MANUAL

02/2014

Incosa Solutions bvba, Molenberglei 21, B-2627 Schelle, tel +32(0)3 451 93 95 - fax +32(0)3 887 30 61
www.incosasolutions.com
1 Table of contents
1 Table of contents................................................................................................ 2
2 General .............................................................................................................. 3
3 Overview ............................................................................................................ 4
3.1 View .................................................................................................................. 4
4 Description ......................................................................................................... 5
5 Installation .......................................................................................................... 6
5.1 Dimensions ....................................................................................................... 6
5.2 Instructions ....................................................................................................... 6
5.3 Wireless antenna .............................................................................................. 7
6 Connections ....................................................................................................... 8
6.1 Supply ............................................................................................................... 9
6.1.1 Standard power adaptor ................................................................................ 9
7 Communication ................................................................................................ 10
7.1 Architecture..................................................................................................... 10
7.1.1 Wired (CAN) ................................................................................................ 10
7.1.2 Wireless ....................................................................................................... 10
8 Setup ................................................................................................................ 12
9 Conversion factor ............................................................................................. 12
10 Loadcell menu .................................................................................................. 13
11 Monitoring ........................................................................................................ 13
12 Operations........................................................................................................ 15
12.1 Using i-c4c ................................................................................................... 15
12.2 Backup-Restore-Update .............................................................................. 15
12.2.1 Backup i-C4C ........................................................................................... 16
12.2.2 Restore i-C4C .......................................................................................... 16
12.2.3 Update i-C4C ........................................................................................... 17
13 Technical specifications ................................................................................... 18
13.1 General data ................................................................................................ 18
13.2 Electrics/electronics ..................................................................................... 18
13.3 Mechanical data .......................................................................................... 19
13.4 Ambient data ............................................................................................... 19

Incosa Solutions bvba, Molenberglei 21, B-2627 Schelle, tel +32(0)3 451 93 95 - fax +32(0)3 887 30 61
www.incosasolutions.com
2 General
The i-C4C is a new generation of programmable controller which integrates the most
advanced technology in order to cope with the most complex applications. Fully
digital, it has the advantage of being easy to install, to configure and to use.
The i-C4C includes a lot of features which allows to cover a wide range of
applications.

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3 Overview
The product covered by this manual is the i-C4C. This document provides an
overview of the installation, configuration and use of this device.

The i-C4C is available in two main models: master and slave. The slave model has
as main purpose to extend the I/Os. For each system, at least one master is needed.

Basic
 6 digital inputs
 4 relay outputs
 1 analogue input
 1 analogue output
 2 CAN interfaces
 display (only master model)
 keypad (only master model)
 USB interface

Options
 Wireless interface
 Mobile phone interface

By default, the i-C4C is configured as a load limiter with 2 set points. Given the
numerous variations of possibilities concerning the connections and software
configurations, this document will handle the default application of the i-C4C.

All other application configurations will be detailed in the production file of each
custom made system.

3.1 View

DISPLAY

KEYPAD

Figure 1: Master model Figure 2: Slave model

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 4 Description

1 2 3 4

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5

1 2 3

6  4 5 6 
12
7 8 9

C 0 

7 8 9 10 11

1 Digital inputs i1

2 Power supply + supply +

- supply -
+ supply+
- supply-
3 Can-bus1 H CAN bus line H
L CAN bus line L
- ground (shield)
4 Can-bus2 H CAN bus line H
L CAN bus line L
- ground (shield)
5 USB interface
6 SIM card tray
7 Digital outputs 1
8 Display
9 Analogue input/output Ai 0 | Ao 0
10 Wireless antenna connector
11 Mobile antenna connector
12 Keypad
12 Indication LEDs i-C4C status LED
mobile communication status LED
CAN CAN communication status LED
wireless communication status LED

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5 Installation
Follow the instructions as described in this manual for the installation of this product.

5.1 Dimensions
The following diagram shows the dimensions for the i-C4C.
182mm 27mm

54mm
DISPLAY
109mm

116mm
KEYPAD

mounting on 35mm DIN rail

Figure 3: mounting dimensions i-C4C on DIN rail

5.2 Instructions
- Turn off the power supply.

- Locate a suitable and accessible place to install the i-C4C, away from any
devices that produces strong electro-magnetic fields.

- Connect the power supply cable to the i-C4C.

- Connect the input and output cables to the corresponding connectors

according the connection diagram.

- Connect the CAN communication cable(s) to the corresponding CAN

interfaces according the connection diagram.

- Install the cables (inputs, outputs, communication) away from power cables.

It is advised to use shielded cables for the inputs, outputs and

communication connections.

It is advised to respect a distance of at least 200mm between the i-C4C

cables (inputs, outputs, communication) and power cables
230Vac/380Vac 50/60Hz. A greater distance is indicated for larger power
and/or high frequency.

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5.3 Wireless antenna

Optional, the i-C4C can be configured for wireless communication. By means of the
magnetic foot, the antenna can easily be installed on any magnetic metal surfaces.
For optimal communication you need to locate the antennas of the wireless modules
according these recommendations.

 Line of sight

OK NOT OK

 Pointing up

OK NOT OK NOT OK

 Free surrounding

OK NOT OK

 Max range*: 50m (with standard antenna)

*Wireless communication performance depends on many factors, conditions and variables, including building materials and
construction, mix of wireless products used, interference and other adverse conditions, which can affects the wireless signal
range.

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6 Connections
There are several rules that must be followed when wiring the i-C4C.
Recommendations, when needed, are provided on how to comply with the rules.

DANGER

ELECTRIC SHOCK

 Be sure to remove ALL power from ALL devices before connecting or

disconnecting inputs or outputs to any terminal or installing or
removing any hardware.
 Be sure to connect the grounding wire to a proper ground.

Failure to follow this instruction will result in death, serious injury, or

equipment damage.

WARNING

FAILURE OF OUTPUTS
 If outputs should fail, outputs may remain on or off. Where personnel
and or equipment hazards exist, use appropriate safety interlocks.

Failure to follow this instruction can result in death, serious injury, or

equipment damage.

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  Each terminal accepts wires from 24 AWG (0,20mm²) up to 14 AWG (2.08
mm²) fitted with cable ends or tags.

 Depending on the load, a protection circuit may be needed for relay outputs on
modules.

 The power supply wire should be between 24 AWG (0.20 mm²) and 14 AWG
(2.08 mm²). Use the shortest wire length possible.

 Incorrect wiring can cause equipment damage.

 Make sure that the operating conditions and environments are within the
specification values.

 Use proper wire size to meet voltage and current requirements.

digital input 1

digital input 2

digital input 6
digital input 3

digital input 4

digital input 5

Supply 1

Supply 2

CAN Bus

CAN Bus
Analog input
Relay output 1

Relay output 2

Analog output
Relay output 3

Relay output 4

6.1 Supply
The main supply of the i-C4C is 12VDC. For other supply voltages, a power adaptor
will be needed to convert the available supply voltage into 12Vdc.

6.1.1 Standard power adaptor

Mean Well MDR-20-12.

 Input voltage: 100-240Vac

 Output voltage: 12Vdc
 Rated power: 20W
 Short circuit protection

Please refer to your dealer/retailer for appropriate power adaptor.

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7 Communication
Data communication (e.g. I/O’s, values ...) between i-C4C modules in a network
configuration is achieved either by wire through CAN-bus or wireless through
advance RF modules.
One wireless network can include max three i-C4C devices. You can connect up to
16 devices in a wired network.
Communication between CAN modules can occur wired and wireless at the same
time.

Note
The configuration of the wired and wireless network is set by the i-C4C dealer.

7.1 Architecture
7.1.1 Wired (CAN)
The wiring-topology of a CAN-network should be as close as possible to a single line
structure in order to avoid cable-reflected waves. The total length of all the branches
of the bus must not exceed 200 meters (650 ft.).

DISPLAY

KEYPAD

For a proper communication, terminating resistors Rt of 120 at each end of the bus
are required to prevent reflections. The i-C4C includes an internal terminating resistor
which can be enabled/disabled with a jumper depending its location in the network.

7.1.2 Wireless
i-C4C use a point to multipoint architecture for wireless communication. One master
device can communicate with maximum two slave devices. The typical range

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between two devices with standard antenna is 50m. Actual range varies based on
environmental conditions (indoor, outdoor, line of sight, etc.).

DISPLAY

KEYPAD

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8 Setup
Depending of the application, you can set up some parameters of the program with
the help of the keypad and display of an i-C4C master module.
Follow this procedure to modify your application parameters:

1) press  key to enter the menu

2) with the arrow keys ▲or ▼, scroll to item Update config
3) press  key
4) with the arrow keys ▲or ▼, scroll to the proper parameter
5) press  key to view or edit selected parameter
a. view value
i. press twice C to return to previous menu
b. edit value:
i. press C to clear the value
ii. enter the new value with the numerical keys
iii. press  key to confirm the new value and return to the previous
menu
6) press a few times the C key to return to the main menu

! Refer to the production sheet for the available parameters related to the application.

9 Conversion factor
It is possible to set a up to 8 conversion factors for inputs. This conversion factor will
be applied to the value of the input to the following scenarios:

 The interpreter (when calculating the formulas)

 The display

In all other scenarios, the iC4C continues to use the original read value. This
provides transparency when inputs are used on other iC4Cs (one does not have to
wonder if the conversion has already been done or not).

If the configuration is programmed, the user can then optionally adjust the conversion
factor using the iC4C menu:

1) press  key to enter the menu

2) with the arrow keys ▲or ▼, scroll to System
3) press  key
4) with the arrow keys ▲or ▼, scroll to Conv. Factors
5) press  key
6) with the arrow keys ▲or ▼, scroll to select the Conv. Factors (1..8)
7) press  key

The user can see the value of each conversion factor or enter a new value. When a
new value is saving becomes increasingly rounded to 1/1024. There is a confirmation
of the value before stored.

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Caution: If an invalid value (exam. overflow) or invalid characters (exam. letters) are
entered the system convert to '0', a valid value. So is. It is therefore advisable to
always check the new values.

10 Loadcell menu
From the menu of iC4C each connected load cells can be read. Moreover, even the
CAN ID and the cable diameter can be adjusted.

We have the following configurations:

- Load cell in the program:
The current measured value can be displayed on the menu: Value (direct)
The measured value is converted menu: Value (conv.)

To this extent, the conversion factor associated charge

- Load cell is not included in the program:
The current measured value can be displayed in the "Value (Direct) menu.
The converted value of the measurement is shown as "N / A". In fact, it is not
associated with an entry.

1) press  key to enter the menu

2) with the arrow keys ▲or ▼, scroll to Loadcells
3) press  key
4) with the arrow keys ▲or ▼, scroll to device
exam. Device[1,1]: Bus and module ID
5) press  key
6) with the arrow keys ▲or ▼, scroll to the parameter:
 Value (direct)
 Value (conv.)
 CAN ID
 Diameter
7) press  key

The CAN ID and the cable diameter can be adjusted. After checking the input
parameters (the validity of the CAN ID and the cable diameter) by the firmware is
sent to the appropriate load cell by the protocol CANopen.

Please note that configuration depends on the interpretation of a CANopen frame by

the load cell. It is therefore advisable to always check the new values.

11 Monitoring
Depending of the application, you can monitor some variables of the program with
the help of the keypad and display of an i-C4C master module.
Follow this procedure to monitor your application variables:

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1) press  key to enter the menu
2) with the arrow keys ▲or ▼, scroll to item ReadVariables
3) press  key
4) with the arrow keys ▲or ▼, scroll to the appropriate module:
Local: current module
CANXX: remote module; XX = node ID
5) press  key to enter the list of variables of the selected module
6) with the arrow keys ▲or ▼, scroll to the proper variable type
7) press  key to confirm your selection
8) with the arrow keys ▲or ▼, scroll to the monitored variable
9) the display shows the name of the variable and the corresponding status or
value
10) press a few times the C key to return to the main menu

! Refer to the production sheet for the available variables related to the application.

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12 Operations
12.1 Using i-c4c
To ensure correct use of the equipment, follow the instructions below.

1) before powering the i-C4C module(s), check the connections of the IOs and
the power supply according the connection diagram.
2) Connect the power supply
3) the green LED will blink at first during the start-up and the message
“Starting up…” appears on the display
4) after a few seconds the green LED will be on continuously and following
message will appear on the display:
i-C4C vx.xx
ENTER FOR MENU
5) test the functionalities of the i-C4C module(s) according your application
requirements

12.2 Backup-Restore-Update
With a USB stick you can backup, restore or update the files of each i-C4C module.

Each i-C4C module contains 3 types of files:

1) firmware file
a. software that performs the basic operations of the device
b. filename: “application_ xxxx-xx-xxx.hex”, where xxxx-xx-xxx is the serial
number of the i-C4C module
c. version of the firmware can be read on the display of the i-C4C module,
e.g. “i-C4C v2.0”
2) configuration file
a. contains the custom made project program
b. filename: “config_xxxx-xx-xxx.bin”, where xxxx-xx-xxx is the serial
number of the i-C4C module
3) flash parameters file
a. contains parameter for wireless, CAN and mobile communication
b. filename: “flashparams_xxxx-xx-xxx.bin”, where xxxx-xx-xxx is the
serial number of the i-C4C module

In order to use a USB memory stick (min. capacity 128Mb) for backup, restore or
update the i-C4C modules, you need to prepare it as followed:
1) format the USB stick as FAT32
2) create a map X:\main\ (where “X” is the device name of the USB stick)

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12.2.1 Backup i-C4C
The i-C4C files can be backuped from the i-C4C module to a USB memory stick. In
order to do this, you need to follow these instructions:
1) Check there is no file in the map X:\main\ (where “X” is the device name of the
USB stick); delete the files if any present.
2) Plug the USB stick into USB interface of the i-C4C module
3) The light indicator of the USB stick will start blinking indicating the transfer of
data.
4) After about 20s the transfer will be done.
(for master i-C4Cs “Safe to remove USB stick” appears on the display)
5) Before removing the USB stick from the i-C4C , check if the light indicator of
the USB stick is off.
6) Copy the 3 i-C4C files from the USB to a backup station or map on your PC or
server.

12.2.2 Restore i-C4C

You can restore the backuped files of an i-C4C as followed:
1) Plug the USB memory stick into the PC with the backup files.
2) Check there is no file in the map X:\main\ (where “X” is the device name of the
USB stick); delete the files if any present.
3) Copy the three corresponding i-C4C files (check the serial number) to the map
X:\main\ (where “X” is the device name of the USB stick)
4) Plug the USB stick into USB interface of the i-C4C module.
5) The light indicator of the USB stick will start blinking indicating the transfer of
data; the i-C4C status led will start blinking; for master i-C4Cs “Starting
up..” will appear on the display.
6) After about 90s the transfer will be done; the i-C4C status led will be steady
on; for master i-C4Cs “Safe to remove USB stick” will appear on the display.
7) Before removing the USB stick from the i-C4C, check if the light indicator of
the USB stick is off.

If the original i-C4C module has been replaced by a new one, rename
the three i-C4C files according the new serial number before the restore
operation.

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12.2.3 Update i-C4C
Due to new requirements or extension of the application, the firmware, the
configuration or the flash parameters file of the i-C4C module(s) may need to be
updated.
You can update one or more i-C4C files as followed:
1) Plug the USB memory stick into the PC with the updated files received from
your dealer.
2) Check there is no file in the map X:\main\ (where “X” is the device name of the
USB stick); delete the files if any present.
3) Copy the updated file(s) of corresponding i-C4C module (check the serial
number) to the map X:\main\ (where “X” is the device name of the USB stick).
4) Plug the USB stick into USB interface of the i-C4C module.
5) The light indicator of the USB stick will start blinking indicating the transfer of
data; if the firmware needs to be updated, the i-C4C status led will start
blinking; for master i-C4Cs “Starting up..” will appear on the display.
6) After max 30s to 5 minutes, depending the updated files, the transfer will be
done; the i-C4C status led will be steady on; for master i-C4Cs “Safe to
remove USB stick” will appear on the display.
7) Before removing the USB stick from the i-C4C, check if the light indicator of
the USB stick is off.

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13 Technical specifications
13.1 General data

Function Description
Human interface  display 2 x 16 characters (master model only)
 numerical keypad (master model only)
 status LEDs
o system
o mobile
o CAN
o wireless
Field of application  load limiter
 summation
 signal transmission (digital/analogue)

13.2 Electrics/electronics

Function Description
Digital inputs  6 optical isolated inputs
 suitable for potential free contacts
Digital outputs  4 change-over relays
 galvanic insulated
 max 250Vac - 3A
Analogue inputs  1 analogue 0-10Vdc
 resolution: 8 bits
Analogue outputs  1 analogue 0-10Vdc
 resolution: 8 bits
 max 10mA
Interfaces  2 CANOpen field bus, 125kbits/s, 250kbits/s
 1 USB
 1 wireless PAN (optional)
 1 Mobile phone (optional)
Supply  12Vdc  10%
 optional 100-240Vac
Power consumption  max 7W

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13.3 Mechanical data

Function Description
Dimensions  182 x 109 x 27 mm (width x height x depth)
Mounting  DIN rail 35mm
Weight  0,5kg
Housing  PC/ABS

13.4 Ambient data

Function Description
Temperature range  operational : -10°C to +60°C
 storage : -40°C to +85°C
Relative Humidity  10 to 95% (without condensation)
Index of protection  IP20

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 incosa solutions bvba
Molenberglei 21 - B-2627 Schelle - BELGIUM
Tel: +32 3 451 93 95 | Fax: +32 3 887 30 61

commercial@incosalutions.com

www.incosasolutions.com

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