HORNER HE-XE1E2, HE-XE102, HE-XE106, HE-XE1E0, HE-XE1E3 User Manual
...
User Manual
for XLE/XLT OCS
HE-XE100, HE-XE102, HE-XE103, HE-XE104, HE-XE105, HE-XE106
HE-XE1E0, HE-XE1E2, HE-XE1E3, HE-XE1E4, HE-XE1E5, HE-XE1E6
HE-XT100, HE-XT102, HE-XT103, HE-XT104, HE-XT105, HE-XT106
HE-XT1E0, HE-XT1E2, HE-XT1E3, HE-XT1E4, HE-XT1E5, HE-XT1E6
HEXE220C100, HEXE220C000, HEXT240C100
HEXE220C112, HEXE220C012, HEXT240C112
HEXE220C113, HEXE220C013, HEXT240C113
HEXE220C114, HEXE220C014, HEXT240C114
HEXE220C115, HEXE220C015, HEXT240C115
HEXE220C116, HEXE220C016, HEXT240C116
HEXE221C100, HEXT241C100
HEXE221C112, HEXT241C112
HEXE221C113, HEXT241C113
HEXE221C114, HEXT241C114
HEXE221C115, HEXT241C115
HEXE221C116, HEXT241C116
August 23, 2018 MAN0878-09-EN_XLE_XLT_UserManual
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PREFACE
This manual explains how to use the XLE/XLT OCS.
Copyright (C) 2008 Horner APG, LLC., 59 South State Avenue, Indianapolis, Indiana 46201. All
rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored
in a retrieval system, or translated into any language or computer language, in any form by any
means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the
prior agreement and written permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the
terms and conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Horner APG.
Cscape, SmartStack, SmartStix and CsCAN are trademarks of Horner APG.
Ethernet is a trademark of Xerox Corporation.
Micro SD and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, please visit our website:
North America:
Tel: (+) (317) 916-4274
Fax: (+) (317) 639-4279
Website: https://hornerautomation.com
Email: techsppt@heapg.com
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: www.horner-apg.com
Email: tech.support@horner-apg.com
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LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC. ("HE-APG") warrants to the original purchaser that the XLE/XLT OCS module
manufactured by HE-APG is free from defects in material and workmanship under normal use
and service. The obligation of HE-APG under this warranty shall be limited to the repair or
exchange of any part or parts which may prove defective under normal use and service within
two (2) years from the date of manufacture or eighteen (18) months from the date of installation
by the original purchaser whichever occurs first, such defect to be disclosed to the satisfaction
of HE-APG after examination by HE-APG of the allegedly defective part or parts. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL
OTHER OBLIGATIONS OR LIABILITIES AND HE-APG NEITHER ASSUMES, NOR AUTHORIZES
ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH
THE SALE OF THIS XLE/XLT OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS
XLE/XLT OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT,
NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY
WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE
TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN
THAT PERSON FOR WHOM THE XLE/XLT OCS module IS ORIGINALLY INSTALLED. THIS
WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED
STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or
otherwise, shall HE-APG or its suppliers be liable of any special, consequential, incidental or
penal damages including, but not limited to, loss of profit or revenues, loss of use of the
products or any associated equipment, damage to associated equipment, cost of capital, cost
of substitute products, facilities, services or replacement power, down time costs, or claims of
original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the
problem, proof of purchase, post paid, insured and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying media are
included solely for illustrative purposes. Due to the many variables and requirements associated with any
particular installation, Horner APG cannot assume responsibility or liability for actual use based on the
examples and diagrams. It is the sole responsibility of the system designer utilizing the XLE/XLT OCS
module to appropriately design the end system, to appropriately integrate the XLE/XLT OCS module
and to make safety provisions for the end equipment as is usual and customary in industrial applications
as defined in any codes or standards which apply.
NOTE: The programming examples shown in this manual are for illustrative
purposes only. Proper machine operation is the sole responsibility of the
system integrator.
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VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS
The following map is provided to show the major types of tasks that need to be performed and
the key chapters in this manual needed to refer to for information and help.
Directions: Major tasks are listed at the top of the map with the key chapters listed beneath that
should be consulted in order to perform the tasks.
FIRST STEP of ANY TASK: DATASHEET
The datasheet is the first document to refer to for model-specific information related to
XLE/XLT models such as pin-outs, jumper settings, and other key installation information.
The web version of this manual has all the XLE/XLT datasheets attached to it. Visit the
website to obtain updates to datasheets and user documentation.
North America: https://hornerautomation.com or Europe: http://horner-apg.com
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety / Compliance
Page 9
Safety / Compliance
Page 9
Safety / Compliance
Page 9
Safety / Compliance
Page 9
Introduction
Page 11
Introduction
Page 11
Introduction
Page 11
Introduction
Page 11
Mechanical
Installation
Page 16
System Settings
Page 48
Fail-Safe System
Page 129
Electrical Installation
Page 22
Removable Media
Page 64
Clone Unit
Page 138
Serial
Communications
Page 25
General I/O
Page 71
Maintenance
Page 142
CAN
Communications
Page 29
High Speed I/O
Page 80
Modbus
Communications
Page 145
Downloadable
Communication
Protocols
Page 32
User Interface
Page 100
Troubleshooting
Page 149
Ethernet
Communications
Page 41
Registers
Page 106
Cscape Configuration
Page 113
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Table of Contents
PREFACE ....................................................................................................................................................... 2
LIMITED WARRANTY AND LIMITATION OF LIABILITY ................................................................................ 3
VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS ....................................................................... 4
Table of Contents .......................................................................................................................... 5
CHAPTER 1: SAFETY / COMPLIANCE .......................................................................................................... 9
1.1 Safety Warnings and Guidelines ................................................................................................. 9
1.2 Grounding ................................................................................................................................. 10
1.3 CE Compliance .......................................................................................................................... 10
CHAPTER 2: INTRODUCTION ..................................................................................................................... 11
2.1 Visual Overview of XLE/XLT and Topics Covered in this Manual ............................................ 11
2.1.1 Where to Find Information about the XLE/XLT ....................................................................... 12
2.2 Connectivity to the XLE/XLT .................................................................................................... 13
XLE/XLT .................................................................................................................................... 13
2.3 Features of XLE/XLT ................................................................................................................ 14
2.4 Accessories ............................................................................................................................... 15
2.5 Useful Documents and References .......................................................................................... 15
2.6 Opening Cscape Help File................................................................................................................. 15
CHAPTER 3: MECHANICAL INSTALLATION .............................................................................................. 16
3.1 Overview ................................................................................................................................... 16
3.2 Mounting Requirements ........................................................................................................... 16
3.2.1 Mounting Procedures (Installed in a Panel Door) ................................................................. 16
3.2.2 Mounting Procedures (Installed on DIN Rail) ....................................................................... 17
3.3 Mounting Orientation ............................................................................................................... 18
3.4 Panel Cut-Out ........................................................................................................................... 18
3.5 Dimensions................................................................................................................................ 19
3.6 Factors Affecting Panel Layout Design and Clearances .......................................................... 20
3.6.1 Clearance / Adequate Space ................................................................................................ 20
3.6.2 Grounding .............................................................................................................................. 20
3.6.3 Temperature / Ventilation .................................................................................................... 20
3.6.4 Orientation ............................................................................................................................ 21
3.6.5 Noise ...................................................................................................................................... 21
3.6.6 Shock and Vibration .............................................................................................................. 21
3.6.7 Panel Layout Design and Clearance Checklist ..................................................................... 21
CHAPTER 4: ELECTRICAL INSTALLATION ............................................................................................... 22
4.1 Grounding Definition ................................................................................................................ 22
4.2 Ground Specifications .............................................................................................................. 22
4.3 How to Test for Good Ground .................................................................................................. 23
4.4 Primary Power Port .................................................................................................................. 24
CHAPTER 5: SERIAL COMMUNICATIONS ................................................................................................. 25
5.1 Overview ................................................................................................................................... 25
5.2 Port Descriptions ...................................................................................................................... 25
5.3 Wiring ........................................................................................................................................ 26
5.4 RS-485 Termination ................................................................................................................. 27
5.5 RS-485 Biasing ......................................................................................................................... 27
5.6 Cscape Programming via Serial Port ....................................................................................... 27
5.7 Ladder-Controlled Serial Communication ................................................................................ 27
5.8 Configuration via USB .............................................................................................................. 28
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CHAPTER 6: CAN COMMUNICATIONS ...................................................................................................... 29
6.1 Overview ................................................................................................................................... 29
6.2 Port Description ........................................................................................................................ 29
6.3 Wiring ........................................................................................................................................ 30
6.4 Cscape Programming via CAN ................................................................................................. 30
6.5 Ladder-Controlled CAN Communication .................................................................................. 31
6.6 Using CAN for I/O Expansion (Network I/O) ............................................................................ 31
CHAPTER 7: DOWNLOADABLE COMMUNICATION PROTCOLS ................................................................ 32
7.1 Overview ................................................................................................................................... 32
7.2 Protocol Config ......................................................................................................................... 34
7.3 Network Configuration ............................................................................................................. 35
7.4 Device List and Device Configuration ...................................................................................... 37
7.5 Scan List ................................................................................................................................... 38
7.6 Data Mapping Configuration (Scan List Entry) ................................................................................. 39
CHAPTER 8: ETHERNET COMMUNICATION .............................................................................................. 41
8.1 Ethernet Module Protocols and Features ................................................................................ 41
8.2 Ethernet System Requirements ............................................................................................... 41
8.3 Ethernet Module Specifications ............................................................................................... 41
8.4 Ethernet Module Configuration ................................................................................................ 42
8.5 Ethernet Configuration – IP Parameters .................................................................................. 46
8.6 Ethernet Module Protocol Configuration ................................................................................. 47
CHAPTER 9 SYSTEM SETTINGS AND ADJUSTMENTS ............................................................................ 48
9.1 System Menu - Overview .......................................................................................................... 48
9.2 System Menu – Navigation and Editing .................................................................................... 48
XLE System Menu ............................................................................................................................... 49
XLT System Menu ............................................................................................................................... 50
9.3 System Menu – Details .............................................................................................................. 51
CHAPTER 10: REMOVABLE MEDIA .................................................................................................... 64
10.1 Overview ................................................................................................................................... 64
10.2 microSD Cards .......................................................................................................................... 64
10.3 micro SD File System ................................................................................................................ 65
10.4 Using the Removable Media Manager ...................................................................................... 65
10.5 Using Removable Media to Log Data ....................................................................................... 65
10.6 Using Removable Media to Load and Save Applications ......................................................... 66
10.7 Using Removable Media to View and Capture Screens ........................................................... 66
10.8 Removable Media (RM) Function Blocks in Cscape .................................................................. 67
10.9 Removable Media (RM) Features—Program Features .............................................................. 67
10.10 Removable Media (RM) Features—Graphic/Screen Editor ....................................................... 68
10.11 Removable Media (RM) Features—Additional Configuration ................................................... 68
10.12 Filenames used with the Removable Media (RM) Function Blocks .......................................... 69
10.13 System Registers used with RM ............................................................................................... 70
CHAPTER 11: GENERAL I/O ................................................................................................................... 71
11.1 Overview ................................................................................................................................... 71
11.2 Removing the XLE/XLT Back Cover ......................................................................................... 71
11.3 Model I/O Overview .................................................................................................................. 72
11.4 Solid-State Digital Outputs ....................................................................................................... 73
11.5 Relay Outputs ........................................................................................................................... 74
11.6 Digital Inputs ............................................................................................................................. 75
11.7 Analog Inputs ............................................................................................................................ 76
11.7.1 Thermistor Option for Special Orders .................................................................................. 76
11.7.2 Common Cause of Analog Input Tranzorb Failure, Models 2, 3, 4, & 5 ................................ 76
11.8 Universal Analog Inputs............................................................................................................ 77
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11.9 Analog Outputs ......................................................................................................................... 79
CHAPTER 12: HIGH SPEED I/O (HSC / PWM) ......................................................................................... 80
12.1 Overview ................................................................................................................................... 80
12.2 Glossary .................................................................................................................................... 81
12.2 High Speed Counter (HSC) Functions ...................................................................................... 82
12.2.1 Frequency ............................................................................................................................. 82
12.2.2 Totalize .................................................................................................................................. 83
12.2.3 Pulse Width Measurement .................................................................................................... 85
12.2.3 Period Measurement ............................................................................................................. 86
12.2.4 Quadrature ............................................................................................................................ 87
12.3 HSC Functions Register Map .................................................................................................... 91
12.4 Pulse Width Modulation (PWM) Functions ............................................................................... 92
12.4.1 Normal ................................................................................................................................... 92
12.4.2 PWM ...................................................................................................................................... 92
12.4.3 PWM Output Waveform ........................................................................................................ 95
12.4.4 HSC (High Speed Counter) .................................................................................................... 96
12.4.5 Stepper Function ................................................................................................................... 96
12.5 PWM functions register map .................................................................................................... 97
12.6 PWM Examples .......................................................................................................................... 98
12.7 STP Examples ........................................................................................................................... 99
CHAPTER 13: USER INTERFACE ........................................................................................................... 100
13.1 Overview ................................................................................................................................. 100
13.2 Screen Navigation .................................................................................................................. 100
13.3 Using Editable Screen Objects ............................................................................................... 101
13.4 Ladder Based Screen Navigation ........................................................................................... 102
13.5 Alarms ..................................................................................................................................... 103
13.6 Screen Saver ........................................................................................................................... 105
13.7 Screen Brightness................................................................................................................... 105
CHAPTER 14: REGISTERS ..................................................................................................................... 106
14.1 Register Definitions ................................................................................................................ 106
14.2 Useful %S and %SR registers ................................................................................................ 108
14.3 Register Map for XLE/XLT I/O................................................................................................ 111
14.4 Resource Limits ...................................................................................................................... 112
CHAPTER 15: CSCAPE CONFIGURATION ............................................................................................. 113
15.1 Overview ................................................................................................................................. 113
15.2 Updating Programs from First Generation to Second Generation XLE/XLT ........................ 113
15.3 Cscape Status Bar .................................................................................................................. 114
15.4 Establishing Communications Overview ................................................................................ 115
15.4.1 Communicating via MJ1 Serial Port ......................................................................................... 120
15.4.2 Communicating via On Board Ethernet Port .......................................................................... 121
15.6 Configuration .......................................................................................................................... 122
15.7 Digital / HSC Input Configuration ........................................................................................... 123
15.8 Digital / PWM Output Configuration....................................................................................... 124
15.9 Analog Input Configuration .................................................................................................... 125
15.10 Analog Output Configuration ................................................................................................. 126
15.11 Scaling Analog Inputs ................................................................................................................... 127
CHAPTER 16: FAIL – SAFE SYSTEM ...................................................................................................... 129
16.1 Overview ................................................................................................................................. 129
16.2 Settings ................................................................................................................................... 130
16.3 Backup / Restore Data............................................................................................................ 130
CHAPTER 17: CLONE UNIT ................................................................................................................... 138
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17.1 Overview ................................................................................................................................. 138
17.2 Clone ....................................................................................................................................... 138
17.3 Load Clone .............................................................................................................................. 140
CHAPTER 18: MAINTENANCE .................................................................................................................. 142
18.1 Firmware Updates .................................................................................................................. 142
18.2 Backup Battery ....................................................................................................................... 143
18.2.1 Indications the battery needs replacing ............................................................................. 143
CHAPTER 19: MODBUS COMMUNICATIONS ............................................................................................. 145
19.1 Modbus Overview ................................................................................................................... 145
19.2 Modbus Slave Overview .......................................................................................................... 145
19.3 Modbus Master Overview ....................................................................................................... 146
19.4 Modbus Addressing Table for XLE/XLT Units ........................................................................ 147
CHAPTER 20: TROUBLESHOOTING / TECHNICAL SUPPORT.................................................................. 149
20.1 Connecting to the XLE/XLT .................................................................................................... 149
20.1.1 Connecting Troubleshooting Checklist ............................................................................... 150
20.2 Local Controller and Local I/O ............................................................................................... 151
20.2.1 Local I/O Troubleshooting Checklist .................................................................................. 151
20.3 CsCAN Network ............................................................................................................................. 152
20.3.1 CsCAN Network Troubleshooting Checklist ....................................................................... 152
20.4 Removable Media ................................................................................................................... 153
20.4.1 Basic Troubleshooting ........................................................................................................ 153
20.5 Technical Support Contacts ................................................................................................... 153
INDEX ........................................................................................................................................................ 154
INDEX OF FIGURES AND TABLES ............................................................................................................. 157
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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
• All applicable codes and standards need to be followed in the installation of this product.
• For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG
or larger.
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING: EXPLOSION HAZARD – Substitution of components may impair suitability for
Class I, Division 2.
WARNING: EXPLOSION HAZARD – Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth)
ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of
fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING: Only qualified electrical personnel familiar with the construction and operation
of this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe bodily injury or
loss of life.
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Adhere to the following safety precautions whenever any type of connection is made to the
module.
• Connect the green safety (earth) ground first before making any other connections.
• When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not make connections to live power lines.
• Make connections to the module first; then connect to the circuit to be monitored.
• Route power wires in a safe manner in accordance with good practice and local codes.
• Wear proper personal protective equipment including safety glasses and insulated
gloves when making connections to power circuits.
• Ensure hands, shoes, and floors are dry before making any connection to a power line.
• Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
• Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.
1.2 Grounding
Grounding is covered in various chapters within this manual.
▪ For grounding specifications and testing for a good ground, refer to Page 23.
▪ For panel grounding, refer to Page 20.
1.3 CE Compliance
To check for compliance and updates, visit our website.
North America https://hornerautomation.com/certifications
Europe http://www.horner-apg.com/en/support/certification.aspx
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CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XLE/XLT and Topics Covered in this Manual
Figure 2.1 – Visual Overview of XLE/XLT
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2.1.1 Where to Find Information about the XLE/XLT
a. Datasheets - The datasheets are the first documents to refer to for key information related
to specific XLE/XLT models. (A basic datasheet is provided in the box with the unit.) Datasheets
for each model can be found on our website.
Table 2.1 – Datasheet Manual Numbers
Model 0
MAN1112
Model 2
MAN1113
Model 3
MAN1114
Model 4
MAN1115
Model 5
MAN1116
Model 6
MAN1117
Datasheets contain pin-outs, jumper settings and other model specific information.
b. User Manual -This manual provides general information that is common to XLE/XLT models
and can be downloaded from our website. Visit our website, North America
https://hornerautomation.com or Europe http://www.horner-apg.com , to obtain user
documentation and updates.
Four main types of information are covered in the manual.
▪ Safety and Installation guidelines / instructions (Mechanical and Electrical)
▪ Descriptions of hardware features (Serial ports, Removable Media, Communication
Options, etc.)
▪ Configuration and Use of the XLE/XLT
▪ Maintenance and Support
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2.2 Connectivity to the XLE/XLT
The XLE/XLT has excellent capabilities for connecting to a variety of devices. The diagram below shows
some examples of devices that can be used with the XLE/XLT. XLEe/XLTe have Ethernet options.
Figure 2.2 –Overview of Types of Devices that can be connected to XLE/XLT
CAN
Serial
I/O
XLE/XLT
Other OCS Devices
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
Sensors
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
Other OCS Devices
Smart Stix I/O
Smart Block I/O
Smart Rail I/O
USB
Ethernet
Options
Other OCS Devices
Drives
PLCs
SCADA
OPC Server
Portal
I/O Devices
Smart Rail Devices
USB Slave,
Programming /
monitoring port
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2.3 Features of XLE/XLT
The XLE/XLT is an all-in-one industrial control device. It combines control, user interface, I/O
and networking into a single, integrated package. Unique features of the XLE/XLT include:
• Bright, graphical LCD display (in XLE) (with touch sensing in XLT)
• Display of complex graphical objects including trends, gauges, meters and animations
• Advanced control capabilities including floating point, multiple auto-tuning PID loops
and string handling capabilities
• Removable media for up to two terabytes of storage of programs, data logging or screen
captures
• CsCAN networking port (optional) for communication with remote I/O, other controllers
or PCs.
• Ethernet version (XLEe/XLTe) with native Ethernet for communication with other
controllers, drives, PCs, etc.
• Configurable serial protocols for communication to drives, PLCs, or other serial
peripherals.
• USB 2.0 full speed port for programming and monitoring.
• Full featured, built-in I/O including high resolution analog, thermocouple, RTD, high-
speed counters, PWM outputs, and relays (depending upon the XLE/XLT model used).
• Cscape programming software that allows all aspects of the XLE/XLT, XLEe/XLTe to be
programmed and configured from one integrated application.
• Optional communication add-on modules that allow additional capabilities such as
Ethernet (pre rev TA only) or modems.
• Fail – Safe System which allows an application to continue running in the event of “Soft”
failures such as (Battery power loss or Battery Backed register RAM / Application Flash
corruption)
• Clone Unit allows the user to “clone” the OCS of the exact same model. This feature
“clones” application program and unit settings stored in Battery backed RAM of an OCS.
It can then be used to clone a different OCS (exact same model).
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2.4 Accessories
Please visit the Horner Control Accessories website for communication, programming, and I/O
accessories.
North America: http://hornerautomation.com/product-category/home/control-accessories/
Europe: http://horner-apg.com/en/products.aspx
2.5 Useful Documents and References
Visit our website, North America https://hornerautomation.com or Europe http://www.horner-
apg.com, to obtain user documentation, supplemental documents, certificates, and other
documentation.
2.6 Opening Cscape Help File
After opening the Cscape Help file, either use the Contest, Index or Search tabs to located
information. The Cscape Help file has more information than the scope of this user manual.
Select tab.
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CHAPTER 3: MECHANICAL INSTALLATION
NOTE: The datasheet is the first document to refer to for model-specific information related
to XLE/XLT models such as pin-outs, jumper settings, and other key installation information.
Visit our website, North America https://hornerautomation.com or Europe http://www.horner-
apg.com, to obtain datasheets, user documentation, and updates.
3.1 Overview
The mechanical installation greatly affects the operation, safety, and appearance of the system.
Information is provided to mechanically install the unit such as cut-out sizes, mounting
procedures, and other recommendations for the proper mechanical installation of the unit.
3.2 Mounting Requirements
XLE/XLT products can be mounted through a panel or on DIN rail.
3.2.1 Mounting Procedures (Installed in a Panel Door)
Figure 3.1 – Panel Mounting of the XLE/XLT and Close-up View of Back
Slot
for Clip
DIN
Rail
001XLE055
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Once the panel design has been completed using the criteria and suggestions in the following
sections, use the following steps to panel mount the XLE/XLT.
1. Remove all connectors from the XLE/XLT unit.
2. Press the DIN rail clip up to make passing the unit through the cutout easier.
3. Make sure the gasket is installed on the XLE/XLT and is free from dust and debris. Check that
the corners of the gasket are secure.
4. Pass the unit through the panel.
5. Insert the each of the four (4) mounting clips into the slots in the XLE/XLT case. One clip
should be installed on each corner. Lightly tignten each screw so the clip is held in place.
6. Tighten the screws on the clips such that the gasket is compressed against the panel.
Recommended torque is 7-10 in-lbs [0.8-1.13 Nm]).
3.2.2 Mounting Procedures (Installed on DIN Rail)
Figure 3.2 – DIN Rail Mounting of the XLE/XLT
The XLE/XLT is designed to clip onto standard 35mm DIN rail. If your installation requires
liquid or dust protection, make sure the XLE/XLT is placed in an appropriate sealed panel
when mounting on DIN rail. Use the following steps to mount the XLE/XLT on DIN rail.
1. Move the DIN rail clip to the lower position.
2. Clip the “Top Clips” on the top of the DIN rail.
3. Press the unit into place and press the DIN rail clip up. A small flat-head screwdriver
can be used in the slot of the DIN rail clip if clearance is an issue.
NOTE: The DIN rail connection does not provide an earth ground. Refer to Page 20 for proper
grounding information.
DIN
Rail Clip
Top
Clip
NOTE: Mount the XLE/XLT with
the DIN Rail in the horizontal
position to avoid slippage.
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3.3 Mounting Orientation
Figure 3.3 – Orientation of XLE/XLT OCS
3.4 Panel Cut-Out
For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut
with a tolerance of +/- 0.005” (0.1 mm). The XLE/XLT is designed to fit
1
4
DIN panel openings.
There are a number of punches and enclosures designed to accommodate opening of this size.
Figure 3.4 – XLE/XLT Panel Cut-out
3.622 [92mm]
3.622 [92mm]
001XLE002
CAUTION: For DIN Rail mounting:
To prevent the unit from slipping off the DIN Rail,
do not install the unit on its sides as shown. Be sure
the DIN Rail is in the horizontal position.
NOTE: For panel or DIN rail mounting:
The orientation shown above provides
for optimum legibility of the screen and
ease of use of the keypad.
001XLE056
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3.5 Dimensions
XLT XLE
Figure 3.5 – XLE/XLT Dimensions
NOTE: When the communication add-on modules are installed such communication and I/O, the
depth of the product increases from 2.264” (57.5mm) to 2.68” (68mm).
NOTE: The keypad overlay
appearance may differ.
Standard US/EU overlays
pictured here for example.
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3.6 Factors Affecting Panel Layout Design and Clearances
The designer of a panel layout must assess the requirements of a particular system and to
consider the following design factors. A convenient checklist is provided in Section 3.6.7.
3.6.1 Clearance / Adequate Space
Install devices to allow sufficient clearance to open and close the panel door.
Table 3.1 – Minimum Clearance Requirements for Panel Box and Door
Minimum Distance between base
of device and sides of cabinet
2” (50.80mm)
Minimum Distance between base
of device and wiring ducts
1.5” (38.10mm)
If more than one device installed in panel box
(or on door):
Minimum Distance between bases of each device
4” (101.60mm) between bases of each device
When door is closed:
Minimum distance between device and closed door
(Be sure to allow enough depth for XLE/XLT.)
2” (50.80mm)
3.6.2 Grounding
Panel box: The panel box must be properly connected to earth ground to provide a good
common ground reference.
Panel door: Tie a low impedance ground strap between the panel box and the panel door
to ensure that they have the same ground reference.
3.6.3 Temperature / Ventilation
Ensure that the panel layout design allows for adequate ventilation and maintains the
specified ambient temperature range. Consider the impact on the design of the panel
layout if operating at the extreme ends of the ambient temperature range. For
example, if it is determined that a cooling device is required, allow adequate space and
clearances for the device in the panel box or on the panel door.
WARNING: It is important to follow the requirements of the panel manufacturer and to follow all
applicable electrical codes and standards.
WARNING: Be sure to meet the ground requirements of the panel manufacturer and also meet
applicable electrical codes and standards.
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3.6.4 Orientation
When panel-mounted, there are no orientation restrictions on the XLE/XLT. However,
the orientation shown in Figure 3.3 provides for optimum legibility of the screen and
ease of use of the keypad. When DIN Rail mounted, observe the orientation shown in
Figure 3.3
3.6.5 Noise
Consider the impact on the panel layout design and clearance requirements if noise
suppression devices are needed. Be sure to maintain an adequate distance between
the XLE/XLT and noisy devices such as relays, motor starters, etc.
3.6.6 Shock and Vibration
The XLE/XLT has been designed to operate in typical industrial environments that may
inflict some shock and vibration on the unit. For applications that may inflict excessive
shock and vibration please use proper dampening techniques or relocate the XLE/XLT
to a location that minimizes shock and/or vibration.
3.6.7 Panel Layout Design and Clearance Checklist
The following list provides highlights of panel layout design factors.
✓ Meets the electrical code and applicable standards for proper grounding, etc.?
✓ Meets the panel manufacturer’s requirements for grounding, etc.?
✓ Is the panel box properly connected to earth ground? Is the panel door properly
grounded? Has the appropriate procedure been followed to properly ground the devices
in the panel box and on the panel door?
✓ Are minimum clearance requirements met? (See Table 3.1) Can the panel door be easily
opened and closed? Is there adequate space between device bases as well as the sides
of the panel and wiring ducts?
✓ Is the panel box deep enough to accommodate the XLE/XLT?
✓ Is there adequate ventilation? Is the ambient temperature range maintained? Are
cooling or heating devices required?
✓ Are noise suppression devices or isolation transformers required? Is there adequate
distance between the base of the XLE/XLT and noisy devices such as relays or motor
starters? Ensure that power and signal wires are not routed in the same conduit.
✓ Are there other requirements that impact the particular system, which need to be
considered?
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CHAPTER 4: ELECTRICAL INSTALLATION
NOTE: The datasheet is the first document to refer to for model-specific information related
to XLE/XLT models such as pin-outs, jumper settings, and other key installation information.
Visit our website, North America https://hornerautomation.com or Europe:
http://www.horner-apg.com, to obtain datasheets, user documentation, and updates.
4.1 Grounding Definition
Ground: The term Ground is defined as a conductive connection between a circuit or piece of
equipment and the earth. Grounds are fundamentally used to protect an application from
harmful interference causing either physical damage such as by lightning or voltage
transients or from circuit disruption often caused by radio frequency interference (RFI).
4.2 Ground Specifications
Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality it
typically is higher. The U.S. National Electrical Code (NEC) states the resistance to ground
shall not exceed 25Ω. Horner APG recommends less than 15Ω resistance from the equipment
to ground. Resistance greater than 25Ω can cause undesirable or harmful interference to the
device.
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4.3 How to Test for Good Ground
In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground
Resistance Meter Kit contains a meter, two or three wire leads, and two ground rods.
Instructions are supplied for either a two-point or a three-point ground test. Figure 4.1 shows
a two-point ground connection test.
Figure 4.1 – Two-Point Ground Connection Test
METAL WATER PIPE OR
OTHER GOOD GROUND
GROUND ROD
GROUND
DISCONNECTED
FROM SERVICE
GROUND RESISTANCE METER
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4.4 Primary Power Port
Table 4.1– Primary Power Port Pins
Pin
Signal
Description
1 Frame Ground
2
0V
Input power supply 0V
3
+10 to 30VDC
Input power supply positive voltage
Figure 4.2 – Power Connector (Primary Power Port)
Figure 4.3 – As Viewed Looking at the XLE/XLT
001NX002
PIN 1
PIN 2
PIN 3
+
10-30VDC
supply
-
+
+
Power Connector
Power Up:
Connect to Earth Ground.
Apply 10 – 30VDC.
Screen lights up.
Torque rating 4.5 - 7 in-lbs
(0.50 – 0.78 N-m)
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CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XLE/XLT models provide two serial ports, which are implemented with 8-pin modular RJ45
connectors and are labeled MJ1 and MJ2. The MJ1 serial port is normally used for XLE/XLT
programming by connecting it to the COM port of a PC running Cscape. In addition, both MJ1
and MJ2 can be used for application-specific communication, using a variety of standard data
exchange protocols.
5.2 Port Descriptions
The MJ1 serial port contains both a half-duplex RS-485 interface and an RS-232 interface with
RTS/CTS handshaking.
NOTE: MJ1 shares its serial port with the optional COM module, so when an optional Modem
COM or other module is installed and active, the MJ1 connector is inactive.
The MJ2 serial port contains both a full-duplex RS-485 interface and an RS-232 interface with
no handshaking. Both the MJ1 and MJ2 RS-485 interfaces provide switchable termination and
bias resistors internally. Also, both MJ1 and MJ2 can be set as the serial programming port.
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5.3 Wiring
The figures along with Table 5.1 and Table 5.2 show how the MJ1 and MJ2 serial port pins are
assigned.
Figure 5.1 – MJ1 & MJ2 Serial Ports
Table 5.1 – MJ1 Serial Port Pin Assignments
Pin
Signal
Signal Description
Direction
1
RX/TX+
RS-485 Receive/Transmit Positive
In/Out
2
RX/TX−
RS-485 Receive/Transmit Negative
In/Out
3
CTS1 RS-232 Clear to Send
Out 4 RTS1
RS-232 Request to Send
In 5 +5*
+5 VDC 60mA max
Out
6
0V
Ground
−
7
TD1
RS-232 Transmit Data
In 8 RD1
RS-232 Receive Data
Out
Table 5.2 – MJ2 Serial Port Pin Assignments
Pin
Signal
Signal Description
Direction
1
RX+
RS-485 Receive Positive
In
2
RX−
RS-485 Receive Negative
In
3
TX+
RS-485 Transmit Positive
Out
4
TX−
RS-485 Transmit Negative
Out
5
+5*
+5 VDC 60mA max
Out
6
0V
Ground
−
7
TD1
RS-232 Transmit Data
In 8 RD1
RS-232 Receive Data
Out
Signals are labeled for connection to a DTE device.
8
1
NOTE: MJ1 and MJ2 look the
same but have different pin
assignments and functions.
• * +5 on XLE Rev E and later
• * +5 on all revisions XLT
MJ2 Pinouts in Full and Half Duplex Modes
Pin
MJ1 Pins
MJ2 Pins
Signal
Direction
Signal
Direction
8
TXD
OUT
TXD
OUT
7
RXD
IN
RXD
IN
6
0V
Ground
0V
Ground
5*
+5 60mA
OUT
+5 60mA
OUT 4 RTS
OUT
TX-
OUT 3 CTS
IN
TX+
OUT
2
RX- / TX-
IN / OUT
RX-
IN
1
RX+ / TX+
IN / OUT
RX+
IN
1
8
* +5Vdc 60mA Max
Pin
MJ2 Pins
Signal
Direction
8
TXD
OUT
7
RXD
IN 6 0V
Ground
5*
+5 60mA
OUT 4 TX-
OUT
3
TX+
OUT
2
RX-
IN 1 RX+
IN
1
8
MJ2 Full Duplex Mode
MJ2 Half Duplex Mode
Pin
MJ2 Pins
Signal
Direction
8
TXD
OUT
7
RXD
IN 6 0V
Ground
5*
+5 60mA
OUT 4 TX-
OUT
3
TX+
OUT
2
TX-/RX-
IN/OUT
1
TX+/RX+
IN/OUT
1
8
* +5 VDC 60mA Max
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5.4 RS-485 Termination
Proper RS-485 termination minimizes reflections and improves reliability.
Both serial ports allow an internal 121Ω RS-485 termination resistor to be placed across pins 1
and 2. This can be done by installing a jumper / switching the dip switch. Please refer to the
XLE/XLT data sheet for jumper / switch locations.
NOTE: Only the two devices physically located at the endpoints of the RS-485 network should
be terminated.
5.5 RS-485 Biasing
RS-485 biasing passively asserts a line-idle state when no device is actively transmitting,
which is useful for multi-drop RS-485 networking.
Both serial ports allow internal 390 Ω RS-485 bias resistors to be switched in, pulling pin 1 up
to 3.3V and pin 2 down to ground. The Set Serial Ports item in the System Menu (Chapter 9)
can be used to enable RS-485 biasing. Also, an application graphics screen that writes to
%SR164 can do the same thing. Setting %SR164.1 enables MJ1 biasing and setting %SR164.2
enables MJ2 biasing.
If biasing is used, it should be enabled in only one of the devices attached to the RS-485
network.
5.6 Cscape Programming via Serial Port
If a PC COM port is connected to the XLE/XLT MJ1 serial port, Cscape can access the XLE/XLT
for programming and monitoring.
5.7 Ladder-Controlled Serial Communication
Using Serial Communication function blocks, both MJ1 and MJ2 support Generic, Modbus
Master and Modbus Slave Protocols. In addition, external modems can be connected and
accessed using Init, Dial and Answer Modem function blocks.
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5.8 Configuration via USB
It is possible to load the program and monitor data via the USB 2.0 slave port on XLE/XLT Rev
T and later. To load via USB configure the communications port in Cscape as follows, the unit
must be connected via the USB mini-USB port to the PC or laptop:
Select Tools → Applications Settings → Communications → USB button.
It is possible to download/upload and use the data monitoring functions once connected.
NOTE: It is advisable to use an isolated USB cable between the PC/laptop and the XLE/XLT
when third party devices are connected to the XLE/XLT to avoid damaging ground loops to
the PC/laptop and/or the XLE/XLT.
Figure 5.2 – Configuration via USB
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CHAPTER 6: CAN COMMUNICATIONS
NOTE: For additional CAN information, refer to the CAN Networks manual (MAN0799) on the
website, North America https://hornerautomation.com or Europe: http://www.horner-apg.com
6.1 Overview
Some XLE/XLT models (XE1xx) provide a CAN networking port, which is implemented with a 5pin connector, labeled CAN 1.
The CAN1 port allows the XLE/XLT OCS to exchange global data with other OCS/RCS
controllers and to access remote Network I/O devices (SmartStix, Smart Blocks and Smart
Rail Modules).
The CAN1 port also supports pass-through communications for programming multiple OCS
controllers over the CsCAN network.
The CAN 1 port also allows the XLE/XLT to exchange global data with other OCS/RCS controllers
and to access remote Network I/O devices (SmartStix Modules).
6.2 Port Description
The XLE/XLT CAN 1 port implements the ISO 11898-2 physical layer and the CAN 2.0A data link
layer standards. Also, since the CAN 1 port is powered by an internal isolated power supply,
external CAN power is not required. The CAN1 port does not supply power to the network.
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6.3 Wiring
Figure 6.1 and Table 6.1 show how the CAN 1 port pins are assigned.
Figure 6.1 – CAN1 Port Connector
Table 6.1 – CAN 1 Port Pin Assignments
Pin
Signal
Signal Description
1
V-
CAN Ground
2
CN_L
CAN Data Low
3
SHLD
Shield Ground
4
CN_H
CAN Data High
5
NC
No Connect
6.4 Cscape Programming via CAN
The CAN 1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed
(via PCI card or USB), and the PC CAN port is connected to the XLE/XLT CAN 1 port, Cscape can
access the XLE/XLT for programming and monitoring.
In addition, the XLE/XLT supports single-point-programming of all XLE/XLT and other OCS/RCS
devices that are connected to a CAN network. If the PC COM port is connected to the XLE/XLT
programming port (see Chapter 5), the XLE/XLT can act as a pass-through gateway allowing
Cscape to access all XLE/XLT and OCS/RCS devices that are attached to the CAN network.
NOTE: The V+ connection is
not required on the XLE/XLT.
The XLE/XLT network port is
self-powered. Supporting
devices can require this
connection, and this pin can
be used to land the extra wire
required for those devices.
CAN Connector
Use the CAN Connector
when using CsCAN
network.
Torque rating: 4.5 – 7
in-lbs
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