HORNER XL7 OCS User Manual
User Manual for XL7 OCS
MAN0974-09-EN_XL7_UserManual
HE-XW1E0 / HEXT391C100
HE-XW1E2 / HEXT391C112
HE-XW1E3 / HEXT391C113
HE-XW1E4 / HEXT391C114
HE-XW1E5 / HEXT391C115
HE-XW1E6 / HEXT391C116
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PREFACE
This manual explains how to use the XL7 OCS.
Copyright© 2013 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, SmartRail, SmartMod, and CsCAN are trademarks of Horner
APG.
Ethernet™ is a trademark of Xerox Corporation.
microSD™ 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: http://www.horner-apg.com
Email: technical.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 XL7 (HEXW/HEXT391) 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 XL7 OCS module. THIS WARRANTY
SHALL NOT APPLY TO THIS XL7 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 HEAPG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED
TO MEAN THAT PERSON FOR WHOM THE XL7 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, postpaid, 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 XL7 OCS module to appropriately design the end system, to appropriately
integrate the XL7OCS 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 CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each XL7 OCS unit is sent with a datasheet in the box. The datasheets are the first
documents to refer to for model-specific information related to XL7 OCS models for
specific installation information. To obtain updates to datasheets, manuals and user
documentation, visit a Horner website.
North America https://hornerautomation.com Europe http://www.horner-apg.com
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
Serial
Communications
Maintenance
Introduction
Electrical Installation
CAN Communications
Modbus
Communications
Ethernet
Communications
Troubleshooting
Downloadable
Communication
Protocols
System Settings
Removable Media
General I/O
High-Speed I/O
User Interface
Registers
Cscape Configuration
Audio Configuration
Video Configuration
Back-up Battery
Fail-Safe System
Clone Unit
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TABLE OF CONTENTS
PREFACE ..................................................................................................................................................... 2
ABOUT PROGRAMMING EXAMPLES ....................................................................................................... 3
VISUAL MAP OF CHAPTERS .................................................................................................................... 4
TABLE OF CONTENTS ............................................................................................................................... 5
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................. 9
1.1 Safety Warnings and Guidelines ............................................................................................... 9
1.2 Grounding ...................................................................................................................................... 10
1.3 Compliance ................................................................................................................................... 10
CHAPTER 2: INTRODUCTION ................................................................................................................. 11
2.1 Visual Overview of XL7 OCS ...................................................................................................... 11
2.2 Connectivity to the XL7 OCS .................................................................................................... 13
2.3 Features of XL7 OCS .................................................................................................................. 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
3.3 Mounting Orientation ................................................................................................................. 17
3.4 Panel Cut-Out ............................................................................................................................... 19
3.5 Factors Affecting Panel Layout Design and Clearances .................................................. 20
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 and Dip Switches ........................................................................................................... 25
5.4 RS485 Termination ................................................................................................................... 26
5.5 RS485 Biasing ............................................................................................................................. 26
5.6 Cscape Programming via Serial Port .................................................................................... 27
5.7 Ladder-Controlled Serial Communication ............................................................................ 27
5.8 Configuration via Mini-B USB .................................................................................................. 27
CHAPTER 6: CAN COMMUNICATIONS............................................................................................... 28
6.1 Overview ....................................................................................................................................... 28
6.2 Port Description .......................................................................................................................... 28
6.3 CAN Port Wiring .......................................................................................................................... 29
6.4 Cscape Programming via CAN ................................................................................................ 29
6.5 Ladder-Controlled CAN Communication .............................................................................. 29
6.6 Using CAN for I/O Expansion (Network I/O) ........................................................................ 29
CHAPTER 7: ETHERNET COMMUNICATION ..................................................................................... 30
7.1 Ethernet Module Protocols and Features ............................................................................ 30
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7.2 Ethernet System Requirements ............................................................................................. 30
7.3 Ethernet Module Specifications .............................................................................................. 30
7.4 Ethernet Module Configuration ............................................................................................... 31
7.5 Ethernet Configuration – IP Parameters .............................................................................. 34
7.6 Ethernet Module Protocol Configuration ............................................................................. 34
CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS ............................................... 35
8.1 Overview ....................................................................................................................................... 35
8.2 Protocol Config ........................................................................................................................... 37
8.3 Network Configuration.............................................................................................................. 38
8.4 Device List and Device Configuration ................................................................................... 40
8.5 Scan List ........................................................................................................................................ 41
8.6 Data Mapping Configuration (Scan List Entry) ................................................................... 42
CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................ 44
9.1 System Menu - Overview .......................................................................................................... 44
9.2 System Menu – Navigation and Editing ................................................................................. 45
9.3 System Menu – Details .............................................................................................................. 47
9.4 Touch screen calibration .......................................................................................................... 66
CHAPTER 10: REMOVABLE MEDIA ..................................................................................................... 67
10.1 Overview ....................................................................................................................................... 67
10.2 microSD Cards ......................................................................................................................... 67
10.3 microSD File System .............................................................................................................. 67
10.4 Using the Removable Media Manager ............................................................................... 68
10.5 Using Removable Media to Log Data ................................................................................. 68
10.6 Using Removable Media to Load and Save Applications .............................................. 69
10.7 Using Removable Media to View and Capture Screens ................................................ 69
10.8 Configuration of a Removable Media ................................................................................ 70
10.9 Removable Media (RM) Function Blocks in Cscape ........................................................ 70
10.10 Removable Media (RM) Features—Program Features .................................................... 71
10.11 Removable Media (RM) Features—Graphic/Screen Editor ............................................ 71
10.12 Removable Media (RM) Features—Additional Configuration ........................................ 71
10.13 Filenames used with the Removable Media (RM) Function Blocks ............................ 72
10.14 System Registers used with RM .......................................................................................... 73
CHAPTER 11: GENERAL I/O ................................................................................................................... 74
11.1 Overview ....................................................................................................................................... 74
11.2 Removing the XL7 OCS I/O Cover .......................................................................................... 74
11.3 Model and I/O Overview ........................................................................................................... 76
11.4 Solid-State Digital Outputs ...................................................................................................... 77
11.5 Relay Outputs .............................................................................................................................. 78
11.6 Digital Inputs................................................................................................................................ 80
11.7 Analog Inputs ............................................................................................................................... 81
11.8 Universal Analog Inputs ............................................................................................................ 82
11.9 Analog Outputs ........................................................................................................................... 83
CHAPTER 12: HIGH SPEED I/O (HSC / PWM) ................................................................................... 84
12.1 Overview ....................................................................................................................................... 84
12.2 Glossary ........................................................................................................................................ 85
12.3 High Speed Counter (HSC) Functions ................................................................................... 86
12.4 HSC Functions Register Map ............................................................................................... 94
12.5 High Speed Output Functions .............................................................................................. 97
12.6 High Speed Output Functions Register Map .................................................................... 101
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12.7 PWM Examples ...........................................................................................................................102
12.8 STP Examples ......................................................................................................................... 103
12.9 HSC I/O Filtering ................................................................................................................... 104
CHAPTER 13: USER INTERFACE ......................................................................................................... 107
13.1 Overview ...................................................................................................................................... 107
13.2 Screen Specifications ............................................................................................................... 107
13.3 Displaying and Entering Data ................................................................................................ 108
13.4 Alpha-numeric Keypad ........................................................................................................ 109
13.5 Screen Navigation ....................................................................................................................... 111
13.6 Ladder Based Screen Navigation ....................................................................................... 112
13.7 Beeper Acknowledgement ....................................................................................................... 112
13.8 Touch (Slip) Sensitivity ......................................................................................................... 113
13.9 Alarms ....................................................................................................................................... 114
13.10 Removable Media ................................................................................................................... 116
13.11 Screen Saver............................................................................................................................ 118
13.12 Screen Brightness .................................................................................................................. 118
13.13 Touch Screen Pressure ......................................................................................................... 119
CHAPTER 14: REGISTERS ..................................................................................................................... 121
14.1 Register Definitions ................................................................................................................... 121
14.2 Useful %S and %SR registers ............................................................................................. 121
14.3 Register Map for XL7 OCS I/O ............................................................................................ 125
14.4 Resource Limits ..................................................................................................................... 127
CHAPTER 15: CSCAPE CONFIGURATION ......................................................................................... 128
15.1 Overview ...................................................................................................................................... 128
15.2 Cscape Status Bar ................................................................................................................. 128
15.3 Establishing Communications ................................................................................................ 129
15.4 Configuration .......................................................................................................................... 137
15.5 Digital / HSC Input Configuration ...................................................................................... 139
15.6 Digital / PWM Output Configuration ................................................................................ 140
15.7 Analog Input Configuration ..................................................................................................... 141
15.8 Analog Output Configuration ............................................................................................. 142
CHAPTER 16: AUDIO PLAYBACK CONFIGURATION ...................................................................... 143
16.1 Audio Configuration in Cscape .............................................................................................. 143
16.2 Audio Config Details ............................................................................................................ 144
16.3 Audio Files .............................................................................................................................. 144
CHAPTER 17: VIDEO OBJECT............................................................................................................. 146
17.1 Video Object Overview ............................................................................................................ 146
17.2 Opening Video Object in Cscape............................................................................................ 147
17.3 Video Properties: Video Type ................................................................................................ 149
17.4 Video Properties: Control ................................................................................................... 150
17.5 Configuring Display Properties ............................................................................................... 151
17.6 Video Object Performance ....................................................................................................... 151
17.7 Web Cameras............................................................................................................................... 151
CHAPTER 18: BACK-UP BATTERY ..................................................................................................... 152
18.1 Overview ...................................................................................................................................... 152
18.2 Storing Register Contents ................................................................................................... 152
18.3 Battery Life ............................................................................................................................. 152
18.4 Lithium Battery Safety ......................................................................................................... 152
18.5 Battery Charging Cycle ........................................................................................................ 153
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18.6 Battery Charging Status ...................................................................................................... 153
18.7 Battery Charging State ........................................................................................................ 153
18.8 Battery Status in System Registers .................................................................................. 153
CHAPTER 19: FAIL – SAFE SYSTEM ................................................................................................. 154
19.1 Overview ..................................................................................................................................... 154
19.2 Settings ....................................................................................................................................155
19.3 Backup / Restore Data .........................................................................................................155
19.4 AutoLoad .................................................................................................................................159
19.5 AutoRun .................................................................................................................................... 161
CHAPTER 20: CLONE UNIT ................................................................................................................. 162
20.1 Overview .................................................................................................................................. 162
20.2 Clone ......................................................................................................................................... 162
20.3 Load Clone ............................................................................................................................. 166
CHAPTER 21: MAINTENANCE ............................................................................................................ 168
21.1 Firmware Updates .................................................................................................................... 168
21.2 Backup Battery ......................................................................................................................... 169
CHAPTER 22: MODBUS COMMUNICATIONS .................................................................................... 171
22.1 Modbus Overview ....................................................................................................................... 171
22.2 Modbus Slave Overview ........................................................................................................ 171
22.3 Modbus Master Overview .................................................................................................... 172
22.4 Modbus Addressing Table ................................................................................................... 173
CHAPTER 23: TROUBLESHOOTING & TECHNICAL SUPPORT.................................................... 174
23.1 Connecting to the XL7 OCS .................................................................................................... 174
23.2 Local Controller and Local I/O ........................................................................................... 176
23.3 CsCAN Network ...................................................................................................................... 177
23.4 Removable Media - Basic Troubleshooting ..................................................................... 178
23.5 Technical Support Contacts ................................................................................................ 178
MAIN INDEX ........................................................................................................................................... 179
INDEX OF FIGURES & TABLES ........................................................................................................ 183
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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
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 – EXPLOSION HAZARD: Substitution of components may impair suitability for
Class I, Division 2
WARNING: The USB parts are for operational maintenance only. Do not leave permanently
connected unless area is known to be non-hazardous
WARNING – EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA
KNOWN TO BE NON-HAZARDOUS
WARNING: Battery May Explode If Mistreated. Do not recharge, disassemble or dispose of in
fire.
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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a. All applicable codes and standards need to be followed in the installation of this product.
b. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG
or larger.
Adhere to the following safety precautions whenever any type of connection is made to the
module.
a. Connect the green safety (earth) ground first before making any other connections.
b. When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not make connections to live power lines.
c. Make connections to the module first; then connect to the circuit to be monitored.
d. Route power wires in a safe manner in accordance with good practice and local codes.
e. Wear proper personal protective equipment including safety glasses and insulated
gloves when making connections to power circuits.
f. Ensure hands, shoes, and floors are dry before making any connection to a power line.
g. Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
h. 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.
1.3 Compliance
To check for compliance and updates, visit the Horner website.
North America https://hornerautomation.com
Europe http://www.horner-apg.com
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CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL7 OCS
Figure 2.1 – Overview of the XL7
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2.1.1 Where to Find Information about the XL7 OCS
a. Datasheet - The datasheet is the first document to refer to for key information
related to specific XL7 OCS models. The datasheets for all XL7 OCS models are
available on the Horner websites and contain pin-outs, jumper settings and
other model specific information.
Table 2.1 – Datasheet Manual Numbers
Model 0
MAN1161
Model 2
MAN1162
Model 3
MAN1163
Model 4
MAN1164
Model 5
MAN1165
Model 6
MAN1166
b. User Manual -This manual provides general information that is common to XL7 OCS
models and can be downloaded from our web. Visit the Horner website to obtain user
documentation and updates.
North America https://hornerautomation.com
Europe http://www.horner-apg.com
2.1.2 Four main types of information are covered in this manual
a) Safety and Installation guidelines / instructions (Mechanical and Electrical)
b) Descriptions of hardware features (Serial ports, Removable Media, Communication
Options, etc.)
c) Configuration and Use of the XL7 OCS
d) Maintenance and Support
2.1.3 Manual Index
Major topics of interest may be found in the Index towards the end of this manual.
2.1.4 Table of Figures
Location of important drawing, illustrations (etc.) may be found in the Table of Figures.
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2.2 Connectivity to the XL7 OCS
The XL7 OCS has excellent capabilities for connecting to a variety of devices. The diagram
below shows some examples of devices that can be used with the XL7 OCS.
Figure 2.2 – Visual Overview of Types of Devices that can be connected to XL7 OCS
CAN
Serial
I/O
XL7 OCS
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
RCX116 I/O Base
OPC Server
Ethernet
Cscape
OPC Server
Modbus TCP Devices
USB
Flash Drive
Cscape
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2.3 Features of XL7 OCS
The XL7 OCS are all-in-one industrial control devices. They combine control, user interface,
I/O and networking into a single, integrated package. Unique features of the XL7 OCS include:
- Bright, 65,536 color graphical touch sensing LCD display in all models of XL7.
- Display of complex graphical objects including trends, gauges, meters and animations.
- High performance graphic processing.
- Advanced control capabilities including floating point, multiple auto-tuning PID loops
and string handling capabilities.
- Removable media for 32GB of storage of programs, data logging or screen captures.
- CsCAN networking port for communication with remote I/O, other controllers or PCs.
- High speed USB port for communication with PCs and programming of controller.
- Configurable serial protocols for communication to drives, PLCs, or other serial
peripherals.
- Full featured, built-in I/O including high resolution analog, thermocouple, RTD, high
speed counters, PWM outputs and relays (depending upon the XL7 OCS model used).
- Advanced high speed I/O capabilities.
- Cscape programming software that allows all aspects of the XL7 OCS to be programmed
and configured from one integrated application.
- Optional communication add-on modules.
- On board Ethernet port (10/100Mbps) for Cscape programming and application defined
communication, with Auto MDI/MDI-X.
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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 to obtain user documentation, supplemental documents, certificates, and
other documentation.
North America https://hornerautomation.com
Europe http://www.horner-apg.com
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 “Index” 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 XL7 OCS models such as pin-outs, jumper settings, and other key installation information.
Visit the Horner websites to obtain datasheets, user documentation, and updates.
North America https://hornerautomation.com
Europe http://www.horner-apg.com
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
3.2.1 Mounting Procedures (Installed in a Panel Door)
Figure 3.1 – Panel Mounting of an XL7 Series OCS
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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 XL7 OCS.
1. Remove all connectors from the XL7 OCS unit.
2. Make sure the gasket is installed on the XL7 OCS and is free from dust and debris.
Check that the corners of the gasket are secure.
3. Pass the unit through the panel.
4. Insert each of the four (4) mounting clips into the slots in the XL7 OCS case. One clip
should be installed on each corner. Lightly tighten each screw so the clip is held in
place.
5. 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).
3.3 Mounting Orientation
3.3.1 XL7 OCS Mounting Clip
Figure 3.2 – XL7 OCS with Mounting Clips
Slots for mounting clips
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3.3.2 XL7 OCS Mounting Orientation
Figure 3.3 – Orientation of XL7 OCS
NOTE: There are no orientation restrictions on the XL7 OCS. However, the above orientation
provides for optimum readability of the screen and ease of use of the keypad.
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3.4 Panel Cut-Out
For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut
with a tolerance of +/- 0.005” (0.1mm).
Figure 3.5 – XL7 OCS Dimensions
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3.5 Factors Affecting Panel Layout Design and Clearances
The designer of a panel layout needs to assess the requirements of a particular system and to
consider the following design factors
.
3.5.1 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 the OCS.)
2” (50.80mm)
3.5.2 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.
3.5.3 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 meet
applicable electrical codes and standards.
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3.5.4 Orientation
When panel-mounted, there are no orientation restrictions on the XL7 OCS.
3.5.5 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 XL7
OCS and noisy devices such as relays, motor starters, etc.
For details on output protection, especially when using contactors, solenoids, etc., see
MAN0962.
3.5.6 Shock and Vibration
The XL7 OCS 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 XL7 OCS to a location that
minimizes shock and/or vibration.
3.5.7 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? 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 XL7 OCS?
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 XL7 OCS 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 datasheets are the first documents to refer to for model-specific information
related to XL7 OCS models such as pin-outs, jumper settings, and other key installation
information. Visit the Horner websites to obtain datasheets, user documentation, and updates.
North America https://hornerautomation.com
Europe http://www.horner-apg.com
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). Grounding is also for the
safety of the user.
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 our 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 three-point ground 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
Frame Ground
-
0V
Input power supply ground
+
+24V
Input power supply positive voltage
Figure 4.1 – Power Connector (Primary Power Port)
Figure 4.2 – Primary Power Port
--
+
+
10-30VDC
supply
+
+
DC INPUT / FRAME
Solid/Standard Wire: 12-24 awg (2.5-0.2mm).
Strip Length: 0.28” (7mm).
Torque Rating: 4.5 – 7 in-lbs (0.50 – 0.78 N-m).
DC- is internally connected to I/O, but is isolated from
CAN-V.
A Class 2 power supply must be used.
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CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XL7 OCS models provide two independent serial ports, on the first 8-pin modular RJ45
connector, which is labeled MJ1/MJ2. The MJ1 serial port is RS232 while the MJ2 port is
RS485. By default, MJ1 can be connected to the COM port of a PC running Cscape, for OCS
programming. In addition, both MJ1 and MJ2 can be used for application-specific
communication, using a variety of standard data exchange protocols.
The second 8-pin modular RJ45 connector, which is labeled MJ3, provides a multiplexed serial
port, which can be configured for either RS232 or RS485. MJ3 can be optionally set for OCS
programming via the System Menu for connection to the COM port of a PC running Cscape.
5.2 Port Descriptions
The MJ1 serial port contains an RS232 interface with RTS/CTS handshaking. The MJ2 serial port
contains a half-duplex RS485 interface with no handshaking. The MJ3 serial port can be
configured as either RS232 or RS485. The MJ2 and MJ3 RS485 interfaces provide switchable
termination and bias resistors internally, which can be enabled/disabled with DIP switches.
5.3 Wiring and Dip Switches
Figure 5.1 – Serial Ports
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Figure 5.2 – Dip Switches
5.4 RS485 Termination
Proper RS485 termination minimizes signal reflections and improves reliability.
Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across
Pins 1 and 2 by DIP Switch Setting.
Only the two devices physically located at the endpoints of the RS485 network should be
terminated.
5.5 RS485 Biasing
RS485 biasing passively asserts a line-idle state when no device is actively transmitting, which
is useful for multi-drop RS485 networking.
Both the MJ2 and MJ3 serial ports allow internal bias resistors to be switched in, pulling pin 1
up to 3.3 V and pulling Pin 2 down to ground. The Set Serial Ports item in the System Menu
can be used to enable RS485 biasing. Also, an application graphics screen that writes to
%SR164 can do the same thing. Setting %SR164.1 enables MJ2 biasing and setting %SR164.2
enables MJ3 biasing.
If biasing is used, it should be enabled in only one of the devices attached to the RS485
network.
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5.6 Cscape Programming via Serial Port
The XL7 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM
port is connected to the XL7 OCS MJ1 or MJ3 serial port, Cscape can access the XL7 OCS for
programming and monitoring. Programming can also be done via the CAN port, USB A port, or
Ethernet.
5.7 Ladder-Controlled Serial Communication
Using Serial Communication function blocks, MJ1, MJ2, and MJ3 serial ports 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.
5.8 Configuration via Mini-B USB
NOTE: The unit must be connected via the mini-USB port to the PC or laptop.
It is possible to load the program and monitor data via the Mini-B USB. To load via Mini-B USB,
configure the communications port in Cscape as follows:
Select Tools from the toolbar → Application Settings → Communications → USB button
It is possible to download or upload and use the data monitoring functions once connected.
NOTE: It is advisable to use an isolated USB cable between the PC or laptop and the EXL6 when
third party devices are connected to the EXL6 to avoid damage to the PC or laptop and/or the
EXL6.
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CHAPTER 6: CAN COMMUNICATIONS
NOTE: For additional CAN information, refer to the CAN Networks manual (MAN0799) on the
Horner websites.
6.1 Overview
All XL7 OCS models provide two CAN network ports, which are implemented with 5-pin
connectors. The connectors are labeled CAN1 and CAN2.
Figure 6.1 – CAN1 & CAN2 Connector Locations
The CAN1 port allows the XL7 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.
CAN2 port supports CsCAN, CANopen, J1939 and DeviceNet Master (layer 3 as a selectable
option – one only).
6.2 Port Description
The XL7 OCS CAN ports implement the ISO 11898-2 physical layer and the CAN 2.0 A data link
layer standards. Also, since the CAN ports are powered by an internal isolated power supply,
external CAN power is not required.
NOTE: The CAN ports do not supply power to the network.
CAN1
CAN2
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6.3 CAN Port Wiring
Figure 6.2 – CAN1 / CAN2 Port Pins
6.4 Cscape Programming via CAN
The CAN1 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 XL7 OCS CAN1 port, Cscape
can access the XL7 OCS for programming and monitoring.
In addition, the XL7 OCS supports single-point-programming of all XL7 OCS and other
OCS/RCS devices that are connected to the CAN1 port network. If the PC COM port is
connected to the XL7 OCS MJ1 serial port, the XL7 OCS can act as a pass-through gateway
allowing Cscape to access all XL7 OCS and OCS/RCS devices that are attached to the CAN1
port network.
6.5 Ladder-Controlled CAN Communication
Using Put and Get Network Words function blocks, the CAN 1 port can exchange digital and
analog global data with other XL7 OCS or OCS/RCS devices (nodes) attached to the CAN1 port
network.
In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port
network to regularly announce their presence and to detect the presence (or absence) of other
nodes on the network.
6.6 Using CAN for I/O Expansion (Network I/O)
Connecting Network I/O devices (SmartStix, SmartBlock, SmartMod or SmartRail) to the XL7
OCS CAN1 or CAN2 port, allows the XL7 OCS I/O to be economically expanded and distributed.
A variety of modules are available for this purpose.
CAN1 & CAN2 Port Pins
Pin
Signal
Signal Description
1
V-
Power - Black
2
CN_L
CAN Data
Low - Blue
3
SHLD
Shield – No color
4
CN_H
CAN Data
High - White
5
V+
Power + Red
CAN Connector
Use the CAN Connector
when using CsCAN or other
CAN network.
Torque rating 4.5 – 7 in-lbs
(0.50 – 0.78 N-m)
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CHAPTER 7: ETHERNET COMMUNICATION
7.1 Ethernet Module Protocols and Features
The following table describes the Ethernet Module Protocols and features supported by XL7.
Table 7.1 – Ethernet Module Protocols & Features
Protocol / Feature
Protocol / Feature Description
ICMP (Ping)
Internet Control Message Protocol
EGD
Ethernet Global Data
SRTP (Slave 90-30
Service Request)
Service Request Transfer Protocol
CsCAN TCP Server
Horner APG CsCAN over Ethernet (for Cscape to OCS programming)
Modbus Slave
Modbus over Ethernet
Ethernet / IP
ODVA CIP over Ethernet
FTP (File Server)
File Transfer Protocol
ASCII over TCP/IP
ASCII Data over Ethernet
NTP (File Server)
Network Time Protocol (Obtain clock from web-based server)
HTTP (Web Server)
Hypertext Transfer Protocol (Web Server)
7.2 Ethernet System Requirements
Full Ethernet functionality requires:
- PC running Cscape Programming Software Version 9.3 SP6 or later (for configuration).
- XL7 controller with onboard Ethernet port.
7.3 Ethernet Module Specifications
Table 7.2 – Ethernet Module Specifications
Speeds
10 BaseT Ethernet (10Mbps)
100 BaseTx Fast Ethernet (100Mbps)
Modes
Half or Full Duplex
Auto-Negotiation
Both 10/100Mbps and Half/Full Duplex
Connector Type
Shielded RJ-45
Cable Type
(Recommended)
CAT5 (or better) UTP
Port
Auto MDI/MDI-X (Auto Crossover)
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