Procedure to setup and configure a

XC-CPU201 PLC (P/N PS440316015842) in a

S5000 R4 P1 cabinet (P/N PS429300.01.5.815)
This procedure can be used to solve some issues with a faulty PLC.
These manuals have been used to troubleshoot and configure the PLC:
10/10 MN05003001Z-EN - Modular PLC XC-CPU201-...(-XV)
04/03 AWB2700-1437GB - PLC Programming XSoft version 2.3

First of all, make sure the PLC is powered on. Power to

the PLC can be confirmed with the two LEDs indicating
the status. The inputs sending a signal should also be
visible. To confirm it, the buttons on the P1 can be
pressed, and if the PLC is powered, the LED associated
with the button will light up.

Then, the status of the PLC needs to be identified.

Looking at the two LEDs (the top one being
RUN/STOP is green, and the bottom one being SF is
red). Following the Operating states chart on the right,
see if it matches the run/stop switch position.

There is a state not identified by the chart: when both

lights are on, not flashing. This is an error state when on
run mode, and usually means there is a problem with
the battery. To fix this, make sure there is a battery, and
that the battery has the correct voltage (Lithium battery
of type ½ AA 3.6V)
The next step consists of checking the files on the SD card. Using an SD card reader, connect the
card to a computer and make sure these files are present in this folder:
\disk_mmc\MOELLER\XC-CPU201-EC256K-8DI-6DO\project

The XCSTARTUP.INI file

can be opened and modified
with notepad. Make sure the
configuration in it matches
the settings needed for the
network.

The initialisation file needs these configurations:

[STARTUP]
TARGET=XC-CPU201
HOST_NAME=p1_plc
IP_ADDRESS=142.39.255.235
IP_SUBNETMASK=255.255.255.0
IP_GATEWAY=142.39.255.1
If the SD card is empty or has files missing, simply copy all the files onto the SD card, and with
the PLC powered down, insert the SD card.
Power it back up and wait for the initialisation of the PLC (30 seconds). This will setup the PLC,
reboot it, and apply the changes.
Then, open a command prompt and ping the PLC (142.39.255.235) from the Opserver. If there is
a reply, this means the configuration was successful and the PLC should be back online and
working.
The following is to configure the PLC manually
First thing needed is the software XSoft-CoDeSys. An Eaton account is required for the rights to
use the software. A demo version can be found, but has limited functionalities.
Then, connect the PC to the PLC. This can be done either with a direct connection with a
crossover Ethernet cable, or connected through a Hub or Switch with a standard Ethernet cable.
To be able to communicate with the PLC,
the PC must first be setup to be on the
same network.
Open the internet properties (usually
found in the network connections from the
control panel), open the Internet Protocol
Version 4 (TCP/IPv4) properties, and use
the following IP address:
IP address: 142.39.255.2 (for the last
number, you can put any number from 2
to 254, except 200)
Subnet mask: 255.255.255.0
Default gateway: 142.39.255.1
Don’t put anything in the DNS section

Then, try to ping the PLC with command

prompt (142.39.255.235). If you can ping
it, skip to next page.

If there is no response, change the internet

properties with the following:
IP address: 192.168.119.2
Subnet mask: 255.255.255.0
Default gateway: 192.168.119.1

Then try to ping the PLC

(192.168.119.200). This is the default
address of the XC-CPU201.
This address will be found on a new PLC
or one that was completely reset.
After getting a positive response from the ping command, the setup with the XSoft program is
now possible.
Open the program. A window should open with the Target Settings.
Select XC-CPU201-EC256K-8DI-6DO, then press OK.
Another window opens, with New POU, just press OK.
Now, the network parameters must be
configured. From the top menu bar,
select Online, and open Configuration
Parameters. A window will open,
select New. Then, click on TPC/IP
(Level 2 Route) and press OK.

Then, double-click on localhost and replace it with the

PLC’s IP address (192.168.119.200). Press Enter then OK.
Go again in the top menu Online, and select Login.
If successful, a prompt should appear saying the program
versions are different and asking if you want to download.
Select No.
If not successful, there will be a communication error. Verify the PC’s Ethernet parameters, the
communication parameters, and the PLC’s IP address.
After successful login, check the bottom left menu, and
click on the Resources tab, then double-click on PLC-
Browser.
Then in the window that opened, click on the […] button located
under the [X] close button. A small command window will open.
From there, the commands needed to configure the PLC can be
found.
First, select ‘removestartupini’ to clear any default or incorrect
startup information. Press Enter twice (once to select the command
in the Browser, and another time to execute it).
Then, select ‘setipconfig’, press Enter, then on the browser window,
click on the right of the command and type “142.39.255.235
255.255.255.0” and Enter. Make sure there is a confirmation saying
OK. Select ‘saveregistry’ and press Enter twice. For the system
settings, a save to the registry is necessary before requesting another command. This can be done
either with the save, shutdown or reboot commands.
Then, select ‘setipgateway’, press Enter, then on the browser window, click on the right of the
command and type “142.39.255.1” and Enter. Select ‘saveregistry’ and press Enter twice.
Then, select ‘settargetname’, press Enter, then on the browser window, click on the right of the
command and type “p1_plc” and Enter. Select ‘saveregistry’ and press Enter twice.
Now with all the configuration settings entered, only part missing is the startup initialisation file.
Select ‘createstartupini’ and press Enter twice.
The parameter settings are now entered, so after a reboot the system should be configured. Select
‘reboot’ and press Enter twice. The PLC will shutdown and turn back on. Meanwhile, to
communicate and test with the new settings, the PC network settings must be changed again.
IP address: 142.39.255.2
Subnet mask: 255.255.255.0
Default gateway: 142.39.255.1
When the PLC is rebooted and in either stop or run state, open file explorer and connect to it via
ftp (fpt://142.39.255.235).
Then open disk_mmc\MOELLER\XC-CPU201-EC256K-8DI-6DO\project
and confirm that the files are there. Open the startup file with notepad and confirm the
configuration settings are correct.
Do the same for disk_sys\project. Then, go back to disk_sys, open the file XC201.INI and
confirm that it’s the same as the other startup files.

With this, the PLC should be back online and working.

For other problems or deeper explanations, please refer to the included manuals.