file to the controller, it gets stored on the controller in the following path: /OS/EC/eni.xml

Figure 43: Step 9 Schleicher EtherCAT configuration

If a new configuration was created, you need to close the window with <Finish>. Next you must compile the PLC project, transfer it to the controller and then restart the controller.

Figure 44: Step 10 Schleicher EtherCAT configuration

The controller can be restarted with <Start XCI 600> in the Multi Function Application (MFA) (see page: 50).

Note!

A detailed description of the EC-Engineer is available online in the ECEngineer under <Help><Display User Manual> .

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 45: EtherCAT configuration when the topology is altered

In the event that the topology is altered, the ENI file must be deleted at this point.

Figure 46: EtherCAT configuration, deleting the ENI file

After completing the steps that you already learned from section 5.4.1, start the EC-Engineer. In order to avoid losing the alterations in the existing master, it is necessary to temporarily introduce another master. To do so, successively click <File> and <New Master Module> to insert the new master.

Figure 47: Inserting a new master module.

The new master had now been inserted into the configuration.

5.4.2 Alteration to the EtherCAT configuration when the topology is changed

This Use Case is described separately, otherwise changes in a configuration as described in section 5.4.4 may be lost.

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Figure 48: Inserting a second master module.

The second master must be given the same IP address as the first. If you have entered the address, select the master with <Select> out.

Figure 49: Assigning an IP address to the Master Module.

Only after the above steps have been completed, should you browse through the EtherCAT network again for the inserted slave modules.

Figure 50: Browsing EtherCAT network.

The new slave module was detected and inserted in the area of the second master.

Figure 51: Newly inserted slave module in the EtherCAT network

Mark the new slave module and copy it with the right mouse button.

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Figure 52: Copying a slave module.

Mark the upper slave area and use the right mouse button to insert the slave module.

Figure 53: Inserting a slave module

The new slave module is thus assigned to the first master, and the second master can now be deleted. Terminate the EC-Engineer and save the alteration. The remaining procedure is identical to section 5.4.1.

Figure 54: Completing the configuration alteration

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Figure 55: EtherCAT variables in MULTIPROG.

Important!

Renaming the EtherCAT variables must be done with the EC-Engineer, not with MULTIPROG.

Figure 56: EtherCAT configuration without alteration to topology

5.4.3 The EtherCAT variables in MULTIPROG

It is recommended to assign the EtherCAT variables in the I/O configuration of MULTIPROG to the tECIO task (see Figure 43). When <Insert EtherCAT configuration into the SPS project> is selected, the variables are inserted into the project (see: Figure 43). The ECIO_Variables group is reserved for the EtherCAT® add-on. All variables already existing in this group are overwritten by the add-on. You should thus not insert any of your own variables into this group and also make no other changes.

5.4.4 Renaming EtherCAT variables

If you want to assign your own names for the EtherCAT variables, proceed as follows. Start <EtherCAT configuration without alterations to topology>

First Steps with MULTIPROG Operating Manual ProNumeric XCI 600 Version 07/16

Start the EC-Engineer.

Figure 57: Starting the ECEngineer to alter the names of variables.

Select the slave area or a slave module. Then click on the tab <Variables>. Select the variable that you want to rename and click <Edit> .

Figure 58: EC-Engineer editing the variable names.

Now you can enter your own variable names. If the variable name is preceded by <@>, the name will also change in MULTIPROG; without <@>, the name is only changed in the comment.

Figure 59: EtherCAT variable name.

After making all alterations, save the project.

Figure 60: Save the EtherCAT variable names

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From here, you can follow the procedure described in section 5.4.1. In MULTIPRO you will find the variable names under <Global_Variables>. Here you can see that the variable names were once taken over just in the comment and once they were taken over completely.

Figure 61: EtherCAT variables in MULTIPROG.

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Figure 62: Taskbar with Schleicher logo

Figure 63: The MFA window

(1)

Menu For an explanation, see "MFA functions".

(2)

Message area With information on memory, real-time operating system and controller software.

(3)

Buttons

(4)

Status Information on PLC status.

6 Operation

6.1 Multi Function Application (MFA)

The MFA tool provides a means for adjusting the behaviour of the controller during start-up and forms the basis for operating the controller.

6.1.1 Starting the Schleicher MFA

The Schleicher MFA starts automatically when the controller is booted up, and it is then placed into the system tray of the taskbar (see: Figure 62). If the MFA programming window is not visible, it can be viewed by doubleclicking the blue Schleicher logo.

6.1.2 The MFA window

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Operating Manual ProNumeric XCI 600 Version 07/16

Figure 64: MFA, "Control system" menu

Figure 65: MFA, "Startup mode" menu

6.1.3 MFA functions

"Control system" menu

Menu items Start ... / Stop ... are used to start and terminate the real-time operating system. The function of menu item <Shut down the control system> corresponds to that of the button with the same name. The controller software including the PC operating system is shutdown and the controller is switched off. The MFA can only be terminated via menu item <Exit Schleicher MFA>.

"Startup mode" menu

In the <Startup mode> menu, you can set how the PLC behaves after controller startup. A detailed description of the start behaviour is given in section "The PLC" (see section 6.1.5 or 7.2).

Operation Operating Manual ProNumeric XCI 600 Version 07/16

Figure 66: MFA, "PLC" menu

Figure 67: MFA, "Extras" menu

"PLC" menu

"Extras" menu

The <PLC> menu can be used to start and stop the PLC. The behaviour is described in detail in section "The PLC" (see: section 7.2).

The condition of a UPS (uninterruptable power supply) that may be connected via a USB port is displayed and tested in the <Extras> menu. UPS devices made by Messrs. Eaton are currently supported.

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Figure 68: MFA, Menu "?"

Note

The log files are intended primarily to support diagnosis by the controller manufacturer.

"?" Menu

The MFA documentation can be called via the ? menu. The help file contains information on the program settings and command line parameters as well as programming examples. The Display BootLog menu item displays the Bootlog file of the real-time operating system VxWorks.

6.1.4 Log files

There are two types of log files, BootLog_xx.txt and LogBook_xx.txt.

 The BootLog_xx.txt file is used to record the controller's boot-up

process.

 The Logbook_xx.txt file is used to record the error history.  These log files are updated at bootup time or every 24 hours.

The log files are generated with each restart of the controller. If the controller is in continuous operation, the LogBook file is generated every 24 hours. The storage intervals can be set between 0 and 256 hours. When set to "Zero", no files are created. The files are assigned a numerical index, which is incremented by one whenever the data is saved. The maximum number is limited to 99 files. The default setting is 10 files. All specifications can be altered in the Schleicher Dialog under

Inbetriebnahme/Boot-Einstellungen/Sonstige Einstellungen) (Translation: startup/boot-settings/other settings).

Memory location and name of file:

SCHLEICHER/Os/Log/BootLog_xx.txt SCHLEICHER/Os/Log/LogBook_xx.txt

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Figure 69: Basic initialisation MFA setting

Figure 70: Examples of error messages after basic initialisation

 NVRAM is reset.  The NVRAM backup files (SRamBackup1.txt, SRamBackup2.txt) are

deleted.

 The SPS Boot project is not loaded.  The PLC does not start.

6.1.5 Basic initialisation

To maintain operation of the real-time operating system under conditions of faulty PLC projects, Q parameters or invalid data in the retentive data memory (e.g. when the buffer battery fails), the controller can use basic initialisation to boot up in safe mode.

Basic initialisation can be selected in the <Startup mode> menu with setting <PLC init>. After the real-time operating system has started with <Start XCI 600>, this setting is reset to <PLC stop".

The following actions are performed during basic initialisation:

After selecting PLC init, the controller must be restarted with <Start XCI 600>. No PLC project is loaded (PLC status: On). MULTIPROG can then be used to transfer a project to the controller (see: section 5.2). The Schleicher Dialog displays an error message (see: ). Figure 70). Confirm this error message with <Acknowledge>. Next, use the MFA tool in the <Startup mode> area to switch to <PLC cold start> and restart the controller under <Control system> <Start XCI 600>. The PLC status changes from (PLC status: On) to (PLC status: Run). After the entire process, the controller can be reset to <PLC warm start> (see: section 6.1.3).

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Figure 71: Schleicher Dialog, startup window

Table 4: Schleicher Dialog, structure of the user interface

Area

Meaning

(1)

Status and messages

(2)

Workspace for settings and information

(3)

Hints

(4)

Softkeys with functional information

6.2 Schleicher Dialog

Schleicher Dialog provides tools for commissioning, parametrizing and diagnosing Schleicher controllers. Schleicher Dialog has been factoryinstalled on the controller and starts automatically after the controller has booted up.

6.2.1 Structure of the User Interface

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Figure 72: Schleicher Dialog, status and messages area

Table 5: Schleicher Dialog, status and messages area

Area

Meaning

(1)

Current mode of operation of the CNC

(2)

Selected CNC sub-system

(3)

Current status of the CNC

(4)

Error display

(5)

Current position in controller menu

(6)

PLC status

(7)

Date and time

Figure 73: Schleicher Dialog, Control menu

Manual mode <Ctrl+F1>

Automatic <Ctrl+F2>

Programming <Ctrl+F3>

Access authorization <Ctrl+F4>

Start external software <Ctrl+F5>

Startup <Ctrl+F6>

Error page <Ctrl+?> or <Ctrl+I>

This button always takes you back one control level.

6.2.2 Schleicher Dialog PLC/CNC

Control menu and control areas of the XCI 600

The highest level of the controller menu consists of the operating elements that are oriented towards important activities for the machine (manual mode, automatic, programming, etc.). They are called with the key combination <Ctrl + Function key>.

Associated options are called using the subordinated softkey level (function keys F1..F8). Softkey F1 is always used for calling help pages. The help page contains further information on the content of the subsequent operating levels.

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Manual mode <Ctrl+F1>

Help

Referen-

cing

Procedure

Subsystem

Axes

Jog Incremental

Target value

specification

Handwheel

Axis

Rapid feed

Zero set

Override

Automatic <Ctrl+F2>

Help

Program

Subsystem

Activate

MDI Single record

Block record

Record sequence

Rapid feed

Override

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Programming <Ctrl+F3>

Help

CNC

programs

parameters

Tool data

Zero offsets

Coordinate

systems

Edit program

Change value

New program

Edit

Activate program

New

Copy program

Entry up

Delete

program

Entry down

Program

properties

Delete New Project

Sort

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7 The PLC

7.1 Programming

The XCI 600 is programmed on a PC using the MULTIPROG programming software according to IEC 61131-3.

The programming system and programming instructions can be ordered as accessories. The PLC is supplied with a ready-configured project, which you can use as the basis for programming the PLC (see: section 5).

7.2 PLC Operating states and Start behaviour

7.2.1 Operating states

Table 6: PLC Operating states

The current state of the PLC is displayed in the project control dialog in the Status line in MULTIPROG. If “debug” is displayed behind the current state in the control dialog it means that breakpoints have been set or variables forced.

The PLC

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 74: MULTIPROG, changing operating states

State change from  to

Button in control dialog

Description of what happens

Stop  Run

 Cold start  All data is initialised  SPG 1 is called  All user tasks are activated  Program execution activated

Stop  Run

 Warm start  Only non-buffered data is initialised  SPG 0 is called  All user tasks are activated  Program execution activated

Stop  Run

 Hot start  No data is initialised  All user tasks are activated  Program execution activated  Not available when you start program execution for the

first time after downloading

State change from  to

Button in control dialog

Description of what happens

Run  Stop

 All user tasks are deactivated when their operating cycle

is complete

 SPG 2 is called  Process map memory outputs are written  Program execution stops  Physical outputs are set to zero or preferred shut-off

state

7.2.2 Change the Operating States with MULTIPROG

You can use the graphic user interface of MULTIPROG to control when program execution on the PLC starts and stops. The buttons for changes which are not possible in the current operating state are shaded in the project control dialog (see: Figure 74).

Start program execution

Table 7: MULTIPROG, start program execution

Stop program execution

Table 8: MULTIPROG, stop program execution

The PLC Operating Manual ProNumeric XCI 600 Version 07/16

State change from  to

Button in control dialog

Description of what happens Stop  On

 The project is deleted  General reset

Name

Data type

Description

PLCMODE_ON

BOOL

TRUE := current PLC state is ON

PLCMODE_RUN

BOOL

TRUE := current PLC state is RUN

PLCMODE_STOP

BOOL

TRUE := current PLC state is STOP

PLCMODE_HALT

BOOL

TRUE := current PLC state is HALT

PLCDEBUG_BPSET

BOOL

TRUE := one or more breakpoints have been set

PLCDEBUG_FORCE

BOOL

TRUE := one or more variables have been forced

PLCDEBUG_POWERFLOW

BOOL

TRUE := powerflow active

PLC_TICKS_PER_SEC

INT

Number of system ticks per second, used by the PLC as the basis for the system time. This value determines the time resolution of the PLC for time delay function blocks like TON, TOF and TP, and the shortest cycle time for the DEFAULT task and cyclical tasks.

PLC_SYS_TICK_CNT

DINT

Number of counted PLC system ticks

PLC_SYS_TICK_256ms

BOOL

Switching with 0.25s clock

PLC_SYS_TICK_512ms

BOOL

Switching with 0.5s clock

PLC_SYS_TICK_1024ms

BOOL

Switching with 1s clock

General reset

Table 9: MULTIPROG, general reset

7.2.3 PLC starting behaviour after power supply is switched on

The PLC startup-behaviour is set using the MFA Tool (see: Figure 65)

7.3 System variables

System variables provide information about the status of the system, for example about forced variables, etc. These variables have fixed memory addresses and can be used by the PLC program to obtain the corresponding information. All the system variables in the following table are already declared in the Global_Variables area of the Global_Variables worksheet.

Table 10: System variables

The PLC

Operating Manual ProNumeric XCI 600 Version 07/16

Important!

The latest version of the libraries that match the controller operating system must always be used.

Table 11: Libraries and Function blocks in MULTIPROG

Libraries

XCA 11xx

XCN 8xx

XCS 8xx

XCN 7xx

XCS 7xx

XCI 6xx

XCI 6xxP

XCN 4xx

XCS 4xx

Simulation

PROCONOS

+ + + + + + + + + + BIT_UTIL

+ + + + + + + + + + CANopen_Vxxx

+ + + + + – – + + – CFB_Vxxx

o o o o o o o o o – CNC_Vxxx

+ + – + – + – + – – CIFSYS

o o o o o – – o o – Date_Time

+ + + + + + + + + – EtherCAT®

* * * – – + + – – – MC_Vxxx

– – – o – – – – – – MMI o o o o o o o o o –

PLC_Vxxx

+ + + + + + + + + – Profibus_Vxxx

o o o o o – – o o – SchleicherLib_Vxxx

+ + + + + + + + + – Serial o o o o o o o o o –

XCx7_Vxxx

+ + + + + – – + +

–

+ Are automatically incorporated when a new project is created. o Can be incorporated manually as needed. – Not possible or unnecessary. * In preparation.

7.4 Libraries and Function blocks in MULTIPROG

Function blocks are combined in libraries. They are automatically integrated according to the controller type when a new MULTIPROG project is created or can be manually integrated if required. There are firmware libraries with the extension "fwl" and user libraries with the extension "mwt". The firmware libraries are supplied by Schleicher and are part of the Schleicher add-ons. Users themselves can create user libraries, Schleicher only provides SchleicherLib_Vxxx.

The PLC Operating Manual ProNumeric XCI 600 Version 07/16

Figure 75: MULTIPROG, context menu "Libraries" or "Firmware library"

Figure 76: MULTIPROG, "Integrate library" dialog window

Figure 77: MULTIPROG, Integrate "Serial" library

 Use the right mouse key in the MULTIPROG project tree to open the

context menu Libraries / Insert / User library (see: Figure 75).

 Use the right mouse key in the MULTIPROG project tree to open the

context menu Libraries / Insert / Firmware library (see: Figure 75).

Function blocks can be integrated as follows:

Select the appropriate file and integrate it (see: Figure 76).

Each library is stored in a separate path. For example, if the Serial library is to be integrated, it must be selected in the library path with the same name. (see: Figure 77)

PLC Operating System ProConOS

Operating Manual ProNumeric XCI 600 Version 07/16

Note!

Online help is available for the libraries (except SchleicherLib) (see: Figure 78). The online help can be accessed via the context menu of the respective library. The context menu is active by right clicking on the icon of the library.

Figure 78: MULTIPROG, Online help for the libraries

Note! The entries in the ProConOS.ini can be adjusted within the Schleicher

Dialog.

7.4.1 Information on the Variable Declarations of the Example Programs of

8 PLC Operating System ProConOS

8.1 ProConOS.INI initialisation file

FBs

The example programs for the function blocks contain variable declarations to IEC 61131-3 with keywords VAR and END_VAR. If you wish to use the example programs with MULTIPROGRAM, you have to enter the variable declarations manually, in tabular form on the variables worksheet of the respective POU.

The ProConOS.INI file can be used to make application-specific advanced settings (e.g. for communication drivers, for system tasks, for the web server and the fieldbus stacks). If ProConOS.INI does not exist or has been deleted, the file is created with default values when the controller software starts up. Path of the file on the drive: D: /Schleicher/OS/PLC/ProConOS.INI

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

Figure 79: Multi-task system, priority levels

Please note!

Incorrectly or inappropriately selected user task settings for type, priority, interrupt mode – especially in conjunction with longer program runtimes – can lead to controller malfunction, because essential operating system tasks are displaced.

Make sure to observe the description in section Task priorities (Table

14).

9 The multi-task system

9.1 Overview

This is based on a real-time operating system controlled by task priorities. The MULTIPROG programming system is used to assign a program to a task. On the other hand, different priority levels and times are assigned to the tasks to ensure that the order in which they are processed and the time taken for processing is in accordance with their importance. There are three priority levels for tasks. (see: Figure 79)

9.2 Monitoring task

The monitoring task is a high-priority, specially protected operating system task that identifies errors such as zero divide, or exceeding the execution time of a task.

9.3 User tasks

User tasks are all tasks that can be incorporated by the application programmer. The user tasks are time-monitored (Watchdog). A number of important firmware tasks, which must be considered when parametrizing user tasks, also run at this level (see: section 9.5). The default task is also on the user task level. It is the user task with the lowest priority. The default task is executed when no other user task is active.

The multi-task system

Operating Manual ProNumeric XCI 600 Version 07/16

9.3.1 Cyclical tasks

Cyclical tasks execute the programs assigned to them within a defined interval under a user-defined priority. In MULTIPROG you can give the individual tasks a priority between 0 and

31. Task 0 has the highest priority, task 31 the lowest. The task with the highest priority is called first. The user-task priorities (Table 14) are mapped to the priority levels of the real-time operating system (see: section 9.5). If the watchdog time of a cyclical task is higher than the set interval time and task execution has not been completed, one or more execution cycles will be omitted.

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

Internal designation

Event No.

Remarks

Interrupts

PLC_EVENT_XFIO_I0

0x00

XFIO Interrupt (Input 0, XCx 3/5)

PLC_EVENT_XUIO_0

0x00

U-Bus Interrupt 0 (XCx7, UBE32 0,1I input 0)

PLC_EVENT_XFIO_I1

0x01

XFIO Interrupt (Input 1, XCx 3/5)

PLC_EVENT_XUIO_1

0x01

U-Bus Interrupt 1 (XCx7, UBE32 0,1I input 1)

PLC_EVENT_XUIO_2

0x02

U-Bus Interrupt 2 (XCx7, UBE32 0,1I input 2)

PLC_EVENT_XUIO_3

0x03

U-Bus Interrupt 3 (XCx7, UBE32 0,1I input 3)

Synchronisation

PLC_EVENT_POS

0x04

Position controller task (XCN only)

PLC_EVENT_CAN

0x05

- CANopen- Task,

PLC_EVENT_IPO

0x06

CNC IPO task (XCN only)

PLC_EVENT_DECO

0x07

CNC DECO task (XCN only)

PLC_EVENT_S3 PLC_EVENT_MCSIO

0x08

- Sercos III task, I/O driver synchronization

PLC_EVENT_ECIO

0x09

EtherCAT®, IO driver synchronization

PLC_EVENT_XFIO_I10

0x0A

Measurement interrupt active 0

PLC_EVENT_XFIO_I11

0x0B

Measurement interrupt active 1

Reserved

0x0C

Reserved

0x0D

Reserved

0x0E

PLC_EVENT_AC_FAIL

0x0F

AC Fail (ProNumeric)

9.3.2 Event tasks

Event tasks are started by the operating system when particular events such as an interrupt signal, a CANopen task or an IPO task occur. The following events are currently defined.

Table 12: Multi-task system, event tasks

The event number is used in the MULTIPROG task setting to specify the event that starts the event task. The specified priority is used unless a bypass option is set by the system. (Bypass cancels the normal task change so that the assigned programs are executed immediately when the event occurs.) Up to 16 events will be put in a queue. So these events are not lost, and will be executed later. This also applies if new events occur before the assigned event task is executed.

The multi-task system

Operating Manual ProNumeric XCI 600 Version 07/16

Note

All drivers in the I/O configuration that are not explicitly assigned to a user task automatically activate the default task and are executed in the context of the default task.

9.3.3 Default task

The default task runs as a background task with the lowest possible user priority and is not time-monitored. It is activated when all higher-priority user tasks have been processed. The default task is configured so that it only uses some of the available residual time. Only one default task is permitted in each resource. It is recommended only to use cyclical tasks.

9.3.4 Operating system tasks

Tasks running at the priority level of the operating system include tasks for communication, debugging, memory management and system control, unaffected by the user.

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

No.

Name

Event

Actions

SPG 0

WARM_START

Is executed during a warm start

 Retentive data is not initialised  Non-buffered data is initialized  The open function of the I/O driver is

executed

 User tasks are activated  PLC switches to run status

SPG 1

COLD_START

Is executed during a cold start

 All data is initialised  The open function of the I/O driver is

executed

 User tasks are activated  PLC switches to run status

SPG 2

TO_STOP

Is executed when program execution is stopped

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 10

WATCHDOG

Is executed when a task has not been completed within its watchdog time

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 11

ZERODIV

Is executed if division by zero occurs during program execution

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 12

STACKOVER

Is executed if a stack overflow has occurred. Is only executed if the

“Stack-Prüfung” [“Stack check”] checkbox in the “Ressource ... einrichten” [Resource ... Set up] dialog

in MULTIPROG was activated.

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 13

BADCAL

Is executed if a non-existent manufacturer-specific POU is called

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 14

IOERROR

Is executed if an error occurs in the I/O driver while the process is running

 PLC continues execution

SPG 16

MATHERR

Is executed if a sliding point error occurs in an arithmetic function

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

9.3.5 System tasks

System tasks and system programs (SPGs) are started automatically by the operating system when an event occurs in connection with the operating system. The SPGs which can be used are listed in the following table:

The multi-task system

Operating Manual ProNumeric XCI 600 Version 07/16

No.

Name

Event

Actions

SPG 17

CPU_OVERLOAD

Is executed if a CPU overload occurs

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 18

INITIODRV_ERR

Is executed if an error occurs in I/O driver initialization during a cold or warm start

 PLC does not start

SPG 19

BOUNDS_ERR

Is executed if the limits of an array or a structure are exceeded. Is only

executed if the “Index-Prüfung” [“Index check”] or “Feldbegrenzungs-Prüfung” [“Array limit check”] checkbox in the “Resource ... einrichten” [Resource ...

Set up] dialog in MULTIPROG was activated.

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 20

BUS_ERR

Is executed if variables with a data type  2 bytes and uneven addresses were used or an internal error has occurred in MULTIPROG. Only on Motorola platforms.

 User tasks are deactivated  All outputs are updated  The close function of the I/O driver is

executed

 PLC switches to STOP

SPG 21

STRING_ERR

Is executed if an error has occurred in a character string operation, e.g. if one character string is to be replaced by another, but cannot be found.

 The behaviour of a character string

exception has changed! In the standard setting SPG 21 is called after a character string exception has occurred. An entry with the module number and line number is also made in the error catalogue. The PLC remains in “RUN” status.

Note

System tasks are not monitored by the watchdog.

Table 13: Multi-task system, system tasks

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

Type definition

Remark

TYPE

TaskNameType : ARRAY [1..10] OF BYTE;

END_TYPE

TYPE

TaskInfoType0 : STRUCT

MaxTask : INT; (* 00: *)

Max. poss. number of tasks

CurTask : INT; (* 02: *)

Current number of tasks

END_STRUCT (* TaskInfoType0 *);

END_TYPE

TYPE

TaskInfoType1 : STRUCT

TaskName : TaskNameType; (* 04: *)

Task name

TaskPrio : INT; (* 14: *)

Task priority

TaskMode : INT; (* 16: *)

Task mode

TaskPeriod : INT; (* 18: [ms] *)

Task period in ms

TaskStack : INT; (* 20: *)

Size of used task stack

MainPoe : INT; (* 22: assigned PLC program *)

assigned PLC programm

TaskWatchDog : INT; (* 24: [ms] *)

Watchdog time in ms

reserve0 : DINT; (* 26: *)

MaxStack : INT; (* 30: max. used stack *)

Size of poss. task stack

CurDuration : INT; (* 32: [ticks] *)

Current task duration including prioritized calls

MinDuration : INT; (* 34: [ticks] *)

Minimum task duration

MaxDuration : INT; (* 36: [ticks] *)

Maximum task duration

AveDuration : INT; (* 38: [ticks] *)

Average task duration

CurDelay : INT; (* 40: [ticks] *)

Current task delay

MinDelay : INT; (* 42: [ticks] *)

Minimum task delay

MaxDelay : INT; (* 44: [ticks] *)

Maximum task delay

AveDelay : INT; (* 46: [ticks] *)

Average task delay

END_STRUCT (* TaskInfoType1 *);

END_TYPE

9.4 User task information

Information is mapped to system variables for each user task. The type definitions listed below for the system variables can be found in the PLC_Types section of the SchleicherLib library.

The multi-task system

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 80: Multi-task system, Variable declaration

The variables are declared with types TaskInfo 0 and TaskInfoType n (see: Figure 80). Each TaskInfoType contains information about a task of the project.

The following user task information is declared with an offset of 64 starting at 1004 (1004 + 64 = 1068 etc.). The sequence of tasks is defined by the rank of the task under the Hardware structure/Configuration/Resource/Tasks project tree.

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

Warning!

Incorrectly or inappropriately selected user task settings for type, priority, interrupt mode, etc. – especially in conjunction with longer program runtimes – can lead to controller malfunction when essential firmware tasks are displaced (tfwLAGE, tfwCANhigh, tfwIPO).

Check and adapt the task assignment and task time setting

MULTIPROG priority

RTOS* priority(defau lt)

RTOS * Task name

Application

Any

e.g. User task (event 0)

Any

e.g. User task (event 1)

Any

e.g. User task (event 4)

tfwLAGE

Reserved for position controller task (XCN only)

Any

e.g. User task (event 5)

tfwCANhigh

Reserved for CANopen task

Any

e.g. User task (event 5, 6)

tfwIPO

Reserved for IPO task (XCN only)

8..15

38..45

Any

E.g. cyclical user tasks

16..31

Any

E.g. other cyclical user tasks

Default

127

default

Background task

Real-time Operating System

Note

The system supports 18 user tasks (priority levels 0..16 and the default task).

9.5 Task priorities

The table gives an overview of recommended task priorities and their relationship to important reserved firmware tasks (tfwLAGE, tfwCANhigh, tfwIPO).

Table 14: Multi-task system, Task priorities

The multi-task system

Operating Manual ProNumeric XCI 600 Version 07/16

Note

If the execution time of the task and the watchdog time are roughly the same, and the CPU workload is high, the watchdog time may be exceeded during certain online operating steps.

The reason for this behaviour may be that you selected address status with powerflow when debugging in online mode.

Figure 81: Multi-Task System, Example for tasks and watchdogs

9.6 Tasks and watchdogs

Each user-defined task has its own settable watchdog. The watchdog checks that task execution has been completed by the end of the watchdog interval. If task execution is not complete at the end of this time the system task SPG 10 'WATCHDOG' is executed and the PLC switches to the 'STOP' state if no other actions were programmed. An entry is also made in the error catalogue. The watchdog time starts when the task is ready to execute. The watchdog interval is defined in the “Task ... Settings” dialog in MULTIPROG.

Example

In example 1 the watchdog time of the displayed task is set to 10 ms. In the figure, the watchdog time is exceeded in the second cycle after 20 ms. Task execution is interrupted and the "Watchdog" system task is called. In example 2 the watchdog time is set to 20 ms. For this reason, it does not address the time overrun of the task in the second cycle. The task is only interrupted for the next cycle, and is performed again at 30 ms in the fourth cycle.

The multi-task system Operating Manual ProNumeric XCI 600 Version 07/16

Figure 82: Multi-Task System, Inserting a task in MULTIPROG

Table 15: Multi-task system, Task parameters

Task

Parameter

Cyclical task

Time interval

Event task

Event number (number of interrupt)

System task

Number of a system program

Default task

Active only when no other task is running.

 In the project tree under the resource for the respective controller, right

click on the Tasks folder to open the context menu (see: Figure 82).

 Select the Insert/Select task menu item. The Insert dialog appears.  Enter the name for the task.  Set the required task type in the Task Type list.

You can choose between Default task, Cyclical task, Event task or System task. Note: If task type 'DEFAULT' is not listed, the resource already has a default task.

 Confirm the dialog with OK.

9.7 Inserting Tasks and Assigning Programs

Inserting tasks

To insert a task, you have to carry out the following steps in MULTIPROG:

The Task settings for ... dialog appears. The dialog contains text and list fields, depending on the previously selected task. You have to enter the following parameters for the task:

The instructions in section Task priorities (Table 14) must be observed when assigning priorities. Programs must be assigned to tasks before they can be executed. Assigning a program to a task means that an instance of the program will be executed when the task is activated. Different instances of a program can be assigned to different tasks. Several programs can be assigned to one task. In this case the first program in the task directory will be executed first. Then the next program will be executed, and so on.

The Shared Memory

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 83: Multi-Task System, Assigning programs in MULTIPROG

Figure 84: Shared memory as a connection of PLC and CNC

 Click with the right mouse button on the project tree icon of the task in

which the program is to be inserted. (see: Figure 83)

 Select Insert/Program instance in the context menu.  Enter an instance name for the program in the Program instance field.  Set the required program in the Program type list box.  Confirm the dialog with OK.

 There are no waiting times or communication overhead.  The PLC can monitor all actions of the CNC  The CNC output setpoints via the PLC.  The PLC can specify the CNC management sizes in the position control

cycle

Assign programs

To insert programs you have to carry out the following steps in MULTIPROG.

The program symbol is inserted in the project tree.

10 The Shared Memory

The shared memory connects the sequence control of the PLC and the motion functions of the CNC. Both controller systems operate synchronously for data exchange on the memory and the PLC can take on a master function. Visualisation systems are also integrated in the communication process via OPC.

The close link between the CNC and the PLC system now enables you to carry out complex processes which would not be possible with separate CNC and PLC controllers. The classic PLC interface enables PLC functions in NC programs, e.g. the setting and requesting of PLC flags. The synchronisation of the PLC task with the CNC position control provides further options:

The Shared Memory Operating Manual ProNumeric XCI 600 Version 07/16

Figure 85: Reading out the operating software version

10.1 Information on the Selection of the Shared memory Version

The shared memory structure is updated or expanded from time to time by Schleicher. A version number is used to distinguish the individual variants. The version number is incremented when there are significant changes to the shared memory structure, and these changes make it necessary to alter the address of variables. For this reason, shared memory versions with different version numbers are incompatible. Compatibility is only ensured for matching version numbers. The latest shared memory version must always be used. However, if the controller has old operating software, the appropriate older shared memory version must be used. The version of the controller operating software can be displayed in the Info dialog window (3) for the corresponding resource in the PLC project (via (1) <Project control dialog>, then (2) in the Resource window Info) (see: Figure 85).

The Shared Memory

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 86: Display of the shared memory error message in the Schleicher Dialog

10.2 Variables and Tasks

10.3 Access to the Shared memory

If the shared-memory version of the operating software and the version in the PLC do not correspond, an error message is entered in the error memory when the PLC starts. This error message is displayed in the Schleicher Dialog as follows.

If such an error message appears, the PLC project must be corrected by inserting the data types and variables for the appropriate shared memory version. Next, the PLC project must be recompiled and transferred to the controller.

Shared-memory data takes the form of variables as per IEC 61131-3, which are declared as global variables during configuration in the MULTIPROG programming system. They are accessible to the OPC server by default and, for example, they are used by the Schleicher Dialog operating tool. In the multi-tasking operating system, PLC task 6 is synchronised with the interpolation task of the CNC controller. The cycle time of task 6 is then oriented on the interpolation cycle of the CNC.

The data structure of the shared memory is created during installation of the PLC or CNC operating system. For pure PLC, only the variable areas for PLC specification and errors are created (plcSect and errSect, see below). The PLC program has access to the entire shared memory via the global variable plcMem (for PLC controllers) or cncMem (for CNC controllers). The individual components of the shared memory can be accessed by using dot notation. For example, the PLC program can read the version number of the controller operating software as follows: cncMem.plcSect.lOSVersion. Visualisation systems have access to the shared memory via the OPC interface. For example, the version number of the operating software can be read from the OPC variables cmpS_lOSVersion. The individual components for read and write access (e.g. version numbers, error messages, bit signals, word ranges, NC data, CAN data, etc.) are combined in sections. The retentive variables (retain) occupy their own sections.

The Shared Memory Operating Manual ProNumeric XCI 600 Version 07/16

 PLC-specific section plcSect  Error section errSect  General section comSect  General section (retain) comSect  System section sysSect  System section (Retain) sysSect  Axis section axSect  Axis section (Retain) axSect

You can access the individual sections and components of the shared memory with the Globale_Variable.Section.Components notation. For example, the PLC program can read the version number of the controller operating software from the cncMem.plcSect.lOSVersion variables. For more information about the integration of shared memory into the MULTIPROG programming system, see page 33. Visualisation systems have access to the shared memory via the OPC interface. The OPC server cannot handle structured variables, so the whole data structure of the shared memory is mapped out as a one-dimensional list. The names are composed of two parts separated by an underline from each other. The first part is the access path, while the second part is identical to the component name of the PLC variable. For example, the version number of the operating software could be read from the OPC variables cmpS_lOSVersion.

10.4 Help about Shared Memory

A more detailed description of the shared memory structure and all versions can be accessed via the online help in both MULTIPROG and Schleicher Dialog.

The Shared Memory

Operating Manual ProNumeric XCI 600 Version 07/16

 TheSharedMemory_Types data type worksheet; the data structure of the

shared memory is declared here.

 The global variables plcMem(for PLC controllers) or cncMem(for CNC

controllers). See worksheet Global_Variables, group SharedMemory_Variables. These variables represent the complete non-retentive (non retain) section of the shared memory. The PLC program can access the individual components (variables) of the shared memory using dot notation as explained above. With shared memory version 8 or higher, there is a retentive (retain) section of the shared memory as well as the non-retentive section. Unlike the non-retentive section, the values of the variables of this section are retained after switching off the controller. For this purpose, the global variable cncRMem is additionall inserted.

 The global variables cmpS..., cmeS..., cmcS..., cmsS...,

cmaS.... See worksheet Global_Variables, groups PLC_Common,

CNC_Common, CNC_System_x (x stands for the number of the CNC sub-system. Such a group exists with system-specific variables for each sub-system) and CNC_Axis_y (y stands for the number of CNC axis. Such a group exists with axis-specific variables for each CNC axis). These variables are provided for the visualisation systems or similar programs to access the shared memory. They provide all the shared memory via the OPC interface. These variables provide the shared memory in an unstructured form. Only simple data types (BOOL, DINT, REAL, STRING) and fields of simple data types are used. This procedure is required because structured data (like the ones that variables plcMem and cncMem contain) can not be transferred via the OPC interface.

10.5 Further Background Information on Shared Memory

The following elements are added or updated when inserting the shared memory in a PLC project:

The CNC Operating Manual ProNumeric XCI 600 Version 07/16

 Up to 16 sub-systems with a total of CNC 32 axes/spindles  Technologies for drilling, milling, grinding, handling  Endless rotating round axes  Spindle packet with comprehensive functionality, e.g. thread cutting

functions, variable pulse evaluation, oriented spindle stop

 Synchronous spindle  Programmable acceleration  Electronic gears  2D+n helix interpolation  Advance and rapid traverse:

0.001 mm/min to 999 m/min

 Tool radius compensation with approach and departure strategy  Tool length compensation  Interpolated compensation of error in spindle pitch and error in

measurement-system

 Backlash compensation  Field of work limit  Software limit switch

11 The CNC

Overview of Functions

The XCI 600 is a CNC with up to 32 axes/spindles and an integrated, PLC.

The CNC programming of the XCI is described in detail in a separate operating manual (see: Table 1).

RS232 Serial Interface

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 87: Setting up the terminal program on the service PC

Tera Term is recommended

Please note:

Do not connect any open wires to serial interfaces (RS232, RS422) (to which, for example, a service PC may be connected from time to time).

Open cables can cause coupling between the transmit and receive lines, leading to malfunctions in the control process.

When not needed, pull off the corresponding connector from the controller.

12 RS232 Serial Interface

The serial interface is by default assigned to the real-time operating system and is used to connect operating devices and service PCs for diagnosing the system. The connection is made via the COM interface of the service PC and the XCI-600 (port X 201). It is used for the output of the bootlog when the XCI 600 is booting up, for example. To set the necessary parameters, open the Schleicher X-Manager (see: section 13.1.4).

Other Operating Software Operating Manual ProNumeric XCI 600 Version 07/16

Important!

First clarify the adaptation of IP addresses with your network administrator for installation with a connection to an existing in-house network.

 Assign a Home network address for connecting the controller to an

existing home network (e.g. 10.208.3.212)

 Change the Windows side address of the "RTOS Virtual Network".

If possible, the default scheme (e.g. 192.168.xxx.1) should be maintained!

 Change the network settings (routing) on the programming PC to

communicate with the controller via the Home network (e.g. programming with MULTIPROG)

13 Other Operating Software

13.1 Schleicher X-Manager

The Schleicher X-Manager provides the means for configuring important parameters and settings for operating the controller:

13.1.1 "IP Configuration"

This function can be used to adapt the network settings required for operation to the characteristics of the local network (home network). The real time operating system VxWorks as well as Windows embedded

operate “simultaneously” on the XCI controller. Both operating systems

communicate with each other via a shared memory and a virtual network. So-called "virtual network adapters" ("RTOS Virtual Network") are provided on both sides for this purpose. The network interface is commissioned in the following sequence:

Other Operating Software

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 88: X Manager, IPConfiguration

When the Reboot checkbox has been activated, the restart is performed automatically.

 The IP address and mask of the XCI 600 controller in the Home network

(the alias name vxHost is defined in file c:\windows\system32\etc\host for this purpose)

 IP address of the default gateway in the Home network.  IP address of the default DNS in the Home network.  IP address of the default WINS in the Home network.

 IP address and mask of the "RtOS virtual network” of the XCI controller

(Windows page, Figure 91)

 IP address and mask of the RtOS virtual network of the XCI controller

(VxWorks page) (the alias name vxTarget is defined in file c:\windows\system32\etc\host for this purpose)

 The "computer name" must be unique across the network and may be

assigned only once (e.g. IPC13-212).

 The computer name currently being used is shown in brackets.  To change the name of the computer it is necessary to restart the

controller.

(1). Host IP address 1 "vxHost" (Local Area Connection) (see: Figure 88)

(2). Host IP address 2 (RtOS virtual network). (see: Figure 88)

(3). Target IP address #1 (alias vxTarget) (see: Figure 88)

(4). Computer name (see: Figure 88)

Other Operating Software Operating Manual ProNumeric XCI 600 Version 07/16

Notes!

Separate tool tip helps are available for some settings.

A “Routing” command for a “Programming PC” is issued for

“Computer name” in the tool-tips (mouse pointer on the appropriate

input field). Depending on the Home network configuration, additional settings may be required.

"F2" can be used to load the default IP configuration (delivery condition) or "F3" can be used to load the current IP configuration into the input masks ("IP configuration")

Hotkey "F5" is used to support the proposed IP address scheme (see above); "F5" automatically takes the last number of the host IP address (e.g. 212) for assigning the host IP #2 or the target IP address



 Deactivates the gateway, DNS, and WINS settings. This can be used to

shorten the time until PLC-start, for example, if no network cable was connected from the Ethernet interface of the XCI 600 to the LAN. Background: In Windows it is not possible to distinguish whether or not the controller is actually connected to the Home network (with access to DNS, WINS etc.). To avoid conflicts ("Race Conditions") when starting the network stack and the real-time operating system, there is a delay until the network is completely ready for operation or the corresponding network time-outs have expired. However, if there is no network connected, these rather long waiting times in practice are unnecessary.

 By default, the EMF on the system is enabled, i.e. all changes to the

system partition are lost after a restart.

 To permanently apply the changed settings a "Commit Changes" order is

issued automatically.

 When the Reboot checkbox has been activated, the restart is performed

automatically.

 However, all changes only become active by restarting the controller (i.e.

after the regular shutdown of Windows).



(5). Deactivate external network settings (see: Figure 88)

(6). Reboot (see: Figure 88)

Other Operating Software

Operating Manual ProNumeric XCI 600 Version 07/16

Notes!

When EWF is activated on systems which are not switched off for longer periods of time, there may be a memory overflow, because the EWF redirects write accesses to the system partition to a RAM overlay.

(Windows system error "Delayed Write Failed"). Therefore, it may be appropriate to disable the EWF so that the memory

space in RAM is not restricted. This leads to increased writes to the SSD.

This also deactivates protection for the system partition. Depending on the respective application, it must therefore be assessed

whether it is possible to operate the system with or without activated EWF, or whether using a UPS should be preferred.

 “Get EWF status”

outputs the current configuration and the status of the EWF.

 “Enable EWF”

activates the EWF

 “Commit changes”

writes back the contents of the overlay memory.

 “Disable EWF Live”

deactivates the EWF

 “Reboot”

A status modification of the EWF (with the exception of deactivation) is merely instructed, but it is actually only executed after a system reboot. The restart can be triggered immediately with the set "reboot" option together with the corresponding EWF command.



13.1.2 “EWF Configuration”

The Enhanced Write Filter is a component in the Windows Embedded 8 PC operating system of the XCI 600. It is used to protect one or several partitions (volumes, e.g. on a SSD) against changes. Write access is diverted to a so-called overlay (e.g. in system RAM) for the activated EWF. This is lost after switching off the system. However, to be able to make the required changes to the system, the contents of the overlay memory can be written back using the corresponding system command or the EWF can be temporarily deactivated.

Other Operating Software Operating Manual ProNumeric XCI 600 Version 07/16

Figure 89: X Manager, EWF Configuration

Other Operating Software

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 90: X Manager, NFS and Hardlink

13.1.3 “NFS and Hardlink”

Used for internal purposes; therefore no further description.

Other Operating Software Operating Manual ProNumeric XCI 600 Version 07/16

Figure 91: X Manager, RTOS Settings

 "Startup Type of VxWorks"  Determines whether VxWorks starts automatically when Windows boots

 or whether VxWorks must be started manually (with the help of the MFA

Utility)

 "COM Port Configuration"  Defines the assignment of the COM ports to the respective operating

system (Windows or VxWorks)

 for COM1 it is additionally possible to determine whether a console can

be activated or not

 “Run”  executes the Device Manager (to check whether the hypervisor has

made the correct assignments)

13.1.4 “RTOS Settings”

Only for XCA1200 and XCI 600

Other Operating Software

Operating Manual ProNumeric XCI 600 Version 07/16

Figure 92: Remote maintenance software UltraVNC

13.2 Remote Desktop UltraVNC

UltraVNC is remote maintenance software under Windows that enables remote access from a PC via the network or Internet on the desktop of a remote Windows computer. The server of UltraVNC is pre-installed on the XCI 600 controller. The software operates according to the client-server model, where the server runs on the computer to be monitored (in the case of the XCI 600, also under Windows Embedded 8). Load the current version of UltraVNC from the website of the manufacturer to install the client on a maintenance computer. http://www.uvnc.com. This site provides help for setup and operation, (online) FAQs, forums and tutorials. The client receives the screen outputs of the server and, in turn, sends mouse and keyboard entries to it. The default password for the PC <-> XCI 600 connection is "pp" (see: Figure

15).

Other Operating Software Operating Manual ProNumeric XCI 600 Version 07/16

13.3 TeamViewer

The TeamViewer remote maintenance tool (QuickSupport) is installed on the XCI 600 as standard. D:\schleicher\Teamviewer\TeamViewerQS_en.exe The password is: <berlin>.

13.4 MicroBrowser

The MicroBrowser (visualization tool, Messrs. IniNet) is installed on the XCI 600, but it is not licensed.

13.5 EC-Engineer

The “EC-Engineer” configuration tool by Acontis is required for configuring and diagnosing the EtherCAT network. EC-Engineer is not a component of the XCI 600. The software and dongle must be ordered separately from Schleicher Electronic and must be installed on the target computer (see: section 4.2.5).

13.6 SSD and SSD Monitor SW (e.g. SSD Scope Pro)

A tool for monitoring the SSD Smart values is advantageous. A corresponding tool is installed under <D:\schleicher\SSD Scope>, but it is not started automatically.

Technical Data

Operating Manual ProNumeric XCI 600 Version 07/16

Electrical data

Supply voltage

DC 24V +-10%

Internal power consumption

max. 4 A (24 V)

Isolation (from internal electronics)

Ethernet / EtherCAT®

Yes (except LAN screen)

USB

DVI

RS232

Interfaces

RS 232

no stationary connection of serial units galvanically isolated RS485 module (optional)

4x Ethernet (10/100/1000 MBit)

Programming, diagnostic and control unit interface, drive interface (EtherCAT®)

7x USB 2.0

USB interface (e.g. mouse, keyboard, USB memory stick, etc.)

DVI

Monitor interface DVI-I (digital / analog)

Other technical data

Processor

Performance version 1

COMe-bIP2 i3-3217UE (2x1.60GHz, 17W)

Memory

SDRAM

4 GB (max. 8 GB)

NVRAM

128 KB

SSD

>=32 GB

Additional information

PLC processing times every 1000 instructions

Bit

0.018 ms

Byte / Word / DWord

0.005 ms

Integer (Add / Mul)

0.006 ms

Real (Add)

0.029 ms

Real-time memory (adjustable)

Operating system (data / program)

32768 kB

PLC memory

Programs

4096 kB

Flag retentive

256 kB

Flag not retentive

2048 kB

Dimensions / weight

Measurements

200 mm x 200 mm x 100 mm

Weight

300 g

14 Technical Data

Technical Data Operating Manual ProNumeric XCI 600 Version 07/16

Climatic conditions

Ambient operating temperature

0 ... +50°C (free air circulation)

Storage temperature

-25 ... +70°C

Relative humidity

20 ... 80%, non condensing

Air pressure in operation

860 ... 1060 hPa

Mechanical strength

Vibrations

Acc. to DIN EN 60068-2-6 9 ... 150 Hz constant acceleration 1 g

10-500Hz, 1g

Shock

Acc. to DIN EN 60068-2-27, sinusoidal half-wave 15g / 11ms

Free fall

Acc. to DIN EN 60068-2-32, drop height 1m (in original packaging)

Electrical safety

Protection class

Note for the operator: When connected to the mains, the device must be connected via a safety

transformer (reliable isolation)

Protection type

IP 20 to EN 60529

Air gap/creepage paths

according to EN60950-1

Test voltage

Electromagnetic compatibility

Electrostatic discharge

EN 61000-4-2: 8 kV air discharge, 4 kV contact discharge

Electromagnetic fields

EN 61000-4-3: Field intensity 10 V/m, 80...1000 MHz

Rapid transients (bursts)

1 kV on I/O signal lines

Energetic transients (surges)

EN 61000-4-5:

0.5 kV DM (differential mode) 1 kV CM (common mode) on shielded signal lines

Interference emissions

EN 55011: Limit category A, Group 1

Glossary

Operating Manual ProNumeric XCI 600 Version 07/16

Abbreviation

Explanation

CNC

Computerized Numerical Control

CoE

CANopen over EtherCAT®

COMe

Computer-On-Module Express

DVI-I

With a passive adapter, it is also possible to connect a VGA monitor to this interface.

EC-Engineer

Configuration and diagnostics program for EtherCAT networks, prepared by Acontis.

ENI file

EtherCAT Network Information (ENI file describes the EtherCAT network)

EoE

EoE - Ethernet over EtherCAT® "Standard" Ethernet frames are transparently tunnelled through the EtherCAT® protocol and do not interfere with the EtherCAT® real-time properties.

ESI file

EtherCAT® Slave Information (the ESI file describes one or more EtherCAT® devices (slaves))

EWF

Enhanced Write Filter: A component in Windows XP Embedded to protect one or more partitions against changes (e.g. on a Compact Flash Drive). When EWF is activated, write accesses are diverted into a so-called overlay (e.g. in system RAM). This is lost after switching off the system. However, to be able to make the required changes to the system, the contents of the overlay memory can be written back using the corresponding system command or the EWF can be temporarily deactivated.

Forcing

Variables can be forced and overwritten in online mode. Forcing and overwriting means to assign a new value to a variable.

When you force a variable the new value is used for the variable until force is cancelled for that variable. When overwriting a variable with a value, the new value is used for only one work cycle. When the cycle is finished the variable is processed normally.

FTP

FTP - File Transfer Protocol The File Transfer Protocol is a specified network protocol for transferring files via TCP/IP networks.

Basic initialisation

Start of the real-time operating system in safe mode and reset of retentive data memory.

Industrial Ethernet

Ethernet-based real-time protocol, which is used in the manufacturing industry and is used for data exchange between control systems, actuators and sensors.

IPC

Industry PC (computer for tasks in the industrial sector)

MFA

Multi Function Application

MULTIPROG

An integrated programming environment provided by KW-Software, for creating PLC programs in compliance with IEC 61131.

NC record

(abbreviation for: Numerical Control) This is a data record of control commands, that implements work or movement processes and executes them sequentially

NC subsystems

The CNC controller can subdivide axes into groups (systems) and manage each system as a stand-alone NC controller. Each system has its own program, an operating mode etc. Synonymous terms are multi-carriage operation and multi-channel operation.

NFS

Network File System

NVRAM

Non-volatile RAM (Non-Volatile Random-Access Memory)

OPC

OPC - OLE for Process Control OPC was the original name for standardized software interfaces that enable data exchange between applications of different manufacturers in automation technology.

OPC Server

The OPC server retrieves the process data via a propitiatory communication protocol (here KW protocol) of the PLC and displays them in the OPC server as OPC objects. Applications can access these data as OPC clients.

PAC

Programmable Automation Controller

15 Glossary

Glossary Operating Manual ProNumeric XCI 600 Version 07/16

PCI

Peripheral Component Interconnect Bus standard for connecting peripherals to the chipset of a processor

PCIe

PCI Express Connectivity standard for PC components (replacement for PCI, AGP). Based on individual

serial lanes, each with two differential data lines per transfer direction, which can transfer gross 2.5 GBit/s full duplex at 1.25 GHz frequency and with DDR transmission; due to 8-bit10-bit encoding and longer data blocks, a net of about 250 MBytes/s can be used in both directions simultaneously. (similar to InfiniBand).

If supported under the auspices of the PCI Special Interest Group (PCI SIG). Initially the following lane bundles are defined:

PCIe x1: 1 lane, 250 MBytes/s per direction PCIe x4: 4 lanes, 1 GByte/s per direction PCIe x8: 8 lanes, 2 GByte/s per direction PCIe x16: 16 lanes, 4 GByte/s per direction PCIe x16 is also referred to as PCI Express for Graphics (PEG); graphics cards in x16 slots

may use up to 75 watts power. Cards with x1 interface must run in larger slots, but not vice versa. Compatibility between other bundle sizes is not defined, but possible and recommended. Slots may offer less lanes than their size suggests (example: PCIe x16 slot with only 4 or 8 lanes).

PCIe is also provided for internally linking chipset components. Bridges connect other buses (PCI-X, PCI).

PLC

Programmable Logic Controller

POU

Program Organisation Unit

TDP

"Thermal Design Power" refers to the thermalpower loss of a processor or other electronic components, on the basis of which cooling is designed.

Riser card

Riser cards are angled pieces that make it possible to install expansion cards parallel to the motherboard instead of vertical.

RTOS

Real Time Operating System

SATA

Serial ATA = Hard drive interface for personal computers. Serial ATA behaves fully compatible with Parallel ATA with respect to BIOS and drivers. Unlike Parallel ATA, SATA is not a bus with masters and slaves, but a point-to-point connection. With its transmission speed of 150 MBytes/s, the Serial ATA specification V1.0 (short SATA I) is seamlessly equivalent to the fastest parallel ATA hard drives with 133 MBytes/s; SATA II specifies data transfer rates of 300MBytes/s and SATA III 600 MBytes/s.

SLC / MLC Flash

Single-level cell flash are memory cells consisting of NAND flash, in which each memory cell stores one bit.

Multi-level cell flash are memory cells consisting of NAND flash, in which each memory cell, which is composed of a MOSFET and a capacitor, stores a plurality of bits (currently three).

SoE

SERCOS over EtherCAT®

SPGs

System programs

PLC

Programmable Logic Controller

SSD

A Solid State Drive (also known as Solid State Disk), is a memory medium, that is installed and accessed like a conventional hard drive, but does not contain a rotating disk or other moving parts because it comprises only semiconductor memory chips (usually flash) of similar capacity.

TCP/IP

TCP/IP - Transmission Control Protocol / Internet Protocol is a family of network protocols. The network subscribers are identified by means of IP addresses. Data reception is acknowledged.

UEFI

(Unified Extensible Firmware Interface) UEFI replaces BIOS, but the task to be performed by UEFI has not changed compared to BIOS: It provides the interface between the hardware and the operating system, but offers a number of innovations and advantages compared to

Glossary

Operating Manual ProNumeric XCI 600 Version 07/16

the previous BIOS.

V-Net

This is the alias name of the Windows IP address for communication via the virtual network. The name must be registered in the Hosts file.

VxHost

This is the alias name of the IP address for connecting the controller to the Home network. The name must be registered in the Hosts file.

VxTarget

This is the alias name of the VxWorks IP address for communication via the virtual network. The name must be registered in the Hosts file.

VxWorks

Real-time operating system provided by Wind-River

WinPcap

Program library consisting of a driver that facilitates hardware access to the network card.

Glossary Operating Manual ProNumeric XCI 600 Version 07/16

 WINDOWS is a registered trademark of Microsoft Corporation.  CANopen is a registered trademark of CAN in Automation e.V.,  ProCANopen is a registered trademark of Vector Informatik GmbH.  VxWorks is a registered trademark of Wind River Systems Inc.  PROFIBUS is a registered trademark of the PROFIBUS users

organization.

 MULTIPROG is a registered trademark of KW-Software GmbH.  EtherCAT® is a registered trademark and patented technology licensed

by Beckhoff Automation GmbH, Germany

15.1 Trademark entries

All other trademarks or product names are registered trademarks of their respective owners.

Glossary

Operating Manual ProNumeric XCI 600 Version 07/16

15.2 List of figures

Figure 1: XCI 600 View from the top ...................................................................... 11

Figure 2: XCI 600 View from the bottom ................................................................ 11

Figure 3: Integrating the XCI 600 in an industrial infrastructure ............................. 15

Figure 4: Type-1 hypervisor .................................................................................... 16

Figure 5: Wiring of 7-pin Phoenix connector .......................................................... 17

Figure 6: Installation of MULTIPROG ..................................................................... 20

Figure 7: Installing the ............................................................................................ 21

Figure 8: Installing Schleicher Dialog ..................................................................... 22

Figure 9: Communication-schematic XCI 600 ........................................................ 24

Figure 10: Run window ........................................................................................... 25

Figure 11: Setting up the network route for programming with MULTIPROG ........ 25

Figure 12: Calling the resource settings in MULTIPROG ....................................... 26

Figure 13: Resource settings MULTIPROG specifications .................................... 27

Figure 14: Entering the IP address in the hosts file ............................................... 27

Figure 15: Entering the IP address in MULTIPROG .............................................. 27

Figure 16: Calling the connection to the XCI 600 controller in MULTIPROG ......... 28

Figure 17: Resource window when there is NO online connection to the XCI 600

controller ................................................................................................................. 28

Figure 18: Resource window when there IS an online connection to the XCI 600

controller ................................................................................................................. 29

Figure 19: Opening a new project in MULTIPROG ................................................ 30

Figure 20: Selecting controller type for new project ............................................... 30

Figure 21: Example for project tree in MULTIPROG .............................................. 31

Figure 22: Calling memory dialog ........................................................................... 31

Figure 23: Dialog window "Save project" ................................................................ 31

Figure 24: Compile Project ..................................................................................... 32

Figure 25: Transferring project to the controller ..................................................... 32

Figure 26: Online display of variables .................................................................... 33

Figure 27: Information on controlling and the shared-memory version (must scroll

to see) ..................................................................................................................... 33

Figure 28: Calling the "PLC/MC/CNC shared memory" dialog window ................. 34

Figure 29: "PLC/MC/CNC shared memory" dialog window .................................... 35

Figure 30: Schleicher add-ons for MULTIPROG .................................................... 36

Figure 31: Schleicher EtherCAT configuration use cases: 1 through 6 ............... 36

Figure 32: Step 1 Schleicher EtherCAT configuration ............................................ 38

Figure 33: Step 2 Schleicher EtherCAT configuration ............................................ 38

Figure 34: Step 3 Schleicher EtherCAT configuration ............................................ 38

Figure 35: Step 4 Schleicher EtherCAT configuration ............................................ 38

Figure 36: Step 5 Schleicher EtherCAT configuration ............................................ 39

Figure 37: Browsing EC-Engineer EtherCAT network. .......................................... 39

Figure 38: EC-Engineer ESI administration........................................................... 40

Figure 39: EC-Engineer ESI file list ........................................................................ 40

Figure 40: EC-Engineer ESI file manufacturer list .................................................. 41

Figure 41: Step 7 Schleicher EtherCAT configuration ............................................ 41

Figure 42: Step 8 Schleicher EtherCAT configuration ............................................ 41

Figure 43: Step 9 Schleicher EtherCAT configuration ............................................ 42

Figure 44: Step 10 Schleicher EtherCAT configuration .......................................... 42

Glossary Operating Manual ProNumeric XCI 600 Version 07/16

Figure 45: EtherCAT configuration when the topology is altered ........................... 43

Figure 46: EtherCAT configuration, deleting the ENI file ........................................ 43

Figure 47: Inserting a new master module. ............................................................ 43

Figure 48: Inserting a second master module. ....................................................... 44

Figure 49: Assigning an IP address to the Master Module. .................................... 44

Figure 50: Browsing EtherCAT network. ................................................................ 44

Figure 51: Newly inserted slave module in the EtherCAT network ........................ 44

Figure 52: Copying a slave module. ....................................................................... 45

Figure 53: Inserting a slave module ....................................................................... 45

Figure 54: Completing the configuration alteration ................................................. 45

Figure 55: EtherCAT variables in MULTIPROG. .................................................... 46

Figure 56: EtherCAT configuration without alteration to topology .......................... 46

Figure 57: Starting the EC-Engineer to alter the names of variables. .................... 47

Figure 58: EC-Engineer editing the variable names. .............................................. 47

Figure 59: EtherCAT variable name. ...................................................................... 47

Figure 60: Save the EtherCAT variable names ...................................................... 47

Figure 61: EtherCAT variables in MULTIPROG. .................................................... 48

Figure 62: Taskbar with Schleicher logo ............................................................... 49

Figure 63: The MFA window ................................................................................... 49

Figure 64: MFA, "Control system" menu ................................................................ 50

Figure 65: MFA, "Startup mode" menu ................................................................... 50

Figure 66: MFA, "PLC" menu ................................................................................. 51

Figure 67: MFA, "Extras" menu .............................................................................. 51

Figure 68: MFA, Menu "?" ...................................................................................... 52

Figure 69: Basic initialisation .................................................................................. 53

Figure 70: Examples of error messages after basic initialisation ........................... 53

Figure 71: Schleicher Dialog, startup window ........................................................ 54

Figure 72: Schleicher Dialog, status and messages area ...................................... 55

Figure 73: Schleicher Dialog, Control menu ........................................................... 55

Figure 74: MULTIPROG, changing operating states .............................................. 60

Figure 75: MULTIPROG, context menu "Libraries" or "Firmware library" .............. 63

Figure 76: MULTIPROG, "Integrate library" dialog window .................................... 63

Figure 77: MULTIPROG, Integrate "Serial" library ................................................. 63

Figure 78: MULTIPROG, Online help for the libraries ............................................ 64

Figure 79: Multi-task system, priority levels............................................................ 65

Figure 80: Multi-task system, Variable declaration ................................................. 72

Figure 81: Multi-Task System, Example for tasks and watchdogs ......................... 74

Figure 82: Multi-Task System, Inserting a task in MULTIPROG ............................ 75

Figure 83: Multi-Task System, Assigning programs in MULTIPROG..................... 76

Figure 84: Shared memory as a connection of PLC and CNC............................... 76

Figure 85: Reading out the operating software version .......................................... 77

Figure 86: Display of the shared memory error message in the Schleicher Dialog 78

Figure 87: Setting up the terminal program on the service PC .............................. 82

Figure 88: X Manager, IPConfiguration .................................................................. 84

Figure 89: X Manager, EWF Configuration ............................................................ 87

Figure 90: X Manager, NFS and Hardlink .............................................................. 88

Figure 91: X Manager, RTOS Settings ................................................................... 89

Figure 92: Remote maintenance software UltraVNC ............................................. 90

Glossary

100

Operating Manual ProNumeric XCI 600 Version 07/16

15.3 List of Tables

Table 1: Additional operating manuals ..................................................................... 9

Table 2: Contents of the CD-ROM ......................................................................... 18

Table 3: System requirements ................................................................................ 19

Table 4: Schleicher Dialog, structure of the user interface ..................................... 54

Table 5: Schleicher Dialog, status and messages area ......................................... 55

Table 6: PLC Operating states ............................................................................... 59

Table 7: MULTIPROG, start program execution .................................................... 60

Table 8: MULTIPROG, stop program execution .................................................... 60

Table 9: MULTIPROG, general reset ..................................................................... 61

Table 10: System variables .................................................................................... 61

Table 11: Libraries and Function blocks in MULTIPROG ...................................... 62

Table 12: Multi-task system, event tasks ................................................................ 67

Table 13: Multi-task system, system tasks ............................................................. 70

Table 14: Multi-task system, Task priorities ........................................................... 73

Table 15: Multi-task system, Task parameters ....................................................... 75

Schleicher ProNumeric XCI 600 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Target Group

Applicability of this Operating Manual

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Table of Contents

Document conventions

1 Safety instructions

1.1 Intended Use

1.2 Selection and Qualification of Personnel

1.3 Configuring, Programming, Installation, Commissioning and Operation

1.4 Hazards due to Electrical Energy

1.5 Maintenance

1.6 Dealing with Used Batteries

2 Additional operating manuals

3 System Overview

3.1 Designation / Variants

3.2 Installation of XCI 600

3.3 Connections and interfaces

3.3.1 Top view

3.3.2 Bottom view

3.4 Description of Interfaces

3.4.1 ETH RJ45 Ethernet ports

3.4.2 D-Sub 9 serial

3.4.3 USB 2.0

3.4.4 XCI 600 Control interface

3.4.5 DVI-I interface (digital and analog)

3.4.6 PCIe slot

3.5 Integrating the XCI 600 in an industrial infrastructure

3.6 Keyboard and mouse

3.7 SSD

3.8 Retentive memory

3.9 Installed software

3.10 Operating systems

4 Commissioning

4.1 Switching on the operating voltage

4.2.1 System requirements

4.2.2 MULTIPROG Installation

4.2.3 Installing the OPC Server

4.2.4 Installing Schleicher add-ons for MULTIPROG

4.2.5 Installing EC-Engineer

4.2.6 Install Schleicher Dialog

4.3 Starting up the Network Interface

4.3.1 Preparation

4.3.2 Communication-schematic

4.3.3 Assigning a computer name for the XCI 600

4.3.4 Customizing the XCx-TCP/IP settings

4.3.5 Communication for programming with MULTIPROG

5 First Steps with MULTIPROG

5.1 Start MULTIPROG, open and save a new project

5.2 Compiling a project and sending it to the XCI 600

5.3 Incorporating shared memory

5.4 Configuration of the EtherCAT network

5.4.1 Steps for configuring the EtherCAT network

5.4.2 Alteration to the EtherCAT configuration when the topology is changed

5.4.3 The EtherCAT variables in MULTIPROG

5.4.4 Renaming EtherCAT variables

6 Operation

6.1 Multi Function Application (MFA)

6.1.1 Starting the Schleicher MFA

6.1.2 The MFA window

6.1.3 MFA functions

"Control system" menu

"Startup mode" menu

"PLC" menu

"Extras" menu

"?" Menu

6.1.4 Log files

6.1.5 Basic initialisation

6.2 Schleicher Dialog

6.2.1 Structure of the User Interface

6.2.2 Schleicher Dialog PLC/CNC

Control menu and control areas of the XCI 600

7 The PLC

7.1 Programming

7.2 PLC Operating states and Start behaviour