Horner APG XL4 User Manual
June 29, 2012 Page 1 of 122
User Manual for
XL4
OCS
HE-XC1E0 / HEXT251C100
HE-XC1E2 / HEXT251C112
HE-XC1E3 / HEXT251C113
HE-XC1E4 / HEXT251C114
HE-XC1E5 / HEXT251C115
MAN0964-01-EN
PAGE 2 MAN0964-01-EN
June 29, 2012 Page 2 of 122
PREFACE
This manual explains how to use the XL4 OCS.
Copyright (C) 2012 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 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, contact Technical Support:
North America:
Tel: (+) (317) 916-4274
Fax: (+) (317) 639-4279
Web: www.heapg.com
Email: techsppt@heapg.com
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: www.horner-apg.com
Email: tech.support@hornerapg.com
MAN0964-01-EN Limited Warranty and Liability
June 29, 2012 Page 3 of 122
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL4 (HE-XC/HEXT251) 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 XL4 OCS module. THIS
WARRANTY SHALL NOT APPLY TO THIS XL4 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 XL4 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 HEAPG 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 diskettes 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 XL4 OCS module to appropriately design the end
system, to appropriately integrate the XL4 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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MAN0964-01-EN Table of Contents
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TABLE OF CONTENTS
PREFACE .................................................................................................................................................... 2!
For user manual updates, contact Technical Support: ............................................................................. 2!
LIMITED WARRANTY AND LIMITATION OF LIABILITY ........................................................................ 3!
ABOUT PROGRAMMING EXAMPLES .................................................................................................... 3!
TABLE OF CONTENTS .............................................................................................................................. 5!
INTENTIONALLY LEFT BLANK ............................................................................................................... 10!
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................. 11!
1.1! Safety Warnings and Guidelines ................................................................................................... 11!
1.2! Grounding ..................................................................................................................................... 12!
1.3! CE Compliance ............................................................................................................................. 12!
CHAPTER 2: INTRODUCTION ................................................................................................................ 13!
2.1! Visual Overview of XL4 OCS ........................................................................................................ 13!
2.1.1! Where to Find Information about the XL4 OCS ...................................................................... 13!
2.1.2! Four main types of information are covered in the manual. ................................................... 14!
2.1.3! Manual Index .......................................................................................................................... 14!
2.1.4! Table of Figures ...................................................................................................................... 14!
2.2! Connectivity to the XL4 OCS ........................................................................................................ 14!
2.3! Features of XL4 OCS .................................................................................................................... 14!
2.4! Required and Suggested Accessories .......................................................................................... 15!
2.5! Useful Documents and References .............................................................................................. 16!
CHAPTER 3: MECHANICAL INSTALLATION ........................................................................................ 17!
3.1! Overview ....................................................................................................................................... 17!
3.2! Mounting Requirements ................................................................................................................ 17!
3.2.1! Mounting Procedures (Installed in a Panel Door) ................................................................... 17!
3.3! Mounting Orientation ..................................................................................................................... 18!
3.3.1! XL4 OCS Mounting Clip ........................................................................................................ 18!
3.3.2! XL4 OCS Mounting Orientation .............................................................................................. 18!
3.4! Panel Cut-Out ............................................................................................................................... 19!
3.5! XL4 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 ......................................................................................... 23!
4.1! Grounding Definition ..................................................................................................................... 23!
4.2! Ground Specifications ................................................................................................................... 23!
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! RS-485 Termination ...................................................................................................................... 25!
5.5! RS-485 Biasing ............................................................................................................................. 25!
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5.6! Cscape Programming via Serial Port ............................................................................................ 26!
5.7! Ladder-Controlled Serial Communication ..................................................................................... 26!
5.8! Downloadable Serial Communication Protocols ........................................................................... 26!
CHAPTER 6: CAN COMMUNICATIONS ................................................................................................ 27!
6.1! Overview ....................................................................................................................................... 27!
6.2! Port Description ............................................................................................................................. 27!
6.3! CAN1 Port Wiring .......................................................................................................................... 28!
6.4! Cscape Programming via CAN ..................................................................................................... 28!
6.5! Ladder-Controlled CAN Communication ....................................................................................... 28!
6.6! Using CAN for I/O Expansion (Network I/O) ................................................................................. 28!
CHAPTER 7: ETHERNET COMMUNICATION ........................................................................................ 29!
7.1 ! Ethernet Module Protocols and Features ..................................................................................... 29!
7.2 ! Ethernet System Requirements ................................................................................................... 29!
7.3 ! Ethernet Module Specifications .................................................................................................... 29!
7.4 ! Ethernet Module Configuration .................................................................................................... 29!
CHAPTER 8: COMMUNICATION OPTIONS ........................................................................................... 35!
8.1! Overview ....................................................................................................................................... 35!
8.2! Modem COM Module (XMC) Option ............................................................................................. 36!
CHAPTER 9: REMOVABLE MEDIA ........................................................................................................ 37!
9.1! Overview ....................................................................................................................................... 37!
9.2! Micro SD Cards ............................................................................................................................. 37!
9.3! Micro SD File System .................................................................................................................... 38!
9.4! Using the Removable Media Manager .......................................................................................... 38!
9.5! Using Removable Media to Log Data ........................................................................................... 38!
9.6! Using Removable Media to Load and Save Applications ............................................................. 39!
9.7! Using Removable Media to View and Capture Screens ............................................................... 39!
9.8! Removable Media (RM) Function Blocks in Cscape ..................................................................... 39!
9.9! Filenames used with the Removable Media (RM) Function Blocks .............................................. 40!
9.10! System Registers used with RM ................................................................................................. 40!
CHAPTER 10: GENERAL I/O .................................................................................................................. 41!
10.1! Overview ..................................................................................................................................... 41!
10.2! Removing the XL4 OCS I/O Cover ............................................................................................. 41!
10.3! Model and I/O Overview .............................................................................................................. 42!
10.4! Solid-State Digital Outputs .......................................................................................................... 44!
10.5! Relay Outputs ............................................................................................................................. 44!
10.6! Digital Inputs ............................................................................................................................... 46!
10.7! Analog Inputs .............................................................................................................................. 46!
10.8! Universal Analog Inputs .............................................................................................................. 47!
10.9! Analog Outputs ........................................................................................................................... 47!
CHAPTER11: HIGH SPEED I/O (HSC / PWM) ........................................................................................ 49!
11.1! Overview ..................................................................................................................................... 49!
11.3! High Speed Counter (HSC) Functions ........................................................................................ 50!
11.3.1! Frequency ............................................................................................................................. 50!
11.3.2! Totalize ................................................................................................................................. 50!
11.3.3! Pulse Width Measurement ................................................................................................... 50!
11.3.4! Period Measurement ............................................................................................................ 51!
11.2.5! Quadrature ........................................................................................................................... 51!
11.3! HSC Functions Register Map ...................................................................................................... 53!
11.4! High Speed Output Functions ..................................................................................................... 54!
11.4.1! Normal .................................................................................................................................. 54!
11.4.2! PWM ..................................................................................................................................... 54!
11.4.4! Stepper Function .................................................................................................................. 55!
11.5! PWM functions register map ....................................................................................................... 56!
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11.6! PWM Examples ........................................................................................................................... 57!
11.7! STP Examples ............................................................................................................................ 57!
CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................... 59!
12.1! System Menu - Overview ............................................................................................................ 59!
12.2! System Menu – Navigation and Editing ...................................................................................... 60!
12.3! System Menu – Details ............................................................................................................... 61!
12.4! Touch screen calibration ............................................................................................................. 72!
CHAPTER 13: USER INTERFACE ........................................................................................................... 73!
13.1! Overview ..................................................................................................................................... 73!
13.2! Displaying and entering Data ...................................................................................................... 73!
13.3! Alpha-numeric keypad ................................................................................................................ 74!
13.4! Screen Navigation ....................................................................................................................... 76!
13.5! Ladder Based Screen Navigation ............................................................................................... 76!
13.6! Beeper Acknowledgement .......................................................................................................... 77!
13.7! Touch (Slip) Sensitivity ................................................................................................................ 77!
13.8! Alarms ......................................................................................................................................... 77!
13.9! Removable Media ....................................................................................................................... 79!
13.10! Screen Saver ............................................................................................................................ 80!
13.11! Screen Brightness ..................................................................................................................... 81!
CHAPTER 14: REGISTERS ...................................................................................................................... 83!
14.1! Register Definitions ..................................................................................................................... 83!
14.2! Useful %S and %SR registers .................................................................................................... 84!
14.3! Register Map for XL4 OCS I/O .................................................................................................... 87!
14.4! Resource Limits .......................................................................................................................... 87!
CHAPTER 15: CSCAPE CONFIGURATION ........................................................................................... 89!
15.1! Overview ..................................................................................................................................... 89!
15.2! Cscape Status Bar ...................................................................................................................... 89!
15.3! Establishing Communications ..................................................................................................... 90!
15.3.1 Communicating via MJ1 Serial Port ..................................................................................... 95!
15.3.2 Communicating via On Board Ethernet Port ...................................................................... 96!
15.5! Configuration ............................................................................................................................... 97!
15.6! Digital Input / HSC Configuration ................................................................................................ 97!
15.7! Digital Output / PWM Configuration ............................................................................................ 98!
15.8! Analog Input Configuration .......................................................................................................... 99!
15.9! Analog Output Configuration ..................................................................................................... 100!
CHAPTER 1 6: FAIL – SAFE SYSTEM .................................................................................................. 101!
16.1 Overview ................................................................................................................................. 101!
16.2! Settings ..................................................................................................................................... 102!
16.3! Backup / Restore Data .............................................................................................................. 102!
16.4! AutoLoad ................................................................................................................................... 106!
16.5! AutoRun .................................................................................................................................... 108!
CHAPTER 17: CLONE UNIT ................................................................................................................. 109!
17.1! Overview ................................................................................................................................... 109!
17.2! Clone: ........................................................................................................................................ 109!
17.3! Load Clone ................................................................................................................................ 111!
CHAPTER 18: MAINTENANCE ............................................................................................................. 113!
18.1! Firmware Updates ..................................................................................................................... 113!
18.2! Backup Battery .......................................................................................................................... 113!
18.2.1! Indications the battery needs replacing .............................................................................. 113!
18.2.2! Battery Replacement .......................................................................................................... 114!
CHAPTER 19: TROUBLESHOOTING / TECHNICAL SUPPORT .......................................................... 115!
19.1! Connecting to the XL4 OCS ...................................................................................................... 115!
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19.1.1! Connecting Troubleshooting Checklist (serial port – MJ1 Programming) ................. 116!
19.1.2! Connecting Troubleshooting Checklist (USB Port - Mini B Programming) ................ 116!
19.1.3! Connecting Troubleshooting Checklist (ETN port programming) ............................... 116!
19.2! Local Controller and Local I/O ................................................................................................... 116!
19.2.1! Local I/O Troubleshooting Checklist .............................................................................. 117!
19.3! CsCAN Network ........................................................................................................................ 117!
19.3.1! CsCAN Network Troubleshooting Checklist .................................................................. 117!
19.4! Removable Media ..................................................................................................................... 118!
19.4.1! Basic Troubleshooting ..................................................................................................... 118!
19.5! Technical Support Contacts ...................................................................................................... 118!
Index ..................................................................................................................................................... 119!
Table of Figures ................................................................................................................................... 122!
MAN0964-01-EN Visual Map
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Visual Map of major tasks and the key chapters to assist you
FIRST STEP of ANY TASK: DATASHEET
Each XL4 OCS unit is sent with a datasheet in the box. The datasheet is the first document you
need to refer to for model-specific information related to XL4 OCS models such as pin-outs,
jumper settings, and other key installation information. Visit our website http://www.heapg.com to
obtain updates to datasheets, manuals and user documentation.
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety / Compliance
page 11
Safety / Compliance
page 11
Safety / Compliance
page 11
Safety / Compliance
page 11
Introduction
page 13
Introduction
page 13
Introduction
page 13
Introduction
page 13
Mechanical Installation
page 17
Serial Communications
Page 25
Maintenance
page 113
Electrical Installation
page 23
CAN Communications
page 27
Troubleshooting
page 115
Ethernet
Page 29
Communication Options
page 35
Removable Media
page 37
High Speed I/O
page 49
System Settings
page 59
User Interface
page 73
Registers
page 83
Cscape Configuration
page 89
Fail- Safe System
Page 101
Clone Unit
Page 109
MAN0964-01-EN
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MAN0964-01-EN CH.1
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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
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 floor is 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.
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.
CH.1 MAN0964-01-EN
June 29, 2012 Page 12 of 122
1.2 Grounding
Grounding is covered in various chapters within this manual.
1.3 CE Compliance
To check for compliance and updates, visit our website at:
http://www.heapg.com or http://www.horner-apg.com
MAN0964-01-EN CH.2
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CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL4 OCS
2.1.1 Where to Find Information about the XL4 OCS
a. Datasheets - The datasheets are the first documents you need to refer to
for key information related to specific XL4 OCS models.
The datasheets for all XL4 OCS models are available on our website.
Datasheets contain pin-outs, jumper settings and other model specific
information.
b. User Manual -This manual provides general information that is common to
XL4 OCS models and can be downloaded from our web. Visit our website
at http://www.heapg.com to obtain user documentation and updates.
Top
Left
Bottom
Right
Ethernet
USB 2.0 A
Serial MJ1/2
USB 2.0
mini-B
microSD Memory Slot
Dip Switches
DC Power In (10-30Vdc) &
Frame Ground
CAN Port
J4 I/O Terminal (model 4 only)
J3 I/O Terminal
(model 4 & 5
J2 I/O Terminal
J1 I/O
CH.2 MAN0964-01-EN
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2.1.2 Four main types of information are covered in the 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 XL4 OCS
d. Maintenance and Support
2.1.3 Manual Index
Index
Major topics of interest may be found in the Index towards the end of this manual.
2.1.4 Table of Figures
Table of Figures
Location of important drawing, illustrations (etc) may be found in the Table of Figures .
2.2 Connectivity to the XL4 OCS
The XL4 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 XL4 OCS.
Figure 2.3 – Visual Overview of Types of Devices that can be connected to XL4 OCS
2.3 Features of XL4 OCS
The XL4 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 XL4 OCS include:
• Bright, 65536 color graphical touch sensing LCD display in all models of XL4.
• Display of complex graphical objects including trends, gauges, meters and animations.
• Very high performance graphic processing
• Advanced control capabilities including floating point, multiple auto-tuning PID loops and string
handling capabilities.
CAN
Serial
I/O
XL4 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
MAN0964-01-EN CH.2
June 29, 2012 Page 15 of 122 #1037
• Removable media for 32 gigabytes 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 XL4 OCS model used).
• Advanced high speed I/O capabilities
• Cscape programming software that allows all aspects of the XL4 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.
2.4 Required and Suggested Accessories
The following list contains a sampling of required and suggested XL4 OCS accessories. Visit our website
to view updates on new products and accessories.
Table 2.1 – XL4 OCS Accessories
Part
Number
Description
HE-XMC
14.4 k Telephone modem option kit - field installable. Kit includes all parts necessary for internal installation within
the XL4 OCS case, including a deeper plastic back cover adapted for modem operation.
HE-MC1
Removable Media card - compatible with XL4 OCS. Card capacity is 2 GB or larger.
HE-MR1
Media Card Reader for HE-MC1. Portable device allows HE-MC1 to be plugged into the USB port of personal
computers as a portable hard drive.
HE-X24-AS
Power supply 100-240VAC or 140-340VDC Switching supply that outputs 1.5 A / 3 A
(HE-X24-AS/AL) at 24 VDC. Mounts on Standard DIN rail. Designed for X Family products.
HE-X24-AL
Power supply 100-240 VAC or 140-340 VDC Switching supply that outputs 1.5 A / 3 A
(HE-X24-AS/AL) at 24VDC. Mounts on Standard DIN rail. Designed for X Family products.
HECSP
Cscape Software Package on a reusable USB flash drive with symbol library.
HE-XCK
Programming cables for all X products including a USB to serial adapter in a travel case.
HE-CPK
Cscape on a reusable usb flash drive, Programming cables for all X products including a USB to serial adapter in a
travel case.
Note: The XL4 OCS is not shipped with a programming cable in the box. To obtain a
programming cable, order HE500CBL300.
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2.5 Useful Documents and References
The following information serves as a general listing of Horner controller products and other references of
interest with their corresponding manual numbers. Visit our website to obtain user documentation and
updates.
Table 2.2 – OCS Reference Document numbers
Note: This list is not intended for users to determine which products are appropriate for their application; controller
products differ in the features that they support. If assistance is required, refer to Technical Support.
Controllers
Manual Number
HE-XExxx (XLe and XLt)
MAN0878
XL4
MAN0883
QX Series (e.g., HE-QXxxx)
MAN0798
NX Series (e.g., HE-NXxxx)
MAN0781
Other Useful References
Manual Number
Ethernet Supplement
SUP0740
CAN Networks
MAN0799
Spark Quenchers (output protection)
MAN0962-01-EN
Wiring Accessories and Spare Parts Manual
MAN0347
MAN0964-01-EN CH.3
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CHAPTER 3: MECHANICAL INSTALLATION
Note: The datasheet is the first document you need to refer to for model-specific information
related to XL4 OCS models such as pin-outs, jumper settings, and other key installation
information. Visit our website 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
3.2.1 Mounting Procedures (Installed in a Panel Door)
Figure 3.1 – Panel Mounting of an XL4 Series OCS
Once the panel design has been completed using the criteria and suggestions in the
following sections, use the following steps to panel mount the XL4 OCS.
1. Remove all connectors from the XL4 OCS unit.
2. Make sure the gasket is installed on the XL4 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 the each of the four (4) mounting clips into the slots in the XL4 OCS case. One
clip should be installed on each corner. Lightly tignten 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 4 ft lb (5.4 N m).
001XLE055
CH.3 MAN0964-01-EN
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3.3 Mounting Orientation
3.3.1 XL4 OCS Mounting Clip
Figure 3.2 – XL4 OCS with Mounting Clips
3.3.2 XL4 OCS Mounting Orientation
Figure 3.3 – Orientation of XL4 OCS
Slot
for Clip
DIN
Rail
Clip
001XLE056
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 readability of the screen and
ease of use of the keypad.
MAN0964-01-EN CH.3
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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).
Figure 3.4 – Panel Cutout Tolerances
3.5 XL4 Dimensions
Figure 3.5 – XL4 OCS Dimensions
3.622 [92mm]
3.622 [92mm]
001XLE002
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3.6 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.
3.6.1 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 inches (50.80mm)
Minimum Distance between base of device and
wiring ducts
1.5 inches (38.10mm)
If more than one device installed in panel box (or on
door):
Minimum Distance between bases of each device
4 inches between bases of each device
(101.60mm)
When door is closed:
Minimum distance between device and closed door
(Be sure to allow enough depth for the OCS.)
2 inches (50.80mm)
3.6.2 Grounding
Panel box: The panel box needs to 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 XL4 OCS.
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 XL4 OCS and noisy
devices such as relays, motor starters, etc.
For details on output protection, especially when using contactors, solenoids… see MAN0962-01EN.
3.6.6 Shock and Vibration
The XL4 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 XL4 OCS 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? 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 XL4 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 XL4 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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NOTES
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CHAPTER 4: ELECTRICAL INSTALLATION
Note: The datasheet is the first document you need to refer to for model-specific information
related to XL4 OCS models such as pin-outs, jumper settings, and other key installation
information. Visit our website 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 0 ohms. In reality it typically
is higher. The U.S. National Electrical Code (NEC) states the resistance to ground shall not exceed
twenty-five (25) ohms. Horner APG recommends less than fifteen (15) ohms resistance from our
equipment to ground. Resistance greater than twenty-five (25) ohms can cause undesirable or harmful
interference to the device.
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 shows a two-point ground connection test.
Figure 4.1 – Two-Point Ground Connection Test
METAL WATER PI PE 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 ground
3
+24V
Input power supply positive voltage
Figure 4.2 – Power Connector (Primary Power Port)
Figure 4.3 – Primary Power Port as Viewed Looking at the XL4 OCS
PIN 1
PIN 2
PIN 3
+
10-30 VDC
supply
-
+
+
Power Connector
Power Up:
Connect to Earth Ground.
Apply 10 – 30 VDC.
Screen lights up.
Torque rating 4.5 - 7 Lb-In
(0.50 – 0.78 N-m)
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CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XL4 OCS models provide two serial ports, which are implemented with single 8-pin modular RJ45
connectors, and are labeled MJ1 and MJ2. The MJ1 serial port is RS-232 while the MJ2 port is RS-485.
MJ1 defaults to OCS 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 a RS-232 interface with RTS/CTS handshaking.
The MJ2 serial port contains half-duplex RS-485 interface with no handshaking. The MJ2 RS-485
interface provides switchable termination and bias resistors internally.
5.3 Wiring and Dip Switches
5.4 RS-485 Termination
Proper RS-485 termination minimizes reflections and improves reliability.
The 485 serial port allows an internal RS-485 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 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.
Pin
Name
Function
Default
1
RS-485 Termination
ON = Terminated
OFF
2
Spare
Always Off
OFF 3 Factory Use
Always Off
OFF
Pin
MJ1 Pins
MJ2 Pins
Signal
Direction
Signal
Direction
8
TXD
OUT - - 7 RXD
IN - -
6
0 V
Ground
0 V
Ground
5
+5V@60mA
OUT
+5V@60mA
OUT 4 RTS
OUT - - 3 CTS
IN - - 2 - - RX- / TX-
IN / OUT 1 - - RX+ / TX+
IN / OUT
MJ1/2 Serial Ports
MJ1: RS-232 w/Full
Handshaking
MJ2: RS-485 Half-Duplex
Two Serial Ports on One Modular Jack (8posn)
!
1"
8"
1 2 3
ON
DIP Switches
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The 485 serial ports allow internal RS-485 bias resistors to be switched in, pulling pin 1 up to 3.3V 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 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
The XL4 OCS MJ1 serial port supports CsCAN Programming Protocol. If a PC COM port is connected to
the XL4 OCS MJ1 serial port, Cscape can access the XL4 OCS for programming and monitoring.
Programming can also be done via the CAN port, USB port or Ethernet.
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.
5.8 Downloadable Serial Communication Protocols
Both MJ1 and MJ2 also support downloadable protocols, such as Allen Bradley DF1, CsCAN Master, GE
Fanuc SNP and Modbus Master.
Note: Refer download section of our website for the list of latest supported protocols.
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CHAPTER 6: CAN COMMUNICATIONS
Note: For additional CAN information, refer to the CAN Networks manual (MAN0799) on our website.
6.1 Overview
All XL4 OCS models provide a CAN networking port, which is implemented with a 5-pin connector. The
connector is labeled CAN1.
Figure 6.1 – CAN1 Connector
Like the MJ1 serial port, the CAN1 port can be used for XL4 OCS programming by connecting it to the
CAN port of a PC running Cscape. The CAN1 port also allows the XL4 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).
6.2 Port Description
The XL4 OCS CAN1 port implements the ISO 11898-2 physical layer and the CAN 2.0A data link layer
standards. Also, since the CAN1 port is powered by an internal isolated power supply, external CAN
power is not required.
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6.3 CAN1 Port Wiring
Figure 6.2 – CAN1 Port Connector
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 XL4 OCS CAN1 port, Cscape can access the
XL4 OCS for programming and monitoring.
In addition, the XL4 OCS supports single-point-programming of all XL4 OCS and other OCS/RCS devices
that are connected to a CAN network. If the PC COM port is connected to the XL4 OCS MJ1 serial port,
the XL4 OCS can act as a pass-through gateway allowing Cscape to access all XL4 OCS and OCS/RCS
devices that are attached to the CAN network.
6.5 Ladder-Controlled CAN Communication
Using Put and Get Network Words function blocks, the NET1 port can exchange digital and analog global
data with other XL4 OCS or OCS/RCS devices (nodes) attached to the CAN network.
In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN 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, SmartBlocks or SmartRails) to the XL4 OCS CAN1 port,
allows the XL4 OCS I/O to be economically expanded and distributed. A variety of modules are available
for this purpose.
CAN Network & Power Port Pin Assignments
Pin
Signal
Signal Description
Direction
1
V-
CAN and Device
Ground - Black
−
2
CN_L
CAN Data Low - Blue
In/Out
3
SHLD
Shield Ground - None
−
4
CN_H
CAN Data High - White
In/Out
5
V+
Positive DC Voltage
Input (10-30VDC) - Red
−
CAN Connector
Use the CAN Connector
when using CsCAN or other
CAN network.
Torque rating 4.5 – 7 Lb-In
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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 XL4.
Protocol / Feature
Protocol / Feature Description
ICMP Ping
Internet Control Message Protocol
EGD (Peer)
GE Fanuc Ethernet Global Data
SRTP Server
GE Fanuc Service Request Transfer Protocol
CsCAN TCP Server
Horner APG CsCAN over Ethernet
Modbus TCP Slave
Modbus over Ethernet
Ethernet / IP Server
ODVA CIP over Ethernet
FTP Server
File Transfer Protocol
HTTP Server
HyperText Transfer Protocol (Web Server)
7.2 Ethernet System Requirements
Full Ethernet functionality requires:
1. PC running Cscape Programming Software Version 9.3 SP3 or later (for configuration).
2. XL4 controller with onboard Ethernet port.
3. FTP & HTTP protocols.
7.3 Ethernet Module Specifications
Speeds
10 BaseT Ethernet (10-Mbps)
100 BaseTx Fast Ethernet (100-Mbps)
Modes
Half or Full Duplex
Auto-Negotiation
Both 10/100-Mbps and Half/Full Duplex
Connector Type
Shielded RJ-45
Cable Type
(Recommended)
CAT5 (or better) UTP
Port
Auto MDI/MDI-X (Auto Crossover)
7.4 Ethernet Module Configuration
Note: The following configuration is required for all applications regardless of the protocols used.
Additional configuration procedures must be performed for each protocol used.
To configure the Ethernet Module, use Cscape Programming Software to perform the following steps
1. On the main Cscape screen, select the Controller menu and its I/O Configure sub-menu to
open the I/O Configuration dialog (Figure 7.1)
2. If configuring a different OCS Model than the one shown in the I/O Configuration dialog, click
on the topmost Config button, select the desired OCS Model, and then click OK
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Figure 7.1 – I/O Configuration Dialog
3. Click the Config button to the right of the Ethernet Module, and then select the Module Setup
tab, revealing the Ethernet Module Configuration dialog as shown in figure 7.2
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