Eaton XControl Modular PLC Complete Guide

Eaton XControl Series Modular PLC: XC-104/204/303 Complete Technical Manual

Introduction: A miniaturized control system for future automation

In the field of modern industrial automation, programmable logic controllers (PLCs) serve as the core of control systems, and their performance, reliability, and flexibility directly determine production efficiency and system stability. The Eaton XControl series modular PLCs, including three sub series XC-104, XC-204, and XC-303, are compact high-performance controllers designed to meet diverse needs from small machine control to complex process automation.

The XControl series not only has powerful processing capabilities and rich communication interfaces, but also supports seamless expansion with XN300 series I/O modules, providing users with highly flexible modular solutions. This article is based on Eaton's official technical manual MN050005EN (4th edition, August 2025), providing a comprehensive analysis of the technical characteristics, system architecture, installation requirements, communication configuration, and programming environment of the XControl series PLC.

Chapter 1 Product Series and System Overview

1.1 Product positioning

The XControl series modular PLC is divided into three sub series based on performance and application complexity:

Typical applications of series model positioning

XC-104 XC-104-C10-000 Basic Controller Small Machine Control, System Level Network Connection

XC-204 XC-204-C10-000

XC-204-C11-003

XC-204-C20-002

XC-204-C21-001 Standard Controller Standard Automation Task, Industrial Ethernet Integration

XC-303 XC-303-C11-000

XC-303-C21-001

XC-303-C32-002 High Performance Controller Complex Automation Solution with Multiple Network Connections

1.2 System Architecture

The core components of XControl PLC include:

CPU unit: integrated processor, memory, and real-time clock

Power module: supplies power to the processor unit and system bus

Local I/O: Digital input/output (XC-204 and XC-303)

Communication interfaces: Ethernet, CAN, RS485, USB, etc

Expansion interface: Connect XN300 series I/O modules through the system bus

<center>Figure 1: Schematic diagram of XControl system architecture</center>

1.3 XN300 I/O System

XControl PLC can expand the XN300 series ultra compact modular I/O system through the system bus. XN300 offers a wide selection of I/O modules:

Power distribution and supply module

Digital and analog I/O modules

Technical functional modules (such as weighing module, motor drive module)

The XC-104 can expand up to 6 XN300 modules, the XC-204 can expand up to 16 modules, and the XC-303 can expand up to 32 modules.

Chapter 2 Technical Specifications and Performance Parameters

2.1 Processor and Memory

Parameter XC-104 XC-204 XC-303

Processor NXP CORTEX A7 single core 800MHz+CORTEX M4 200MHz NXP CORTEX A7 dual core 1GHz+CORTEX M4 200MHz Freescale CORTEX A7 dual core 960MHz

Program memory eMMC-FLAS: 2GB eMMC-FLAS: 2GB QSPI-FLAS: 128MB

Cache memory DDR3L-RAM: 256MB DDR-RAM: 512MB DDR-RAM: 512MB

Retention data 4kB 32kB 96kB

Real time clock accuracy ± 3 seconds/day @ 25 ° C ± 3 seconds/day @ 25 ° C ± 3 seconds/day @ 25 ° C

RTC power down for 10 days, 10 days, 10 days

2.2 Environmental conditions

Parameter XC-104 XC-204 XC-303

Working temperature -20...+60 ° C -20...+60 ° C -20...+55 ° C

Storage temperature -25...+70 ° C -25...+70 ° C -40...+80 ° C

Relative humidity 5... 95% (no condensation) 5... 95% (no condensation) 5... 95% (no condensation)

Protection level IP20 IP20 IP20

Vibration tolerance 5-8.4Hz ± 3.5mm

8.4-150Hz ±1.0g 5-8.4Hz ±3.5mm

8.4-150Hz ±1.0g 5-8.4Hz ±3.5mm

8.4-150Hz ±1.0g

Impact tolerance 15g/11ms, 18 times 15g/11ms, 18 times 15g/11ms, 9 times

2.3 Mechanical dimensions

XC-303 series

Dimensions (height x depth x width): 104.7 x 72 x 50 mm (4.12 x 2.83 x 1.97 inches)

Width: 4 modular units

Weight: Approximately 0.3 kg

Installation: IEC EN 60715 35mm DIN rail

Installation direction: Vertical

XC-104/204 series

Dimensions (height x depth x width): 104.7 x 72 x 23 mm (4.12 x 2.83 x 0.91 inches)

Width: 2 modular units

Weight: Approximately 0.11 kg

Installation: IEC EN 60715 35mm DIN rail

Installation direction: Vertical, XC-204 can be installed horizontally and vertically

Chapter 3 Interface and Communication

3.1 Overview of Communication Interfaces

Model Ethernet CAN RS485 USB Local I/O

XC-104-C10-000 1×10/100M - - USB Host -

XC-204-C10-000 2×10/100M - - USB Host -

XC-204-C11-003 2×10/100M CAN1 RS485 USB Host 2×DI/DO

XC-204-C20-002 2×10/100M - RS485 USB Host 2×DI/DO

XC-204-C21-001 2×10/100M CAN1 - USB Host 2×DI/DO

XC-303-C11-000 1×10/100M CAN2 - USB Host 4×DI/DO

XC-303-C21-001 2×10/100M CAN1 RS485 USB Host 4×DI/DO

XC-303-C32-002 3×10/100/1000M CAN1+CAN2 RS485 USB Host 4×DI/DO

3.2 Ethernet interface

Interface characteristics

Connector: RJ45

Transmission rate: 10/100 Mbit/s (some models support 1000 Mbit/s)

Function: Programming debugging, operating system updates, automation protocol communication

Default IP address:

XC-303: eth0 192.168.119.248, eth1 192.168.137.248, eth2 192.168.138.248

XC-204: 192.168.119.204

XC-104: 192.168.119.104

Subnet mask: 255.255.255.0

Pin allocation

Pin 10/100 Mbit 1000 Mbit

1 Tx+ Tx+_D1

2 Tx- Tx-_D1

3 Rx+ Rx+_D2

4 - BI-_D3

5 - BI+_D3

6 Rx- Rx-_D2

7 - BI-_D4

8 - BI+_D4

Cable requirements

Category: Cat 5 or higher

Maximum length: 100 meters

Recommend using shielded twisted pair cable (STP)

3.3 CAN interface

Supported models: XC-204-C11-003, XC-204-C21-001, XC-303-C11-001, XC-303-C21-001, XC-303-C32-002

Technical Specifications

Baud rate: 50/100/125/250/500/1000 kbit/s

Equipment specification: Compliant with DS301 V4

29 bit identifier: Supports

PDO type: asynchronous, synchronous, non cyclic

Connector: 3-pin spring terminal block

terminating resistor

Resistance: 120 Ω

Activation method: via DIP switch (CAN1 corresponds to TC1, CAN2 corresponds to TC2)

Relationship between cable length and baud rate

Maximum cable length for baud rate

50 kbaud 1000 m

100 kbaud 600 m

125 kbaud 500 m

250 kbaud 250 m

500 kbaud 100 m

800 kbaud 50 m

1000 kbaud 25 m

3.4 RS485 interface

Supported models: XC-204-C11-003, XC-204-C20-002, XC-303-C21-001, XC-303-C32-002

Technical Specifications

Connector: 3-pin spring terminal block

Transmission rates: 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 bit/s

Protocol support: Modbus RTU (master/slave), EVENT/ODD/ONE checksum, 1 or 2 stop bits

Terminal resistance: 120 Ω, activated through DIP switch

3.5 USB interface

Technical Specifications

Type: USB 2.0 Host Type A

Output voltage: 5 V DC

Maximum current:

XC-104/204：500 mA

XC-303：100 mA

Cable length: maximum 5 meters (shielded cable)

function

Load user program

Update the operating system

Store external data (FAT32 file system)

3.6 Local I/O

XC-204 Local I/O

Input/output quantity: 2 configurable DI/DO

Power supply: System power supply (V+)

Current: Maximum 0.5 A per channel

Input delay:<0.2 ms

Output delay: Typical 0.1 ms

Short circuit protection: Yes

XC-303 Local I/O

Input/output quantity: 4 configurable DI/DO

Power Supply: External Power Supply (Terminal X2/UL)

Current: Maximum 0.5 A per channel

Total current: 2 A maximum

Input delay:<0.2 ms

Output delay: Typical 0.1 ms

Short circuit protection: Yes

Potential isolation: isolated from the system bus

Chapter 4 Installation and Wiring

4.1 Installation Requirements

Layout of control cabinet

The power supply and control parts are arranged separately

Steel plate partitions can be used to reduce interference

Ensure sufficient ventilation

Ventilation requirements

Minimum distance from passive components: 50 mm

Minimum distance from active components: 75 mm

Installation steps

Place XC-303 at the far left of the system block (XC-104/204 does not require this)

Connect the XN300 module from the right side and ensure that the locking buckle is engaged with the guide rail

Push the front cover forward to ensure that the modules are securely locked together

Pull up all locking components

Tilt the system block onto the lower edge of the DIN rail

Push the system block towards the upper edge of the DIN rail and lock it downwards

4.2 Connecting terminals

Specification of wiring terminals

Type: Spring type terminal block

Wire type:

Solid wire: 0.2-1.5 mm ²

Flexible wire (uninsulated end): 0.25-1.5 mm ²

Flexible wire (with insulated end): 0.25-0.75 mm ²

AWG：24 - 16

Stripping length: 10mm

Diameter of crimping sleeve: ≤ 2.8 mm

4.3 Power Connection

XC-303 power supply

Terminal X6: V+/0V, 24 VDC

Power the XN300 modules on the processor unit and all system buses

XC-104/204 power supply

Terminal X4: V+/0V, 24 VDC

Power the XN300 modules on the processor unit and all system buses

Local output power supply (XC-303)

Terminal X2: UL+/UL -, 24 VDC external power supply

Power supply for local output Q1-Q4

4.4 Potential relationship

XC-303

The system power supply (X6) consists of the processor, system bus CAN、RS485、 Power over Ethernet

Local output power supply (X2/UL) is isolated from the system power supply potential

CAN1 interface isolated from system power supply potential

XC-204

The system power supply (X4) provides power to all components

No potential isolation

4.5 EMC compatible wiring

Cable classification

Power cables: high current power lines, contactor coil lines, etc

Control and signal cables: digital input cables

Measurement and signal cables: fieldbus cables

Wiring principles

Power cables and signal cables should be routed separately as much as possible

Minimum spacing: Power cables and signal cables ≥ 10cm, and data/analog cables ≥ 30cm

The return wires of a pair of circuits should be routed in parallel

Shielding Grounding

The data interface must use shielded cables

Large area low impedance grounding at both ends of the shielding layer

4.6 Suppression Circuit

For inductive loads (contactors, relays, solenoid valves), it is recommended to install suppression circuits (RC suppressors or freewheeling diodes) directly on the load to prevent high induced voltage interference with the system during switching.

Chapter 5 Programming and Debugging Environment

5.1 Programming software

The XControl series PLC uses XSOFT-CODESYS-3 programming software (version 3.5.9 or higher). This software is based on the CODESYS V3 platform and provides complete support for the IEC 61131-3 programming language.

Main functions

Project Creation and Management

Equipment configuration and parameterization

Network communication configuration

Online debugging and monitoring

Firmware Update

5.2 Project Creation and Connection

First connection steps for XC-104/204

Connect the PC to the eth0 port of the device using an Ethernet cable

Set the PC IP address to the same network segment as the device (e.g. 192.168.119.xxx)

Connect the device power supply

Log in to the Device Web Configuration Tool through a browser (https://<Device IP>: 8375)

Set up SSH remote access

Activate USB interface and restore USB to factory settings

Set date and time

Configure network settings

XSOFT-CODESYS-3 connection steps

Create a new project and select the corresponding device model

Double click on the "Device (XC xxx)" device

Select the 'Communication' tab

Click on 'Search network' or enter the PLC IP address

Select the found device and click "Flash" to verify the device (LED flashing)

5.3 Task Configuration

XControl supports multitasking and can configure up to 50 tasks.

Task type

Loop task: Repeat execution at set intervals

Event triggered task: only executed when a specific event occurs

System event task: associated with system events such as PLC start, stop, reset, etc

Task priority

Range: 0 (highest) to 31 (lowest)

Tasks of the same priority are executed in rotation according to time slices

5.4 Interrupt Handling

The local inputs of XC-204 and XC-303 can be configured as interrupt inputs.

Configurable Interrupt

Falling edge trigger

Rising edge trigger

Any edge trigger

Interrupt library

Library Name: EA_XC303Events.lib

Function:

DisabInterrupt: Disable interrupts

Enable Interrupt: Enable interrupts

Precautions

POUs triggered by interrupts will not be time monitored

No response to new interrupts during interrupt execution

Frequent interruptions may cause task timeouts

5.5 Program Download and Startup

Program Download

After logging in online, confirm 'Load the new program?'

The 'Retain' variable is initialized during the loading process

The variable 'PERSISTENT' maintains its value

Create a boot application

Method 1: Online operation

After logging in, select the 'Create boot application' command

Method 2: Automatic generation

Enable 'Implicitly generate boot application during download' in the application properties

Guide the application to save

To SD card: Use PLC Shell command 'copyprojtsd'

To USB devices: Use the PLC Shell command 'copyprojtousb'

5.6 Debugging Function

Breakpoint/single step mode

Can set breakpoints in the application

Pause program execution at breakpoint

Note: The output that has been set when reaching the breakpoint remains in its current state

single-cycle mode

Real time execution of a program cycle

Output cancelled at the end of the cycle

compulsory

All user program tags can be forcibly assigned values

Local output can only be forced when the CPU is in RUN state and the corresponding variable is assigned a value

Chapter 6 Watchdog and Task Monitoring

6.1 Watchdog Principle

Watchdogs are used to monitor the execution time of tasks. Basic relationship:

Processing time<task interval time<watchdog time

If the processing time exceeds the interval time, the task will restart at the end of the second interval (the watchdog will not be activated)

If the processing time exceeds the watchdog time, the watchdog interrupts the program execution

6.2 Watchdog Configuration

Configurable parameters

Watchdog: enabled/disabled

Watchdog Time 

Watch dog sensitivity

Sensitivity Explanation

Sensitivity=1: Triggered immediately after exceeding the watchdog time

Sensitivity=x: Triggered after x consecutive times exceeding the watchdog time

6.3 Precautions for disabling watchdog

If the watchdog is disabled, the accessed output may remain active until the PLC switches from RUN to STOP or the output power is cut off when the task cannot be completed due to a program error (such as a dead loop).

Chapter 7 System Expansion

7.1 Local Expansion

Connect the XN300 module through the system bus for local expansion.

Configuration steps

Ensure that all XN300 modules are connected and powered on

In the XSOFT-CODESYS-3 project device tree, select "Device (XC xxx)"

Right click and select 'Add device...'

Select "XN300 Master" in the "Add device" dialog box

Select the XN300 module that is actually connected, in the same order as the physical connection

Optional device scanning function for automatic detection

7.2 Remote Expansion

Remote expansion through fieldbus interface:

CANopen extension

Using XN-312-GW-CAN CANopen gateway

Up to 32 XN300 modules per CAN node

Distance between PLC and gateway: depends on baud rate, maximum 1000 meters

EtherCAT extension

Using XN-312-GW-EC EtherCAT Gateway

Support SmartWire DT module connection

Chapter 8 Web Configuration Tool (XC-104/204)

8.1 Function Overview

The XC-104/204 series PLC provides a web-based configuration tool for basic system configuration. Access method:

URL: https://<Device IP>: 8375

Port: 8375

Protocol: HTTPS

8.2 Safety Features

2048 bit RSA key encryption

Generate key upon initial startup

Password requirement:

Minimum length of 8 characters

At least one number

At least 1 uppercase letter

At least 1 lowercase letter

At least 1 special character (! @ # $^&)

Automatic logout after 15 minutes of inactivity

8.3 Main Configuration Page

Equipment configuration page

Equipment information display

Password change

USB interface activation

USB auto start

USB factory reset

Power Management (Restart/Shutdown)

Restore factory settings

Network configuration page

Static IP configuration

DHCP enabled/disabled

Host name setting

Update configuration page

Operating system update (. raucb file)

Guide loader update

progress display

Date/Time Configuration Page

Date and time setting

Timezone settings

NTP time synchronization

Remote access configuration page

SSH enable/disable

Chapter 9: PLC Shell Commands

9.1 Command Usage Method

In XSOFT-CODESYS-3:

Double click on "Device (XC xxx)" in the device tree

Select the 'PLC Shell' tab

Enter the command and press Enter to execute it

9.2 Common Commands

Command Description

Display a list of available commands

Applist displays a list of loaded applications

Canload displays CAN bus load

Caninfo displays CAN controller information

Getipconfig displays Ethernet configuration

Getrtc displays date and time

Plcload displays CPU system load (%)

Reboot the PLC

Setipadddr sets the IP address

Setrtc sets the date and time

Xngetversion displays XN driver version

Xnmodules displays configured and connected SDIAS modules

Chapter 10 Diagnosis and Troubleshooting

10.1 LED Status Indication

Meaning of LED color status

PLC green constant light running system has been started

Green flashing and communication with programming system

Red constant light running system error

PRG green constant light application running

Green flashing application stops

Red always on program error

SD green constant light detected MicroSD card

USB green constant light detected USB device

Green flashing to access storage devices

CAN1/CAN2 green flashing bus activity

Red flashing bus error

10.2 Common faults and solutions

Possible causes and solutions for the malfunction

PLC does not start and there is no 24VDC power supply. Check the power wiring

The PLC LED is always red and running. The operating system version suitable for running the system is installed incorrectly

PRG LED red constant on program error (watchdog, data access error) check program, view log file

Unable to connect XSOFT-CODESYS IP address error check network configuration, reset using web configuration tool

10.3 Diagnostic Information Acquisition

XN300 main station diagnosis

Online access devices

Select 'XN300_Saster'

Open the "XN300Master Parameters" tab

View error number and description

log file

Various log files can be downloaded through the "Logs" page of the web configuration tool.

Chapter 11 Maintenance and Disposal

11.1 Cleaning

Clean with a clean, soft, and slightly damp cloth

Stubborn stains can be sprayed with a small amount of cleaning agent on the cloth

Prohibit the use of sharp objects, corrosive cleaning agents, or solvents

11.2 Maintenance

The device can only be opened by the manufacturer or authorized repair center

Use the original packaging when sending for repair

Contact local suppliers or Eaton technical support

11.3 Storage and Transportation

Avoid UV and thermal radiation

Fluctuations in ambient temperature may cause condensation, so turn on the machine after it is completely dry

Transport in original packaging

11.4 Disposal

Abandoned equipment must be professionally disposed of in accordance with local regulations

Recyclable materials must comply with local recycling regulations

Can be returned to the manufacturer or sales point for environmental treatment

Chapter 12 Certification and Standards

12.1 Certification

Certification Instructions

CULus file number E205091 (TBD)

CE complies with all applicable EU directives

12.2 Applicable Standards

IEC/EN/DIN EN 61131-2: Programmable Logic Controller Standard

IEC/EN 60068-2-6: Vibration Testing

IEC/EN 60068-2-27: Impact testing

IEC/EN 61000-4-2: Electrostatic Discharge Immunity

IEC/EN 61000-4-3: Radio Frequency Electromagnetic Field Immunity

IEC/EN 61000-4-4: Electrical fast transient burst immunity

IEC/EN 61000-4-5: Surge Immunity

IEC/EN 61000-6-2: Industrial Environment Immunity